Modular Joining Tool for Threaded Deformable Inserts
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Solution Overview
Problem
Existing joining tools are not easily adaptable to deformable elements of different sizes or geometries, particularly those with threaded shafts, and lack adjustability for various types of inserts, making them inefficient for securing earth bonds or inserts to workpieces.
Innovation Solution
A battery-powered joining tool with a hydraulic system and interchangeable components, including a removable nose and threaded dowel, allows for adjustable settings to accommodate various deformable elements, featuring a contact sensor for automatic screwing and a hydraulic system for precise deformation, enabling secure fastening of deformable elements to workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed design joining tool is used, then the tool structure is simple, but the adaptability to different deformable elements is poor
Solution Approach 1:
The joining tool is divided into modular components including an interchangeable nose, threaded dowel, and body. The nose and threaded dowel can be removed and replaced to accommodate different deformable element geometries and sizes, enabling adaptability without redesigning the entire tool structure.
Solution Approach 2:
The tool body is designed as a universal platform that can perform multiple functions by accepting different noses and threaded dowels. This allows a single base tool to handle various deformable elements (earth bonds, inserts, blind rivets) with different sizes and geometries through component interchangeability.
2Productivity
If manual screwing is used, then the device structure is simple, but the productivity is low
Solution Approach 1:
The manual screwing operation is replaced with an automatic mechanical drive system. The motor-driven first mechanical drive train automatically rotates the threaded dowel during the joining process, eliminating manual intervention and significantly increasing screwing speed and productivity.
3Manufacturing precision
If hydraulic system is added, then the deformation precision is improved, but the device complexity increases
Solution Approach 1:
A hydraulic system is integrated into the second drive train to provide controlled axial displacement of the nose. The hydraulic actuation enables precise deformation of the deformable element by controlling fluid pressure, which translates to precise positional control of the nose during the setting process.
4Ease of operation
If fixed components are used, then the device structure is simple, but the ease of operation is reduced
Solution Approach 1:
The tool transitions from a fixed configuration to a dynamic, adjustable system. The nose and threaded dowel components are designed for quick interchangeability, allowing the operator to easily adapt the tool to different deformable elements by simply replacing components rather than adjusting complex mechanisms.
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
The tool ensures reliable and stable setting of deformable elements with improved adaptability to different sizes and geometries, reducing effort and ensuring secure fastening by distributing setting forces effectively, while allowing easy removal of stuck elements.
Implementation Method 1
a second drive train comprising a hydraulic pump fluidly coupled to a piston chamber containing a traction piston wherein the traction piston is movable from an initial position in the piston chamber by way of fluid pressure from the pump to cause axial displacement of a traction rod towards the housing
Implementation Method 2
the hydraulic system impresses an axial translation on the nose for determining a plastic deformation of a predetermined portion of the deformable element
Data Source
Figure 1~2B
Figure 3~4
Figure 5
AI summary
Method for joining a deformable element (20) to a workpiece and joining tool (10) comprising a threaded dowel (40) adapted to receive a threaded shaft (48) of a deformable element (20), the threaded dowel (40) being rotatably movable around a longitudinal axis with regard to the housing (12), a nose (42) arranged around the threaded dowel (40), wherein the threaded dowel (40) is slidably movable with regard to the nose (42), a first mechanical drive train (46) drivable by the motor (44) to cause rotation of the threaded dowel (40) in a screwing direction or an unscrewing direction, a second drive train (54) comprising a hydraulic system (56) adapted for determining a plastic deformation of a predetermined portion of the deformable element (20). The joining tool (10) further comprises a sliding unit (60), the nose (42) being removably attachable to the sliding unit (60), and in the attached position, the nose (42) is slidably connected to the housing (12) such that the hydraulic system (56) impresses an axial translation on the nose (42) for determining a plastic deformation of a predetermined portion of the deformable element (20).