Punch Riveting Corner Pillars Front Wall Panel
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing commercial vehicle bodies, particularly the connection between corner pillars and the front wall panel, require pre-drilling and multiple steps, making the process complex and time-consuming, and do not provide a smooth inner surface.
Innovation Solution
A method using punch riveting or clinching connections between corner pillars and the front wall panel, eliminating the need for pre-drilling and resulting in a quicker assembly process with a smooth inner surface, enhanced production capacity, and improved visual appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous rivets are used to connect corner pillars to front wall panel, then firm and reliable connection is achieved, but pre-drilling and multiple process steps are required making production complex and time-consuming
Solution Approach 1:
The patent replaces the traditional mechanical riveting system (requiring pre-drilling, alignment, and multiple steps) with a punch connection system. The punch elements are inserted into pre-formed holes in the corner pillars and front wall panel, then deformed to create a firm connection without requiring pre-drilling operations, thereby simplifying the production process while maintaining connection reliability
Solution Approach 2:
The patent applies preliminary action by pre-forming holes in the corner pillars and front wall panel during component manufacturing, before assembly. This eliminates the need for pre-drilling during production, as the holes are already prepared in advance, reducing the number of process steps required during assembly
2Reliability
If continuous rivets are used to connect corner pillars to front wall panel, then firm connection is achieved, but production time increases due to multiple individual process steps
Solution Approach 1:
The patent merges multiple separate operations (pre-drilling, alignment, rivet insertion, and rivet deformation) into a single integrated punch insertion and deformation operation. The punch elements serve both as alignment guides and as the connection medium itself, combining functions that previously required separate steps, thereby increasing production speed while maintaining connection firmness
Solution Approach 2:
The patent extracts the pre-drilling operation from the assembly process by pre-forming holes during component manufacturing. This separates the hole creation function from the connection function, allowing assembly to focus solely on inserting and deforming the punch elements, thus reducing production time while maintaining connection quality
3Reliability
If solid rivets or blind rivets are used, then reliable connection is achieved, but protruding rivet heads are formed reducing visual appearance quality
Solution Approach 1:
The patent inverts the traditional rivet configuration by deforming the connection element on the inside of the corner pillar rather than forming protruding heads on the outside. The punch elements are deformed within the corner pillar structure, creating a smooth outer surface without protruding rivet heads, while maintaining reliable connection through the deformation mechanism
Data Source
AI summary
The commercial vehicle assembly has a frame, which particularly comprises longitudinal carrier and transverse carrier horizontally arranged between the longitudinal carriers. A front wall panel (10) is provided, which forms a front loading space limitation. The front wall panel is arranged between corner columns (20), which extend in the area of the front oblong ends of the longitudinal carrier in vertical direction. The corner columns are connected with the front wall panel by punch rivet connections (30) or overlap joints. An independent claim is included for a method for manufacturing a commercial vehicle assembly.