Joining Components With Pre-Positioned Position Features
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Solution Overview
Problem
Existing methods for joining components often result in post-processing requirements for functional surfaces to achieve dimensional accuracy, which is labor-intensive and costly, and do not effectively compensate for manufacturing inaccuracies.
Innovation Solution
The method involves defining a position feature between functional surfaces as a target value, setting a joining gap based on this feature, and adjusting the joining process to achieve the target value, allowing for pre-positioning and correction of components during the joining process to ensure precise alignment and minimize post-processing needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If components are joined using conventional methods, then the joining process is completed, but post-processing is required for functional surfaces to achieve dimensional accuracy
Solution Approach 1:
The patent applies preliminary action by pre-positioning the components relative to each other before the joining process based on predetermined position features. The components are arranged in a pre-positioned state that anticipates the distortions that will occur during joining, so that after joining, the functional surfaces automatically achieve the desired dimensional accuracy without requiring post-processing. This is accomplished by calculating predetermined position features that compensate for expected joining distortions.
2Manufacturing precision
If conventional joining methods are used, then the joining process is completed, but manufacturing inaccuracies cannot be compensated for
Solution Approach 1:
The patent applies parameter changes by systematically varying the predetermined position features based on different joining parameters such as joining method, joining force, joining temperature, and joining sequence. By adjusting these parameters, the method can compensate for manufacturing inaccuracies and predict the final positions of functional surfaces after joining. This allows the pre-positioning step to account for and compensate for various sources of manufacturing variation.
Solution Approach 2:
The patent applies feedback by using measured actual positions of functional surfaces after joining to update and refine the predetermined position features for subsequent joining operations. This creates a closed-loop system where information from actual joining results feeds back into the pre-positioning calculations, continuously improving the accuracy of distortion compensation and enabling better compensation for manufacturing inaccuracies over time.
3Loss of time
If functional surfaces are finished before joining, then post-processing can be avoided, but the joining process may affect the positional accuracy of these surfaces
Solution Approach 1:
The patent applies preliminary anti-action by pre-positioning the components in a state that counteracts the expected distortions from the joining process. Before joining occurs, the components are arranged with predetermined position features that are calculated to compensate for the anticipated effects of joining on functional surface positions. This preliminary counter-positioning ensures that even though the joining process does affect positional accuracy, the net result achieves the desired accuracy without requiring post-processing correction.
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 approach enables the production of predominantly finished functional surfaces before joining, reducing or eliminating the need for post-processing, achieving high-precision structural units with reduced rejects and operational costs.
Implementation Method 1
The invention relates to a method for joining, in particular laser welding, two components
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for thermally joining two components (1, 2), wherein prior to the joining operation on said components functional surfaces (5, 6) that are predominantly finished at least with respect to the surface finishes thereof are produced in sections, subsequently the two components (1, 2) are positioned relative to each other, and then connected to each other on mutually facing joining surfaces (8, 9). To begin with, a position characteristic is defined as a target value between the functional surfaces (5, 6) configured on the components (1, 2) while taking a joining parameter into consideration. Then, a joining gap (14) is set between the mutually facing joining surfaces (8, 9) of the components (1, 2) to be joined, as a function of the position characteristic, so that the target value of the position characteristic is achieved after completing the joining operation.