Two-Stage Nail Bolt Setting to Cut Robot Load and Noise
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Solution Overview
Problem
Existing bolt-setting methods for connecting components using nail-shaped bolts often result in high noise pollution and mechanical stress on robots due to high reaction forces, making it difficult to transfer these methods to industrial robots of lower classifications, which are less expensive but less stable.
Innovation Solution
A bolt-setting method involving a two-stage process where the bolt is driven into components with a deformation impact followed by a friction impact, reducing the energy required for the second stage and minimizing noise and mechanical stress, using a setting tool with an electronic control unit to manage the kinetic energy and joining speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high joining speeds are used for effective bolt setting, then connection quality and setting effectiveness are improved, but reaction forces on robots increase and noise pollution increases
Solution Approach 1:
The setting process is divided into two distinct stages: a first stage with higher joining speed for effective bolt setting, and a second stage with reduced speed to minimize noise and reaction forces. This segmentation allows each stage to be optimized for its specific function, resolving the contradiction between productivity and noise pollution.
Solution Approach 2:
The setting tool applies periodic action by alternating between two setting speeds during the bolt setting process. The first stage uses higher speed for effectiveness, then transitions to lower speed for noise reduction, creating a periodic speed variation that balances productivity and environmental factors.
2Productivity
If high joining speeds are used for effective bolt setting, then connection quality is improved, but reaction forces on robots increase
Solution Approach 1:
The setting process is divided into two distinct stages: a first stage with higher joining speed for effective bolt setting, and a second stage with reduced speed to minimize noise and reaction forces. This segmentation allows each stage to be optimized for its specific function, resolving the contradiction between productivity and noise pollution.
Solution Approach 2:
The setting tool applies periodic action by alternating between two setting speeds during the bolt setting process. The first stage uses higher speed for effectiveness, then transitions to lower speed for noise reduction, creating a periodic speed variation that balances productivity and environmental factors.
3Productivity
If high stability classification robots are used to handle reaction forces, then bolt setting effectiveness is maintained, but production line costs increase
Solution Approach 1:
The setting tool employs dynamic speed adjustment, changing the joining speed during the bolt setting process based on the stage of insertion. This dynamic adaptation allows the system to maintain effectiveness while reducing peak reaction forces, enabling use of lower-cost robots.
Solution Approach 2:
The system changes the operational parameter (joining speed) during the bolt setting process. By transitioning from higher speed in the first stage to lower speed in the second stage, the system optimizes both effectiveness and cost, allowing use of robots with lower stability classifications.
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 method allows for efficient and quiet bolt setting with reduced mechanical load on robots, enabling the use of less expensive industrial robots by controlling the energy input and reaction forces, thus improving the stability and cost-effectiveness of the bolt-setting process.
Implementation Method 1
the bolt is driven almost without rotation with a rectilinear setting movement which is set in at least two stages in the components... with a deformation impact... by at least one friction impact
Implementation Method 2
by at least one friction impact, with which a frictional connection between the shaft and the components is overcome
Data Source
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AI summary
The present invention discloses a bolt setting method and a setting device for a nail-shaped bolt with a head and a tapered shank extending from it. The bolt setting method comprises the following steps: inserting the bolt into at least one component with a deformation impact, in which the bolt reaches a first insertion velocity of ≤4 m/s and the shank, with a region of maximum diameter relative to a shank length, completely penetrates the component without the underside of the head bearing on the at least one component; and, after the deformation impact, driving the bolt into the at least one component until the underside of the head bears on the at least one component by at least one friction impact, in which a frictional fit between the shank and the component is overcome and in which the bolt reaches a second insertion velocity lower than the first insertion velocity.