Press-In Bolt Setting With In-Axis Hole Forming and Collar Drawing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional systems for setting press-in bolts on complex components require additional steps and can experience position deviations due to complex geometry, leading to faults in the fastening process.
Innovation Solution
A device with a C-arm tool carrier and a setting unit that integrates a two-stage process, combining hole punching and hole forming on the same axis, using a feed unit with an electric drive and a plunger to form a deep-drawn collar, allowing for accurate and reliable setting of press-in bolts without tool changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a deep-drawn collar and punched hole are made in a first step before setting, then reliable fixation of the press-in bolt is ensured, but an additional operation step is required and the process complexity increases
Solution Approach 1:
The patent combines the hole punching operation and the press-in bolt setting operation into a single integrated process step. The setting unit is designed to perform both operations simultaneously using the same tool carrier and robot gripper, eliminating the need for separate deep-drawn collar formation and reducing process complexity while maintaining fixation reliability.
Solution Approach 2:
The setting unit is designed as a multi-functional tool that can both punch holes and set press-in bolts. The same tool carrier and gripper configuration are used for both operations, making the system universal and eliminating the need for tool changes or additional specialized equipment for collar formation.
2Reliability
If the component is specially prepared with a deep-drawn collar and punched hole, then reliable fixation is ensured, but the cycle rate is reduced due to additional steps
Solution Approach 1:
The patent merges the hole punching and press-in bolt setting into one simultaneous operation using the same tool carrier. This eliminates the sequential steps of first forming a deep-drawn collar and then setting the bolt, thereby reducing the overall cycle time while ensuring reliable fixation through the integrated process.
3Measurement precision
If the punched hole is used for centering on a centering mandrel, then positioning is achieved, but position deviations occur due to robot path programming and tension between components
Solution Approach 1:
The patent extracts the centering function from the punched hole and centering mandrel approach. Instead of relying on the punched hole for centering, the system uses the integrated setting unit with tool carrier that maintains consistent positioning through the same lateral position during both hole punching and setting operations, eliminating the source of position deviations.
Solution Approach 2:
Instead of using the punched hole as the reference for centering (traditional approach), the patent inverts the approach by using the tool carrier's consistent lateral position as the reference. The setting unit maintains the same lateral position during both operations, making the tool positioning the reference rather than the workpiece feature.
4Ease of manufacture
If tool changes are required for different operations, then specialized tools can be used, but the cycle rate is reduced and process complexity increases
Solution Approach 1:
The setting unit is designed as a universal tool that can perform both hole punching and press-in bolt setting operations. The same tool carrier and gripper configuration are used for both operations, eliminating the need for tool changes and maintaining high cycle rate while providing specialized functionality for both operations.
Data Source
AI summary
A device and the method serve to set a connecting element, in particular a press-in bolt, on a workpiece. By means of a setting unit, a hole punching operation for introducing a hole and, at the same time, a hole-forming operation are carried out, in which an edge of the hole is deep-drawn using an embossing sleeve and a collar is formed. In a second stage, the connecting element is pressed in, the punching and hole-forming operation and the pressing taking place within the same axial axis without the workpiece being laterally displaced relative to the device.