Rivet Setting Machine Punch Position Monitoring
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Solution Overview
Problem
Conventional rivet setting machines require complex automated control systems that are not always fast or accurate due to the need for multiple sensors, leading to inefficiencies in rivet setting cycles.
Innovation Solution
A rivet setting machine that uses a direct linear displacement sensor to monitor the position of the punch relative to the nosepiece, eliminating the need for force sensors, motor current/voltage sensors, or rotation sensors, and employing a magnetic length sensor for precise displacement measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If multiple sensors (force sensing, motor current/voltage sensing, rotation sensing) are used for automated control, then the control system can monitor various parameters, but the rivet setting cycle time increases and accuracy decreases due to complex sensing and calculations
Solution Approach 1:
The patent extracts and eliminates unnecessary sensing components (force sensors, motor current/voltage sensors, rotation sensors) from the control system, retaining only the essential linear displacement sensor to directly measure punch position, thereby simplifying the system and reducing cycle time
Solution Approach 2:
The patent replaces complex mechanical sensing systems with a direct linear displacement sensing system that provides accurate position information without requiring multiple indirect measurements and calculations
2Extent of automation
If multiple sensors and complex calculations are used for monitoring, then comprehensive control is achieved, but measurement accuracy decreases due to component tolerance variations and backlash gaps
Solution Approach 1:
The patent removes intermediate measurement components (pulley, belt, shaft, plunger) that introduce tolerance variations and backlash, using a linear displacement sensor that directly measures punch position without relying on these mechanical intermediaries
Solution Approach 2:
The patent substitutes indirect mechanical measurement systems with a direct linear displacement sensing system that eliminates the accumulation of mechanical tolerances and backlash effects
3Device complexity
If indirect measurement through angular velocity encoder is used, then positional sensor complexity is reduced, but measurement accuracy decreases due to component tolerance variations and backlash gaps in pulleys, belts, shafts, and plunger
Solution Approach 1:
The patent extracts and removes the intermediate mechanical components (pulley, belt, shaft, plunger) from the measurement system, using a linear displacement sensor that directly measures punch position without relying on these components
Solution Approach 2:
The patent replaces the indirect angular velocity encoding system with a direct linear displacement sensing system, eliminating the mechanical transmission chain that introduces tolerance variations and backlash
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 approach results in faster and more accurate rivet setting cycles with reduced complexity, improved accuracy by avoiding component tolerance variations, and enhanced flexibility in handling various rivet and workpiece dimensions.
Implementation Method 1
The linear displacement sensor directly senses and detects a position of a rivet-setting punch relative to a nosepiece of a rivet setting machine
Data Source
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AI summary
A rivet setting machine (11) is provided with a linear displacement sensor (101, 103, 105) that directly senses and detects a position of a rivet-setting punch (53) relative to a nosepiece (61) of the rivet setting machine. The relative position of the punch (53) and nosepiece (63) is used to determine and monitor a rivet setting position without use of a force sensor, motor current/voltage sensor, or a rotation sensor.