Riveting Punch Inner Contour for Tolerance and Excess Material
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Solution Overview
Problem
Conventional staking and riveting devices face challenges in accommodating tolerance deviations and excess material in workpieces, leading to unreliable joining and increased manufacturing costs due to complex control electronics requirements.
Innovation Solution
A punch with a deformable inner contour featuring a spherical cap-shaped or ellipsoidal cap-shaped surface and a cylinder jacket-shaped or truncated cone jacket-shaped intermediate surface, allowing for compensation of size deviations and excess material, thereby ensuring reliable staking or riveting while simplifying the separation process and reducing control electronics needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional punch with a simple spherical cap-shaped workpiece receiving opening is used, then the device structure is simple, but it cannot compensate for tolerance deviations and excess material in workpieces, leading to unreliable staking or riveting
Solution Approach 1:
The inner contour of the workpiece receiving opening is segmented into three distinct surfaces: a spherical cap-shaped first partial surface for forming the staked or riveted workpiece, a cylinder jacket-shaped or truncated cone jacket-shaped second partial surface for accommodating excess material, and a third partial surface for facilitating separation. This segmentation allows each surface to perform its specific function, enabling the punch to handle tolerance deviations and excess material while maintaining structural clarity.
Solution Approach 2:
Different regions of the inner contour are given different geometric properties tailored to their specific functions. The spherical cap-shaped first partial surface provides a curved forming surface for the workpiece, the cylinder jacket-shaped or truncated cone jacket-shaped second partial surface provides a tapered or cylindrical region for excess material accommodation, and the third partial surface provides a separation facilitation zone. This local differentiation of geometric quality enables the single punch structure to address multiple problems simultaneously.
2Reliability
If control electronics are added to monitor and compensate for workpiece variations, then staking or riveting reliability improves, but manufacturing costs increase
Solution Approach 1:
The punch structure is designed to automatically compensate for workpiece variations and excess material through its geometric configuration. The spherical cap-shaped first partial surface and the cylinder jacket-shaped or truncated cone jacket-shaped second partial surface work together to accommodate different workpiece dimensions and material volumes without requiring external sensing or control systems. The structure itself performs the compensation function that would otherwise require complex electronics.
Solution Approach 2:
Instead of investing in expensive control electronics and sensors for process monitoring and compensation, the invention uses a simple, cost-effective geometric modification to the punch structure. The additional second and third partial surfaces add minimal manufacturing complexity while eliminating the need for costly electronic control systems, achieving the same functional outcome through mechanical design alone.
3Reliability
If excess material is present on the workpiece, then material outflows occur during staking or riveting, but the invention converts this harmful effect into improved interlocking
Solution Approach 1:
The invention transforms the harmful effect of excess material, which would normally cause unwanted outflows and defects, into a beneficial feature that improves interlocking. The cylinder jacket-shaped or truncated cone jacket-shaped second partial surface is specifically designed to receive and redirect excess material into a controlled flow path that enhances the interlocking between the staked or riveted workpiece and the base material, converting what was previously a defect into an advantage.
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 solution enables reliable staking or riveting of workpieces with varying sizes and excess material, preventing material overflow and improving interlocking, while reducing manufacturing costs and simplifying process monitoring.
Implementation Method 1
a pin (not shown) to be staked is at least partially introducible into workpiece receiving opening 12 in a way that makes the pin at least partially deformable in conformity with an inner contour of workpiece receiving opening 12
Implementation Method 2
a further portion of the workpiece be at least deformable in conformity with the cylinder jacket-shaped or truncated cone jacket-shaped inner-contour intermediate surface. The excess material may thus be deformed in a way that prevents any conventional 'material outflows' from remaining on the staked or riveted workpiece
Data Source
AI summary
A punch for a staking/riveting device having a workpiece receiving opening formed on a pressing surface of the punch to make a workpiece, projecting from a contacting surface, that is at least partially introducible into the receiving opening in response to the pressing surface of the punch approaching the contacting surface and is deformable in conformity with an inner contour of the receiving opening; at least a partial surface of the inner contour being formed in a spherical/ellipsoidal cap shape; and the inner contour of the receiving opening having an inner-contour intermediate surface between a rim of the inner contour on the pressing surface and the spherical or ellipsoidal cap-shaped partial surface that is a cylinder truncated cone jacket-shaped. A staking/riveting device, a joining partner for cooperating with the punch or with the staking/riveting device, a device having at least one staked/riveted workpiece, and a method for staking/riveting a workpiece.