Guiding Aid Element Press Joining for Mixed-Material Components
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Solution Overview
Problem
Existing methods for introducing auxiliary joining elements into components, such as those in lightweight vehicle construction, face challenges in achieving strong connections without complex geometries and high production costs, particularly when joining dissimilar materials like aluminum and steel.
Innovation Solution
A method involving punching pilot holes in components during a press stroke, followed by inserting and pressing auxiliary joining elements into these holes, forming a cohesive, form-fitting, and/or force-fitting connection, which can be done in a single or multiple press strokes, allowing for automated or manual insertion and integration into existing production processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If self-stamping auxiliary joining elements with cutting edges are used, then pilot holes can be avoided and the process simplified, but the geometry becomes complicated and production costs increase
Solution Approach 1:
The patent applies preliminary action by forming pilot holes in the component before inserting the auxiliary joining elements. This preliminary preparation simplifies the subsequent insertion process and allows for simpler auxiliary joining element geometries without cutting edges, thereby reducing production costs while maintaining manufacturing ease
Solution Approach 2:
The patent segments the joining process into distinct steps: first forming pilot holes, then inserting auxiliary joining elements, and finally pressing them to create form-fitting connections. This segmentation allows each step to be optimized independently, using simple cylindrical auxiliary joining elements rather than complex self-stamping designs
2Manufacturing precision
If auxiliary joining elements are set individually by robot-guided tools, then precise placement is achieved, but the production cycle time increases
Solution Approach 1:
The patent merges multiple individual setting operations into a single press operation. By forming all pilot holes and inserting all auxiliary joining elements in one pressing motion, the method maintains precise placement through the press tooling while dramatically reducing production cycle time compared to sequential robot-guided setting
Solution Approach 2:
The patent ensures continuity of useful action by performing pilot hole formation, auxiliary joining element insertion, and pressing operations in a continuous single-step process. This eliminates idle time between operations while maintaining precision through the integrated press tooling design
3Manufacturing precision
If multiple press strokes are used for punching and pressing, then precise control is achieved, but the production cycle time increases
Solution Approach 1:
The patent combines punching and pressing operations into a single integrated press stroke. The press tooling is designed to form pilot holes and insert auxiliary joining elements simultaneously in one motion, maintaining precise control through the integrated tool design while halving the production cycle time compared to separate operations
Solution Approach 2:
The press tooling performs preliminary action by forming pilot holes as part of the same operation that inserts the auxiliary joining elements. This preliminary hole formation integrated into the pressing stroke ensures precise positioning while eliminating the need for a separate punching step, reducing cycle time without sacrificing control precision
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
This method enables the cost-effective and efficient introduction of auxiliary joining elements, enhancing connection strength while reducing production complexity and cycle times, and can be integrated into existing manufacturing processes without additional equipment, suitable for both steel and mixed material constructions.
Implementation Method 1
punching the at least one component at the at least one joint in a first press stroke of a press
Implementation Method 2
pressing the at least one auxiliary joining element together with the at least one component in a subsequent press stroke or work step, wherein a cohesive, form-fitting and/or force-fitting connection between the at least one component and the at least one auxiliary joining element is formed
Data Source
AI summary
A method for undetachably introducing a guiding aid element into at least one joining location of at least one component is provided. The method includes the acts of: a) perforating the at least one component at the at least one joining location in a first press stroke of a tool press, wherein a preliminary hole is formed at the at least one joining location; b) inserting a joining aid element into the at least one preliminary hole; and c) pressing the at least one joining aid element with the at least one component in a subsequent press stroke or working step to form a material-bonding, form-fitting and/or force-fitting connection between the at least one component and the at least one joining aid element. A component and a composite component produced by such a method are also provided.