Metal Sheet Joint Quality Control Using Force-Displacement Curves
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Solution Overview
Problem
Existing methods for determining the quality of joints in metal sheets using joining devices are complex and not economically viable, requiring intricate sensor integration and real-time data processing, which is challenging due to space constraints and economic limitations.
Innovation Solution
A method that records a force/displacement curve using sensors during the joining process and compares it to a reference curve to evaluate the joint quality, allowing for the assessment of metal sheet thickness and rivet length, with a simplified structural design that includes a drive element and a hold-down device moved by springs, enabling evaluation of joint quality without the need for extensive real-time control systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If real-time control with multiple sensors and data processing is implemented, then joint quality evaluation precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the essential evaluation information from complex real-time control systems by identifying that only the force/displacement curve is needed for quality assessment. This eliminates the need for multiple sensors and complex real-time data processing while maintaining evaluation precision through curve comparison against reference data.
Solution Approach 2:
The patent applies preliminary action by pre-establishing reference force/displacement curves for different joint quality standards. Instead of performing complex real-time analysis during joining, the system simply compares measured curves against these pre-defined references, dramatically simplifying the control system while maintaining high evaluation precision.
2Measurement precision
If real-time control with multiple sensors is implemented, then joint quality evaluation precision is improved, but economic viability deteriorates
Solution Approach 1:
The patent extracts only the necessary measurement data (force/displacement curve) from the complex sensor system described in prior art. By focusing on a single curve comparison rather than multiple sensor readings and complex real-time processing, the system achieves quality evaluation at a fraction of the cost, improving economic viability while maintaining precision.
Solution Approach 2:
The patent employs simpler, more economical sensing approaches by replacing expensive integrated multi-sensor systems with basic force and displacement measurements. The use of standard sensors and offline curve comparison rather than expensive real-time control systems makes the solution economically viable for widespread adoption.
3Measurement precision
If space for sensor integration is increased, then measurement precision is improved, but available space in setting head is reduced
Solution Approach 1:
The patent extracts the measurement function from the physical setting head by using external or integrated sensors that do not consume valuable internal space. The force/displacement measurements are obtained without requiring multiple sensors to be cramped into the setting head, thus maintaining measurement precision while preserving available space for other critical components.
4Measurement precision
If data processing effort is increased, then joint quality evaluation precision is improved, but processing time and complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing reference force/displacement curves for various joint quality standards. During actual joining operations, the system only needs to measure the curve and compare it against these pre-established references, eliminating the need for complex real-time data processing while maintaining high evaluation precision.
Solution Approach 2:
The patent extracts the essential quality indicator from complex joint characteristics by focusing solely on the force/displacement curve shape and key parameters. This simplification allows for rapid curve comparison against references without requiring extensive real-time analysis of multiple joint parameters, thus reducing processing time while maintaining evaluation precision.
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 simplifies the evaluation of joint quality by comparing recorded force/displacement curves to reference curves, allowing for accurate assessment of joint characteristics such as metal sheet thickness and rivet length, thereby ensuring optimal joint fabrication while reducing the complexity and cost of the joining process.
Implementation Method 1
sensing of a force applied by the drive element with a first sensor
Implementation Method 2
sensing of a distance covered by the drive element with a second sensor
Implementation Method 3
with the drive element transferring the movement to the punch and, via at least one first and one second spring, to the hold-down device
Data Source
AI summary
A method for determining the quality of a joint fabricated in a plurality of metal sheets by a joining device and a control method. The joining device comprises a drive element, and a hold-down device The method may have the following steps: moving the drive element to move the punch and, via at least one first and one second spring, the hold-down device; recording of a force applied by the drive element with a first sensor and of a distance covered by the drive element with a second sensor during a movement of the drive element in a mating direction and opposite thereto as a force/displacement curve; and comparing a linear relief range in the recorded curve with a reference curve.