Integrated Panel Joining for Multi-Material Corrosion Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing joining technologies for vehicle body panels, particularly those combining different materials like aluminum and steel, face issues with galvanic corrosion during welding, requiring additional equipment and increased investment costs, and are complex to maintain due to the need for separate devices and complex processes.
Innovation Solution
A joining apparatus that includes an element punching device for inserting elements into panel sheets and a C-type resistance welding gun for welding, with a distance adjusting mechanism and a unified system that can accommodate various element sizes, reducing the need for multiple devices and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resistance spot welding device is used to join different types of panel sheets, then welding function is achieved, but additional devices and elements are required to prevent galvanic corrosion, increasing investment costs and device complexity
Solution Approach 1:
The punching device and welding device are merged into a single integrated apparatus. The punching unit inserts elements into panel sheets, and the welding unit immediately welds the inserted elements, combining two previously separate processes into one unified system. This reduces the number of separate devices needed and simplifies the overall system while maintaining galvanic corrosion prevention functionality.
Solution Approach 2:
The punching device is designed with an element storage unit that can accommodate multiple types of elements for different panel sheet specifications. The same punching device can handle various element sizes and types by selecting from the stored elements, making it a universal device that replaces the need for multiple specialized punching devices for different panel types.
2Reliability
If separate equipment is provided for each different element size to prevent galvanic corrosion, then specific joining requirements are met, but investment costs and facility size increase substantially
Solution Approach 1:
The element storage unit is designed to store multiple types of elements with different specifications. The punching device can select and insert appropriate elements based on the panel sheet being processed, making a single device capable of handling various joining requirements that previously required multiple separate devices.
Solution Approach 2:
The system incorporates an element selection mechanism that dynamically selects the appropriate element type based on the panel sheet specifications. This dynamic adaptability allows a single device to perform multiple functions that previously required multiple fixed-purpose devices.
3Object-affected harmful factors
If welding apparatuses are replaced with non-welding type joining technique, then galvanic corrosion problem is reduced, but all welding apparatuses need to be replaced, increasing initial investment costs
Solution Approach 1:
Instead of completely replacing welding apparatuses with a different joining technique, the invention uses an intermediary approach: elements are inserted into the panel sheets to prevent galvanic corrosion, and then resistance spot welding is used to join the inserted elements. This hybrid approach mitigates galvanic corrosion while utilizing existing welding infrastructure, avoiding the need for complete system replacement.
4Ease of operation
If RSW device includes moving device and control device, then element supply function is achieved, but process becomes complex and maintenance becomes more difficult
Solution Approach 1:
The element storage unit, punching mechanism, and welding mechanism are merged into a single integrated apparatus. The punching unit and welding unit work in sequence within the same device, eliminating the need for separate moving devices and control systems that would be required if these functions were distributed across multiple independent devices.
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 solution allows for the simultaneous accommodation of multiple element sizes, reducing plant and equipment investment costs and simplifying the process by integrating punching and welding functions, thereby decreasing process time and maintaining system complexity.
Implementation Method 1
a welding device configured to resistively weld a part of the first panel sheet into which the element is inserted by the element punching device
Data Source
AI summary
A joining apparatus for panel sheets and a joining method for panel sheets using the same are provided. The joining apparatus includes an element punching device which stores and supplies elements according to a specification of a panel sheet and inserts the element into a first panel sheet among different types of panel sheets. Additionally, a welding device resistively welds a part of the first panel sheet into which the element is inserted by the element punching device.