Flow Drilling Screw Setting With Adaptive Boost Penetration Control
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Solution Overview
Problem
Existing screw-setting methods require manual adjustment of revolution speed and axial feed force, leading to inefficiencies and material-specific presets, which do not adapt dynamically to fluctuations in material consistency during the screwing process.
Innovation Solution
A method that automatically determines if the screw penetrates the component within a first phase, and if not, increases the revolution speed and axial feed force in a subsequent 'boost' phase to optimize energy input, with continuous or step-wise increases until penetration, allowing for real-time adjustment of tightening torque based on mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of revolution speed and axial feed force is used, then preset values for frequently used materials can be stored, but the process does not adapt dynamically to fluctuations in material consistency
Solution Approach 1:
The system continuously monitors the actual screwing process parameters (revolution speed, axial feed force, penetration status) and automatically adjusts them in real-time based on whether the screw penetrates the component within the first phase. This closed-loop feedback mechanism enables dynamic adaptation to material consistency fluctuations without manual intervention.
Solution Approach 2:
The screwing apparatus transitions from static preset values to dynamic parameter adjustment. The revolution speed and axial feed force are automatically modified during the screwing process based on real-time penetration detection, allowing the system to adapt to varying material properties for each individual screwing operation.
2Productivity
If revolution speed or axial feed force is increased to shorten screw setting time, then productivity improves, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts the revolution speed and axial feed force based on real-time penetration detection. During the first phase, standard parameters are applied. If penetration occurs, parameters are reduced to save energy. If penetration does not occur, parameters are increased in the second phase to ensure completion, optimizing the balance between productivity and energy consumption for each individual screw.
Solution Approach 2:
The screwing parameters (revolution speed and axial feed force) are changed based on the penetration status. The system switches between different parameter sets: standard parameters during the first phase, and adjusted parameters (either reduced after successful penetration or increased during the second phase after failed penetration) to optimize both productivity and energy efficiency.
3Reliability
If higher revolution speed and axial feed force are applied to ensure screw penetration, then reliability of penetration improves, but risk of material overload increases
Solution Approach 1:
The system dynamically adjusts parameters based on penetration status. During the first phase, standard parameters are used. If penetration is detected, parameters are reduced in the second phase to prevent material overload. If penetration is not detected, parameters are increased to ensure reliable penetration. This dynamic adjustment ensures reliable penetration while minimizing the risk of material overload.
Solution Approach 2:
The revolution speed and axial feed force parameters are changed based on penetration detection results. After successful penetration in the first phase, parameters are reduced to avoid over-driving and material damage. If penetration fails, parameters are increased in the second phase to ensure reliable penetration, thus adapting to actual material conditions to prevent both under-penetration and over-loading.
Data Source
AI summary
The invention relates to a method and to an apparatus for setting a screw, in particular a flow drilling screw. In accordance with the method, the screw is driven at a first revolution speed and at a first axial feed force during a time-limited first phase to drive the screw through at least one component. In the event that the screw does not penetrate the component during the first phase, the screw is automatically driven at a second revolution speed that is higher than a first rotation speed and/or at a second axial feed force that is greater than a first axial feed force during a second phase subsequent to the first phase.