Fastener Setting Head With In-Line Electrical Joint Checking
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Solution Overview
Problem
Current methods for fastening functional elements to workpieces, such as sheet metal components, lack effective quality assurance, relying on random and costly laboratory checks that provide limited information about connection quality.
Innovation Solution
Integration of a checking device with a sensor unit and contact sections within the setting device to electrically measure the connection quality between functional elements and workpieces, allowing for real-time determination and documentation of connection quality, and optional warning signals for faulty connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If random laboratory checks are used to verify connection quality, then measurement precision is improved, but productivity deteriorates and loss of time increases
Solution Approach 1:
The patent replaces mechanical/labor-intensive laboratory inspection methods with an automated electrical measurement system. The sensor unit with contact sections electrically measures connection quality directly at the setting device, substituting manual laboratory checks with automated electrical resistance measurements.
Solution Approach 2:
The setting device performs its own quality inspection function through the integrated sensor unit. The device self-verify connection quality by measuring electrical parameters, eliminating the need for separate external laboratory inspection processes.
2Measurement precision
If random laboratory checks are used to verify connection quality, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The quality measurement is performed immediately after setting, during the same production cycle. The sensor unit measures connection quality in real-time before workpieces move to subsequent processes, preventing delayed detection and rework.
Solution Approach 2:
The patent replaces time-consuming laboratory transport and manual inspection with on-site automated electrical measurements, eliminating transit time and manual operation delays.
3Ease of operation
If visual inspection is used to check connection quality, then ease of operation is improved, but measurement precision deteriorates
Solution Approach 1:
The patent replaces subjective visual inspection with objective electrical measurement. The sensor unit quantifies connection quality through electrical resistance measurements, providing precise numerical data instead of subjective visual assessment.
Solution Approach 2:
The sensor unit acts as an intermediary between the connection and the measurement system. It electrically contacts both the functional element and workpiece to obtain accurate connection quality data, serving as a bridge between the physical connection and the evaluation process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables improved and cost-effective quality assurance by providing reliable, real-time assessment of connection quality, enabling immediate identification and documentation of faulty connections, and reducing the need for labor-intensive laboratory checks.
Implementation Method 1
draw a conclusion by means of an electrical measurement on how good the connection of the functional element to the workpiece is
Data Source
AI summary
The present invention relates to a setting device for fastening a functional element to a workpiece, in particular to a sheet metal component. The setting device comprises a die for receiving and supporting the workpiece and a setting head having a setting die which cooperates with the functional element and by which the functional element can be fastened to the workpiece in an axial setting movement. The setting device further comprises a checking device for determining the quality of a connection of the functional element to the workpiece, wherein the checking device has a sensor having a first contact section, which can be electrically conductively contacted with the functional element, and having a second contact section that can be electrically conductively contacted with the workpiece. The present invention furthermore relates to a corresponding method of fastening a functional element to a workpiece.