Hot Riveting Device With Separate Ceramic Forming Element
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Solution Overview
Problem
Existing hot riveting devices face challenges such as manual polishing being time-consuming and costly, limited economies of scale due to varying calotte geometries, high procurement times, and high current requirements for heating, which are space- and cost-intensive.
Innovation Solution
A device with a separate forming element on the punch, made of ceramic via 3D printing, allowing for replaceable and customizable mold elements with integrated cooling channels, and indirect or direct heating, reducing material restrictions and enabling efficient temperature control without thermal sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid metal punch with integrated forming element is used, then structural strength is ensured, but manufacturing complexity increases due to manual polishing and coating requirements
Solution Approach 1:
The punch is divided into two separate components: a metal punch body providing structural strength and a separate forming element (calotte) that can be independently manufactured and replaced. This segmentation allows each component to be optimized for its specific function without the manufacturing complexities of the other.
Solution Approach 2:
The forming element is extracted from the solid metal punch structure and made into a separate replaceable component. This extraction eliminates the need for time-consuming manual polishing and coating processes on the punch body, while the forming element can be manufactured using simpler processes.
2Adaptability or versatility
If different calotte geometries are used for different applications, then adaptability improves, but economies of scale deteriorate due to inability to purchase in large quantities
Solution Approach 1:
The forming element is segmented as a separate interchangeable component, allowing different geometries to be produced independently. This enables specialized forming elements to be manufactured on-demand using 3D printing without requiring large inventory stockpiles, achieving both adaptability and cost-effectiveness for small quantities.
Solution Approach 2:
The forming element geometry can be easily modified by changing the 3D printing digital model parameters, allowing rapid adaptation to different applications without retooling or expensive mold changes. This digital flexibility enables economical production of varied geometries in small quantities.
3Use of energy by moving object
If the stamping die cross-section is reduced to lower current requirements, then space and cost efficiency improve, but structural stability deteriorates
Solution Approach 1:
The heating function is segmented from the structural punch body. The metal punch maintains its stable, robust cross-section for structural integrity, while a separate forming element handles the heating function. This allows the punch structure to remain stable without requiring large cross-sections for heat generation.
Solution Approach 2:
The heating mechanism is replaced from resistive heating of the entire punch to a more efficient localized heating system using induction heating or a dedicated heating element. This substitution reduces the current required while maintaining the structural stability of the punch cross-section.
4Manufacturing precision
If manual polishing is used to create form elements, then manufacturing precision can be achieved, but production time increases
Solution Approach 1:
Manual mechanical polishing is replaced with 3D printing technology for creating the forming element. The additive manufacturing process directly produces the precise geometry through digital modeling, eliminating the time-consuming manual polishing steps while maintaining or improving manufacturing precision through digital control.
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 cost-effective production of mold elements in small quantities, reduces manufacturing costs, and improves heating efficiency by allowing material flexibility and reduced current needs, while ensuring precise riveting quality through integrated control systems.
Implementation Method 1
This is achieved via the electrical resistance of the stamping die at the cap
Implementation Method 2
The resistance can be influenced by the choice of material and the cross-sections
Implementation Method 3
the cooling channels follow the shape of the shaped element at least in one section
Data Source
Figure 1~4
Figure 5~7
Figure 8~10
AI summary
The invention relates to a device for hot riveting a thermoplastic connecting element (10), wherein the device comprises a punch (11) designed to be placed on the connecting element (10) in order to deform the connecting element (10). According to the invention, the punch (11) has a separate forming element (12) arranged on the punch (11) for forming the connecting element (10).