Insertion Head Assembly for Reliable Fastener Transfer and Securing
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Solution Overview
Problem
Existing fastener feeder systems for automated fastening systems often lose contact with the fastener joining element, leading to misloaded fasteners, especially when using gravity, momentum, or magnetic attraction for transfer, and prior solutions like Davern's system are not robust or repeatable for clinching and welding operations.
Innovation Solution
A fastener securing system with an insertion head assembly featuring a movable insertion piston and clamp finger, where the fastener is loaded into opposing insertion jaws supported by flat spring steel jaw springs, allowing for precise engagement and secure transfer of the fastener to a workpiece using a locating pin and a movable fastener joining element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If gravity, momentum, or magnetic attraction is used to transfer the fastener from the feeder to the fastener joining element, then the transfer process is simplified, but contact is lost between the feeder and the fastener joining element, leading to misloaded fasteners
Solution Approach 1:
The patent introduces a transfer finger as an intermediary component that physically contacts both the fastener and the fastener joining element during transfer. This mediator ensures continuous contact and proper positioning, eliminating the misloading issues caused by non-contact transfer methods while maintaining relative system simplicity.
Solution Approach 2:
The patent replaces non-contact transfer mechanisms (gravity, momentum, magnetic attraction) with a controlled mechanical contact system using the transfer finger. This substitution ensures reliable physical guidance and positioning of the fastener throughout the transfer process, improving loading accuracy.
2Device complexity
If Davern's tube with split end is used for fastener transfer, then a transfer mechanism is provided, but the system is not robust or consistently repeatable for fastener clinching and welding operations
Solution Approach 1:
The transfer finger serves as a robust intermediary that provides consistent mechanical guidance for the fastener throughout the transfer process. Unlike Davern's split tube, the transfer finger maintains reliable contact and positioning, ensuring repeatable results for clinching and welding operations.
Solution Approach 2:
The patent divides the fastener securing system into distinct functional components: the feeder, the transfer finger, the fastener joining element, and the workpiece. This segmentation allows each component to be optimized for its specific function, with the transfer finger specifically designed for reliable fastener transfer, improving overall system consistency.
3Device complexity
If the fastener is transferred without continuous contact guidance, then the transfer process is simpler, but misaligned fasteners occur leading to loading errors
Solution Approach 1:
The transfer finger acts as a contact guidance intermediary that maintains continuous physical contact with the fastener during transfer. This ensures proper alignment and positioning, preventing misloading errors while adding only minimal structural complexity to the system.
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
Ensures consistent and robust fastener loading and secure attachment to the workpiece without relying on gravity, momentum, or magnetic attraction, minimizing misalignment and damage, and enabling efficient operation in various orientations for robotic applications.
Implementation Method 1
pushing the fastener past and separating the insertion jaws, the fastener that is pushed past the insertion jaws by deflecting flat spring steel jaw springs that support the insertion jaws
Data Source
AI summary
A method of securing a fastener to a workpiece includes a fastener that is loaded into a feeder, and an insertion head assembly that is provided adjacent to the feeder. The insertion head assembly includes an insertion actuator that has a movable insertion piston, and a clamp finger that is mounted to the insertion piston. The fastener is arranged beneath a movable fastener joining element that is carried by the insertion head assembly, the workpiece is positioned relative to a locating pin, the insertion head assembly is moved to engage the workpiece with the clamp finger, the fastener is brought into engagement with a locating pin, the fastener joining element is advanced relative to the clamp finger, and the fastener that is secured to the workpiece.