Joining Method Force Profile Numerical Quality Mapping
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Solution Overview
Problem
Existing joining methods rely on visual comparison of force profiles with reference profiles to assess connection quality, which is inflexible and requires multiple diagrams to detect trends like wear or fatigue, making it difficult to evaluate the quality of connections accurately and efficiently.
Innovation Solution
A joining method that records and compares the force profile with a reference profile, forming a difference profile which is then mapped numerically to a quality value, allowing for statistical evaluation and detection of trends, enabling targeted assessment of specific joining operation phases and tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual comparison of force profiles with reference profiles is used to assess connection quality, then the method is simple to implement, but the evaluation is inflexible and requires multiple diagrams to detect trends
Solution Approach 1:
The patent transforms the visual force profile comparison into a numerical quality value by integrating the difference between actual and reference force profiles over the joining process. This parameter transformation enables statistical evaluation and trend detection while maintaining ease of implementation through automated calculation.
Solution Approach 2:
The patent introduces an intermediary quality value that mediates between the force profile data and the final quality assessment. This quality value serves as a numerical representation that can be stored, compared, and analyzed statistically, bridging the gap between raw measurement data and actionable quality decisions.
2Reliability
If multiple diagrams are used to detect trends like wear or fatigue, then trend detection becomes possible, but the complexity of evaluation increases
Solution Approach 1:
The patent extracts the essential quality information from the entire force profile by integrating the difference curve into a single quality value. This extraction process captures trend information (such as wear or fatigue) in one numerical parameter, eliminating the need for multiple diagrams while maintaining reliable trend detection.
Solution Approach 2:
The patent segments the force profile evaluation into distinct phases (approach, joining, separation) and integrates the quality assessment across these segments. This segmentation allows comprehensive trend detection while organizing the evaluation in a systematic, manageable way that reduces overall complexity.
3Ease of operation
If force profile comparison is performed without numerical mapping, then the method is straightforward, but statistical evaluation and quality trend analysis are not possible
Solution Approach 1:
The patent replaces the manual visual comparison method with an automated numerical integration process. This substitution transforms the qualitative visual assessment into a quantitative statistical evaluation system, preserving all quality information in numerical form for further analysis while maintaining operational simplicity through automation.
Solution Approach 2:
The patent establishes a feedback loop where the quality value derived from force profile comparison can be stored, analyzed statistically, and used to adjust future joining processes. This feedback mechanism prevents information loss by systematically capturing and utilizing quality data for continuous improvement.
Data Source
AI summary
Joining method, in particular for connecting at least two workpieces, in which during a joining operation the profile (F) of a force exerted by a joining tool is recorded and compared with a reference force profile (FR) in order to be able to check the quality of the joined connection produced, the difference (Δ) between the force profile (F) and the reference force profile (FR) being formed, and at least one segment (A; B) of the difference profile (ΔF) thereby determined being mapped numerically onto a quality value (QW).