Indexed Clinch Nut Attachment to AHSS With Light-Safe Laser Joining
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Solution Overview
Problem
Existing methods for securing clinch nuts to advanced high strength steel sheets are inefficient and pose safety risks due to the need for laser heating, which requires light-safe processing stations to prevent operator exposure to scattered radiation.
Innovation Solution
A joining assembly with a base, indexing member, and laser assembly that moves between heating and joining positions, ensuring safe operation by containing the laser within a light-safe chamber and using a detector assembly to prevent radiation exposure, while allowing for the secure attachment of clinch nuts to the steel sheet using a nut ram and clinch die.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser heating is used to secure clinch nuts to advanced high strength steel sheets, then the mechanical joining process is improved, but operator safety is compromised due to scattered radiation exposure
Solution Approach 1:
The processing station is divided into distinct functional zones: a laser heating zone with light-safe enclosure, and a joining zone accessible to operators. The indexing member moves between these zones, separating the harmful laser operation from operator workspace while maintaining process integration
Solution Approach 2:
The indexing member acts as an intermediary carrier that receives laser heating at one position and transports the heated work location to the joining position. This mediator enables the decoupling of laser heating and mechanical joining operations in space, allowing operator safety without sacrificing process efficiency
2Object-affected harmful factors
If a light-safe enclosed processing station is used to contain laser radiation, then operator safety is improved, but device complexity increases
Solution Approach 1:
The indexing member is designed with dynamic movement between heating and joining positions, allowing the system to transition between enclosed laser heating mode and open joining mode. This dynamic repositioning reduces the need for permanent light-safe enclosures throughout the entire workspace, simplifying the overall structure while maintaining safety
Solution Approach 2:
Only the laser heating zone requires light-safe enclosure, while the joining zone remains accessible. The indexing member bridges these segmented zones, allowing the light-safe requirement to be localized rather than applied to the entire processing station, thereby reducing structural complexity
3Productivity
If the indexing member moves between heating and joining positions, then process efficiency is improved, but device complexity increases
Solution Approach 1:
The indexing member serves multiple functions: it positions the workpiece for laser heating, transports the heated area to the joining position, and coordinates with both the laser assembly and clinch die. This multi-functionality consolidates several positioning and handling operations into a single mechanism, reducing overall system complexity despite the movement requirements
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 safe and efficient attachment of clinch nuts to advanced high strength steel sheets, improving the mechanical joining process and allowing for the use of clinch nuts with threaded holes for further component attachment, while ensuring operator safety during laser operation.
Implementation Method 1
A laser assembly fires a laser beam through the heating opening of the indexing member while in the heating position to provide heating of the work location of the AHSS sheet
Data Source
AI summary
Apparatus (20) and a method for securing a clinch nut (24) to an AHSS sheet (26) as an assembly (22). In one embodiment, a parallel kinematic machine (PKM) (88) sequentially performs the operation, while another embodiment includes a nut ram assembly (112) that attaches clinch nuts (24) to the AHSS sheet (26), and a further embodiment includes a C frame (114) that supports the apparatus and is moved by a robot (130) to sequentially attach clinch nuts (24) to the AHSS sheet (26) at different locations. The attachment of the clinch nuts is performed in a light-safe manner.