Resin Fastener Forming With Induction Heating and Load-Curve QC
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Solution Overview
Problem
Existing fastening apparatuses using fiber-reinforced resin fasteners require high temperatures for forming, leading to prolonged cooling times and potential defects, making rapid and high-quality fastening challenging.
Innovation Solution
A fastening apparatus that heats the shaft part or body in a non-contacting state using high-frequency induction coils, allowing for quick formation and cooling of the fastener without heating the dies, and includes a determining device to assess the load curve for defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If both fastener-forming dies are heated to high temperature to soften the shaft body, then the shaft body can be plastically deformed to form head parts, but the fastener-forming dies maintain high heat for a long time causing prolonged cooling time
Solution Approach 1:
The heating function is segmented from the fastener-forming dies and assigned to a separate induction heating device. This allows the dies to remain at room temperature while the shaft body is heated independently, eliminating the cooling time penalty and enabling continuous production.
Solution Approach 2:
The thermal field is replaced by an electromagnetic field (induction heating) to heat only the shaft body without heating the dies. This substitution enables precise localized heating of the workpiece while keeping the tooling cold, resolving the contradiction between deformation quality and cooling time.
2Manufacturing precision
If high temperature heating is used to soften the shaft body, then plastic deformation can occur, but heating failures and variations among shaft bodies occur leading to defects
Solution Approach 1:
Induction heating provides controlled, consistent thermal energy delivery through electromagnetic fields, eliminating the heating inconsistencies and failures associated with contact-based heating methods. The standardized heating process ensures uniform softening across all shaft bodies.
Solution Approach 2:
The heating parameters (temperature, time, power) are precisely controlled and standardized through the induction heating system, ensuring consistent thermal treatment of all shaft bodies. This parameter control eliminates variations and heating failures that lead to defects.
3Manufacturing precision
If both fastener-forming dies are heated to form the fastener, then the shaft body softens and can be deformed, but the process cannot be performed quickly due to long cooling requirements
Solution Approach 1:
The heating function is separated from the forming dies and performed by an independent induction heating device. This segmentation allows the shaft body to be heated and cooled rapidly without affecting the dies, enabling quick cycle times while maintaining formation quality.
Solution Approach 2:
Induction heating enables rapid heating and cooling cycles through non-contact electromagnetic energy transfer. The process achieves the necessary plastic deformation quality while dramatically reducing the thermal cycle time, thereby increasing productivity.
4Manufacturing precision
If conventional heating methods are used, then the shaft body can be softened, but defect detection is difficult and quality assurance is challenging
Solution Approach 1:
The load curve measurement system provides real-time feedback during the forming process, enabling immediate detection of defects such as insufficient softening, improper deformation, or material anomalies. This feedback mechanism ensures quality assurance while maintaining manufacturing precision.
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
Enables rapid and high-quality fastening of workpieces with reduced defects, as the fastener can be cooled quickly and defects are easily identified, ensuring secure and efficient bonding.
Implementation Method 1
a shaft part heating device that heats the shaft part in a non-contacting state
Implementation Method 2
heats the shaft part or body in a non-contacting state using high-frequency induction coils
Data Source
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AI summary
A fastening apparatus that is capable of rapidly performing the work of fastening a plurality of workpieces using a fastener made of a fiber-reinforced resin and that is capable of increasing the quality of the work of fastening the workpieces, and a fastener pass/fail determining method are provided. The fastening apparatus of the present invention comprises: a fastening device 1, 3 in which, by heating in a non-contacting state and then applying pressure while a shaft part 11b is inserted through the through holes W10, W20 of workpieces W1, W2, a second head part 11c is formed on the intermediate piece 110, and the intermediate piece serves as a fastener 11; and a determining device 5 that determines the pass/fail of the fastener 11. The fastening device 1, 3 comprises: a fastening die 15 that is capable of forming the second head part 11c; and a shaft-part pressure-applying device 9 that is capable of applying pressure to the fastening die 15. The determining device 5 calculates a load curve defined by the time and the load during which pressure is applied and determines whether an amount of change per unit of time in the load curve after a reference load has been exceeded is within a range of a first reference value that is set in advance.