Two-Stage Nail Bolt Setting for Low-Noise Robotic Joining
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Solution Overview
Problem
Existing bolt setting methods using high-speed, nearly rotation-free straight-lined movements for nail-shaped bolts result in noise pollution and high mechanical loads on robots, making it difficult to implement these methods with lower-classification industrial robots due to excessive reaction forces.
Innovation Solution
A two-step bolt setting method involving a deforming stroke to penetrate the bolt into components with a maximum diameter and a subsequent friction stroke to complete the connection, reducing energy consumption and reaction forces, accompanied by a setting device with an electronic control unit to manage kinetic energy and adjust joining speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed straight-lined setting movement is used for nail-shaped bolts, then joining speed is improved, but noise emission and mechanical loads on robots increase
Solution Approach 1:
The patent divides the single high-speed setting movement into two distinct phases: a first setting movement at reduced speed to penetrate the bolt into the component, and a second setting movement to complete the connection. This segmentation eliminates the need for high-speed operation while achieving reliable joining, thereby reducing noise emission and mechanical loads on robots.
2Productivity
If high-speed straight-lined setting movement is used for nail-shaped bolts, then joining speed is improved, but reaction forces on robots increase
Solution Approach 1:
The patent segments the setting process into two phases with different speed characteristics. The first phase operates at reduced speed to minimize reaction forces during penetration, while the second phase completes the connection. This approach allows use of lower-classification robots with reduced stability requirements, lowering system costs.
Solution Approach 2:
The patent dynamically adjusts the setting speed during the two-phase process, using reduced speed in the first phase to minimize reaction forces, and can optimize speed in the second phase. This dynamic speed adjustment enables effective bolt setting with lower-classification industrial robots.
3Use of energy by moving object
If two-step setting method is used, then energy consumption is reduced, but process complexity increases
Solution Approach 1:
The patent segments the setting process into two distinct phases: penetration at reduced speed and completion phase. This segmentation reduces overall energy consumption by avoiding high-speed operation throughout the entire process. The electronic control unit automates the transition between phases, managing the increased process complexity through intelligent control.
Solution Approach 2:
The electronic control unit monitors the setting process and automatically adjusts parameters between the two phases, managing the process complexity through feedback control. This enables the system to handle the two-step method efficiently without requiring complex manual intervention.
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 method reduces noise emission and mechanical loads on robots, allowing for effective bolt setting with lower-classification industrial robots by optimizing energy use and controlling reaction forces, thereby enhancing the efficiency and cost-effectiveness of the bolt setting process.
Implementation Method 1
the bolt is set into the at least one component nearly rotation-free with a straight-lined setting movement in at least two steps... during which the bolt reaches a first joining speed of ≤ 4 m/s and the shaft completely penetrates the at least one component
Implementation Method 2
with at least one friction stroke with which a frictional connection between the shaft and the components is overcome
Data Source
AI summary
A bolt setting method and device for a nail-shaped bolt with a head and a shaft, ending in a tapered manner. The bolt setting method includes: joining the bolt into a component with a deforming stroke during which the bolt reaches a first joining speed of ≤4 m/s and the shaft completely penetrates the components with a portion of a maximum diameter with respect to a shaft length, without a bottom side of the head abutting the at least one component, and after the deforming stroke, driving the bolt into the at least one component until a head abutment of the bottom side of the head on the at least one component by at least one friction stroke with which a frictional connection between the shaft and the components is overcome and with which the bolt reaches a second joining speed that is smaller than the first joining speed.