Rivet Reloading Channel and Gate Design for Continuous Spot Welding

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Solution Overview

Problem

Current rivet dispensing systems in resistance spot rivet welding face challenges in efficiently reloading rivets, 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 with a channel and gate mechanism that aligns and introduces rivets in a series arrangement to the dispensing system, utilizing pressurized gas to facilitate smooth rivet transport and ensure proper orientation, allowing for automated and efficient reloading without direct coupling to the robotic manipulator.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual replenishment of rivets is used, then device complexity is reduced, but productivity decreases due to interruptions in the welding process

Engineering Contradiction:

Improvewelding process continuityVSAvoidrelloading system structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The rivet dispensing system automatically replenishes rivets from the storage magazine through the channel and gate mechanism without requiring manual intervention. The system uses its own internal components (compressor, channel, gate, dispensing mechanism) to perform the reloading function, eliminating the need for external manual replenishment and maintaining continuous welding operation.

Inventive Principle:

Principle #25Self-service

2Productivity

If automated rivet dispensing is implemented, then productivity increases, but device complexity increases due to additional components

Engineering Contradiction:

Improverivet dispensing speedVSAvoiddispensing system components

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into a single integrated system: the storage magazine holds multiple rivets, the channel transports them, the gate controls flow, and the dispensing mechanism delivers rivets to the welding head. This merging of storage, transport, control, and dispensing functions into one compact unit achieves automated high-speed rivet supply without proportionally increasing overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Loss of time

If rapid rivet replenishment is achieved, then machine cycle time is reduced, but manufacturing precision may deteriorate due to alignment issues

Engineering Contradiction:

Improvemachine cycle timeVSAvoidrivet alignment accuracy

Core Design Contradiction:

Loss of timeVSManufacturing precision

Solution Approach 1:

The system performs preliminary actions by pre-storing multiple rivets in the magazine in the correct orientation and pre-positioning them in the channel before they reach the dispensing point. The gate mechanism pre-controls the release sequence, ensuring that rivets are already aligned and ready for immediate dispensing, thus achieving rapid replenishment without compromising alignment accuracy during the critical welding cycle.

Inventive Principle:

Principle #10Preliminary action

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 reliable and efficient reloading of rivets, reducing machine cycle time and minimizing interruptions during the welding process by ensuring continuous operation and precise alignment, thus enhancing production efficiency.

Implementation Method 1

utilizing pressurized gas to facilitate smooth rivet transport and ensure proper orientation

Methodology Applied

Scientific EffectPressurized gas transport: Pressure Gradient

Implementation Method 2

The first gate is selectively positionable between a first configuration inhibiting movement of rivets through the second port, and a second configuration enabling movement of rivets through the second port

Methodology Applied

Scientific EffectMechanical gating: Valve