Optical Assembly Press for Precise Component Press-Joining
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Solution Overview
Problem
Conventional press-joining processes require complex and costly devices, result in inconsistent pressing dimensions, high scrap rates due to re-measuring, and are inflexible in geometry adjustments, leading to unreliable dimensional accuracy.
Innovation Solution
An assembly press system with a linear unit, optical measuring unit, and gripper stamp for automated component alignment and measurement, allowing precise and flexible press-joining within predefined tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional press-joining devices are used, then pressing force can be applied, but device complexity and cost increase significantly
Solution Approach 1:
The patent combines the pressing function and measurement function into a single integrated device. The press device includes both a pressing unit that can apply pressing force and an optical measuring unit that can measure pressing dimensions, eliminating the need for separate complex devices and reducing overall system complexity.
Solution Approach 2:
The press device is designed with multi-functionality, serving both as a pressing device and a measurement device. This universal design allows the same equipment to perform multiple functions (pressing and measuring), reducing device complexity and cost while maintaining the required pressing force capability.
2Productivity
If conventional press-joining processes are used, then components can be joined, but pressing dimension consistency deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where the optical measuring unit continuously measures the pressing dimension during the press-joining process. The control unit receives this measurement data and adjusts the pressing process in real-time to ensure consistent pressing dimensions, achieving both high productivity and manufacturing precision.
Solution Approach 2:
The optical measuring unit measures component dimensions before pressing to verify they meet tolerance requirements. This preliminary measurement action prevents defective components from entering the pressing process, ensuring consistent pressing dimensions and reducing rework.
3Ease of manufacture
If conventional press-joining methods are used, then joining can be performed, but scrap rate increases due to re-measuring requirements
Solution Approach 1:
The integrated optical measuring unit provides real-time feedback on pressing dimensions during the process. This allows immediate detection and correction of dimensional deviations, eliminating the need for post-pressing re-measuring and reducing scrap rate while maintaining process simplicity.
Solution Approach 2:
The patent replaces manual re-measuring processes with an automated optical measuring system integrated into the press device. This substitution eliminates the need for laborious post-pressing measurements and reduces scrap by providing continuous automated dimensional verification.
4Productivity
If conventional press-joining processes are used, then components can be joined, but adaptability to geometry changes decreases
Solution Approach 1:
The patent implements a dynamic system where the optical measuring unit and control unit can adapt to different component geometries. The system can adjust measurement parameters and pressing conditions based on the specific geometry being processed, enabling flexible adaptation to design changes while maintaining joining efficiency.
Solution Approach 2:
The system allows for parameter changes in response to geometry variations. The optical measuring unit can detect different component geometries and the control unit adjusts pressing parameters accordingly, providing adaptability to geometry changes without sacrificing productivity.
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
Ensures accurate and reliable press-joining with reduced scrap rates by measuring components before and during the process, achieving dimensional tolerances of up to 1 µm, and optimizing press-in forces through artificial intelligence.
Implementation Method 1
an optical measuring unit (2) comprising a detection region directed onto a portion of the linear unit (1) in order to measure a component placed on the linear unit (1)
Data Source
AI summary
The disclosure relates to an assembly press for press-joining components, which comprises a linear unit that is configured for moving a component placed thereon back and forth along one direction, an optical measuring unit comprising a detection region directed onto a portion of the linear unit in order to measure a component placed on the linear unit, and a gripper stamp which is configured for lifting a first component, optionally an inner partner, from the linear unit and, after displacement of the linear unit, for joining it to a second component, optionally an outer partner, placed in the detection region.