Rivet Dispenser Reloading for Continuous Resistance Spot Rivet Welding
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Solution Overview
Problem
Current resistance spot rivet welding systems face challenges in efficiently reloading rivets into the dispensing system, leading to interruptions in the welding process and increased cycle times due to the need for manual replenishment and potential misalignment issues.
Innovation Solution
A rivet dispenser reloading system that includes a rivet receiving member with a channel and gate configuration, allowing for series arrangement and preselected orientation of rivets, and a method for aligning with the rivet dispensing system to introduce rivets automatically, using pressurized gas to facilitate movement and ensure proper alignment and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual replenishment of rivets is used, then device complexity is reduced, but productivity decreases and loss of time increases due to interruptions in the welding process
Solution Approach 1:
The rivet dispensing system automatically replenishes rivets from the rivet receiving member through the use of a rivet dispenser with a channel and gate mechanism. The system self-regulates rivet flow using a gate that can be selectively positioned to control rivet dispensing, eliminating the need for manual intervention and maintaining continuous welding operation.
Solution Approach 2:
Rivets are pre-loaded into the rivet receiving member in a series arrangement with preselected orientation before the welding process begins. This preliminary preparation ensures that rivets are ready for immediate dispensing without interruption to the welding cycle, improving productivity while managing system complexity through advance preparation.
2Productivity
If automated rivet dispensing is implemented, then productivity increases, but manufacturing precision requirements increase due to alignment needs
Solution Approach 1:
Rivets are pre-positioned in a series arrangement with preselected orientation within the rivet receiving member channel before dispensing. This preliminary alignment ensures that when rivets are automatically dispensed to the rivet holder, they are already oriented correctly, reducing the precision requirements for the dispensing mechanism itself while maintaining high productivity.
Solution Approach 2:
The rivet receiving member with its structured channel acts as an intermediary between the bulk rivet supply and the rivet holder. This intermediary component pre-organizes rivets in the correct orientation and spacing, simplifying the final dispensing action and reducing the precision demands on the automated dispensing mechanism while maintaining high productivity.
3Manufacturing precision
If rivets are transported in series arrangement with preselected orientation, then manufacturing precision is improved, but device complexity increases due to channel and gate configuration
Solution Approach 1:
The rivet receiving member is segmented into a structured channel with distinct regions: a first port for receiving rivets, a channel for transporting and orienting them in series arrangement, and a second port for dispensing. This segmentation allows each portion to perform its specific function efficiently, achieving consistent rivet orientation while managing complexity through functional division.
Solution Approach 2:
The gate mechanism provides dynamic control over rivet flow through the channel. The gate can be selectively positioned between configurations that inhibit and enable rivet movement, allowing the system to adapt to different operational states (loading, dispensing, pausing) without requiring complex mechanical structures for each state transition.
4Reliability
If gate mechanism is used to control rivet flow, then reliability of rivet delivery is improved, but device complexity increases due to additional moving parts
Solution Approach 1:
The gate mechanism provides dynamic control over rivet flow through the channel. The gate can be selectively positioned between configurations that inhibit and enable rivet movement, allowing the system to adapt to different operational states (loading, dispensing, pausing) without requiring complex mechanical structures for each state transition.
Solution Approach 2:
The gate mechanism responds to the presence and position of rivets within the channel, automatically controlling flow based on system needs. This feedback-based control ensures reliable rivet delivery by preventing premature dispensing or blockages, while the automated nature of the feedback loop reduces the need for complex manual control mechanisms.
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 system enables reliable and efficient reloading of rivets, reducing machine cycle time and minimizing interruptions by ensuring consistent and precise rivet delivery to the rivet holder, thus enhancing the productivity of resistance spot rivet welding processes.
Implementation Method 1
using pressurized gas to facilitate movement and ensure proper alignment and orientation
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Resistance spot rivet welding systems, subsystems, and methods of use thereof are provided.