Motor Vehicle Panel Fixing with Induction Heating and Welding
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Solution Overview
Problem
Conventional methods for fixing motor vehicle body panels, such as projection welding and induction heating, fail to provide sufficient rigidity and elasticity required for modern vehicles, often leading to panel deformation and increased costs due to separate apparatuses and processes.
Innovation Solution
A combined apparatus that integrates seaming, welding, and induction heating to fix motor vehicle body panels, allowing for simultaneous execution of these processes, reducing costs and time while maintaining panel geometry, using a single apparatus with continuous centering and reference tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If projection welding is used to fix panel elements, then the panel can be assembled, but the panel lacks sufficient rigidity and undergoes excessive deformation during assembly
Solution Approach 1:
The patent combines projection welding and induction heating in a single integrated apparatus. The induction heating unit heats the adhesive to pre-polymerization temperature while the projection welding unit simultaneously or sequentially welds the panel elements, achieving both rigidity enhancement and deformation control in one process cycle
Solution Approach 2:
The patent changes the thermal parameter of the adhesive by heating it to a specific temperature range (close to but below polymerization temperature) using induction heating. This thermal parameter change brings the adhesive to a pre-polymerization state that provides optimal bonding characteristics and panel rigidity without causing excessive deformation
2Strength
If induction heating is used to pre-polymerize adhesive, then panel rigidity increases, but the panel structure deforms and may require scraping
Solution Approach 1:
The patent applies preliminary action by heating the adhesive to a pre-polymerization state before final assembly and painting. The induction heating unit heats the adhesive to a temperature close to but below the polymerization temperature, creating an optimal bonding state that provides rigidity while allowing subsequent geometry correction during final assembly
Solution Approach 2:
The patent ensures continuity of useful action by integrating the induction heating and projection welding operations in a single continuous process within one apparatus. The heating and welding actions are coordinated to maintain panel geometry throughout the process, eliminating the need to interrupt centering and reference operations
3Productivity
If separate apparatuses are used for welding and heating, then each process can be optimized, but the costs and time increase
Solution Approach 1:
The patent merges the projection welding apparatus and induction heating apparatus into a single integrated fixing apparatus. This combination allows both processes to be performed in one location with shared components such as the base structure, support feet, and centering tools, reducing overall system complexity and cost while improving productivity
Solution Approach 2:
The patent implements multi-functionality by designing the apparatus to perform both induction heating and projection welding operations. The apparatus includes both an induction heating unit with generator and a projection welding unit with electrodes, allowing it to execute multiple fixing operations on panel elements without requiring separate dedicated apparatuses
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 solution achieves panels with optimal assembly on the vehicle body, increased mechanical resistance, and structural stiffness, reducing design, production, and manufacturing costs, while minimizing panel deformation and maintaining geometry.
Implementation Method 1
the arrangement of the panel in a heating apparatus, typically of the induction type, with its elements already seamed, which heats the edges of the panel where the adhesive has been applied, to a temperature lower than the polymerization temperature, that is close to 180°C
Implementation Method 2
the polymerization of the adhesive interposed between the elements of the panel takes place during a step following to the welding one, when, after the panel has been mounted on the motor vehicle body during the so-called 'hinged panels fitting' step, the whole motor vehicle is subjected to a painting step and subsequently heated to a temperature of the order of 200°C to obtain the polymerization of the paint, during which the polymeric adhesive interposed between the elements of the panel reaches the complete polymerization condition
Data Source
Figure 1
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AI summary
An apparatus for fixing the elements of a panel for a motor vehicle body, comprises a base (12, 14) and a shaped support structure (16, 18) adapted to support a composite panel (20) including two sheet elements (20a, 20b) to be fixed to each other and between which a polymeric adhesive is interposed (23). The apparatus (10) is provided with welding tools (26) intended to weld the sheet elements (20a, 20b) at predetermined zones, and with reference and locking tools (24) of the elements (20a, 20b) adapted to assure their positioning and mutual blocking during the operation of the welding means (26). The base (12, 14) comprises an induction heating tool (33) associated with the support structure (16, 18), adapted to heat the polymeric adhesive (23) to a preset temperature, in order that the adhesive (23) reaches a condition of pre-polymerization when the sheet elements (20a, 20b) are locked by the reference and locking means (16, 18).