Optical Inner Die for Simultaneous Laser Heating and Plastic Deformation
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Solution Overview
Problem
Existing methods for connecting components in automobile construction through plastic deformation, such as tensile-compressive forming, face challenges like heat loss due to cooling between heating and deformation, and inefficiencies in heating control during the process.
Innovation Solution
A method involving an inner die with optical components that directs light for heating the deformation region of a first component, allowing simultaneous heating and deformation, thereby avoiding heat losses and enabling precise control of the heating process, using focused light sources like lasers and integrated optical systems within the inner die for efficient heating and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the deformation region is heated before plastic deformation, then the material becomes more formable and easier to deform, but heat losses occur during the time between heating and deformation
Solution Approach 1:
The patent combines the heating function and deformation function into a single integrated process step. The optical component (laser) is positioned within the inner die so that heating and deformation occur simultaneously at the deformation region, eliminating the time gap that causes heat loss while maintaining material formability.
Solution Approach 2:
The heating action is made continuous with the deformation action. By integrating the optical heating component into the deformation device, the material remains heated throughout the entire deformation process, ensuring continuous thermal energy application and eliminating idle cooling periods.
2Ease of manufacture
If heating is performed separately before deformation, then the process steps are simple and clear, but the cycle time increases due to sequential operations
Solution Approach 1:
The patent merges two separate process steps (heating and deformation) into one simultaneous operation. The optical component is integrated into the inner die structure, allowing both heating and deformation to occur in the same time frame, thereby reducing cycle time while maintaining process clarity through functional integration.
Solution Approach 2:
The heating capability is prepared in advance by integrating the optical component into the inner die structure before the deformation process begins. This preliminary integration ensures that heating can immediately accompany deformation without requiring separate setup or timing coordination, thus reducing overall cycle time.
3Device complexity
If conventional heating methods are used, then the equipment is simple, but heat control precision and monitoring capability are insufficient
Solution Approach 1:
The patent implements feedback control by using the optical component for both heating and monitoring. The same optical system that delivers heating energy can detect thermal radiation from the deformation region, enabling real-time temperature monitoring and adjustment to maintain precise heating control throughout the deformation process.
Solution Approach 2:
The optical component serves multiple functions: it acts as both a heating source (laser) and a monitoring device (detector). This multi-functionality reduces the need for separate heating and monitoring equipment, maintaining relative equipment simplicity while achieving precise heating control and real-time temperature measurement.
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 enhances the quality of connections by maintaining heat during deformation, reducing cycle time, and improving the interlocking or frictional engagement between components, while minimizing heat losses and allowing for real-time monitoring and adjustment of the heating process.
Implementation Method 1
light for heating the first component is directed onto the deformation region by way of the optical component
Implementation Method 2
connecting of a first component to a second component by plastic deformation
Implementation Method 3
the connection between the first and the second component is obtained by the interlocking and/or frictionally engaging interaction
Data Source
AI summary
A method is provided for connecting a first component to a second component, wherein the first component has a deformation region. The deformation region is at least partially heated in a first step. In a second step an inner die, having an optical component for plastic deformation, is provided. In a third step the first component is plastically deformed in the deformation region in order to connect the first component to the second component. Light for heating the first component is directed at the deformation region by means of the optical component of the inner die in the first and/or third step.