Axially Movable Suction Insert for Coated Fastener Setting
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Solution Overview
Problem
Existing devices for setting connecting elements with coated surfaces face issues due to unevenness in coatings, leading to unreliable negative pressure holding and processing errors, especially when dealing with parts of lower quality.
Innovation Solution
A device with an insert element featuring a suction surface that is movable axially relative to the drive bit, allowing for reliable suction of connecting elements with uneven coatings by contacting unstructured areas, and utilizing a spring preload for improved sealing and axial mobility, ensuring effective transmission of negative pressure and axial forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum suction is used to hold the connecting element on the drive bit, then the connecting element can be securely retained, but coating unevenness on the drive structures prevents reliable vacuum achievement
Solution Approach 1:
The drive bit is divided into two functional zones: drive structures for rotational engagement and a separate suction surface for vacuum retention. This segmentation allows the drive structures to engage the connecting element's drive portion while the suction surface contacts the head surface, isolating the vacuum function from coating unevenness on the drive structures.
Solution Approach 2:
The suction surface acts as an intermediary between the vacuum source and the connecting element. It transfers the negative pressure from the suction unit to the connecting element's head surface, enabling reliable vacuum retention without direct contact between the vacuum system and the coated drive structures.
2Reliability
If the suction surface contacts the drive structures of the connecting element, then vacuum can be applied, but coating agents build up and prevent reliable interlocking
Solution Approach 1:
The suction surface is designed to contact only the head surface of the connecting element, which is specified as an uncoated or minimally coated area. This local quality distinction separates the vacuum contact zone from the coated drive structures, preventing coating agent buildup on the suction interface while maintaining rotational engagement through the drive structures.
3Productivity
If higher tolerances are allowed for coated fasteners, then more parts can be processed, but vacuum holding becomes unreliable
Solution Approach 1:
By segmenting the drive bit into drive structures and a separate suction surface, the system can accommodate varying coating qualities on different parts. The suction surface contacts the consistent head surface area while the drive structures handle rotation, allowing parts with coating variations to be processed reliably without compromising vacuum holding.
4Device complexity
If the suction surface is fixed relative to the drive bit, then the structure is simpler, but it cannot reliably contact unstructured areas of the fastener
Solution Approach 1:
The suction surface is made axially movable relative to the drive bit through a movable connection (spring-loaded or cam-driven mechanism). This dynamic adjustment allows the suction surface to contact the head surface of the connecting element at the appropriate position, ensuring reliable vacuum engagement even with variations in fastener dimensions or coating thickness.
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 solution enables reliable mounting and processing of connecting elements with surface irregularities, enhancing system availability by maintaining secure holding and efficient force transmission, even with coated parts, and allowing for higher tolerances in manufacturing.
Implementation Method 1
a suction unit (18), through which air can be sucked out at the front end of the drive bit (20), by means of which a connecting element (100) can be sucked onto the front end of the drive bit (20)
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a device (10) for setting a connecting element (100, 300) with a top-side drive structure (22, 44), comprising a feed device (12) for applying an axial force, a rotary spindle (14, 40. 68,82, 140) and a drive bit (20, 42, 60, 70, 80, 142, 242) connected to same, which has drive structures (22, 44) arranged circumferentially and at the end in a setting direction (S) in order to interlockingly cause the connecting element (100, 300) to rotate, wherein the drive bit (20, 42, 60, 70, 80, 142, 242) has an axial through-opening, and the device also comprises a suction unit (18) with which air can be suctioned out at the end side of the drive bit (20, 42, 60, 70, 80, 142, 242), characterised in that an insert element (24, 50, 72, 150) is provided having a suction surface (26, 54) on the end side, which circumferentially borders a suction cross-section (30), wherein the insert element (24, 50, 72, 150) is designed in such a way that the suction surface (26, 54) can move relative to the drive bit (20, 42, 60, 20 70, 80, 142, 242) in the axial direction, and a negative pressure can be transmitted from the side of the insert element (24, 50, 72, 150) facing away in the setting direction (S) to the suction surface (26, 54) of the insert element (24, 50, 72, 150), wherein, before the suctioning of a connecting element (100, 300), the suction surface (26, 54) adopts a first end position which is spaced apart from the end-side edge region of the through-opening in the setting direction (S), and adopts a second position, shifted opposite the setting direction (S), during the setting process.