Setting Head Connection Checking for Functional Element Joining
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Solution Overview
Problem
Current methods for attaching functional elements to workpieces lack effective quality assurance, relying on random and costly laboratory testing, which is inefficient and provides limited information on connection quality.
Innovation Solution
Integration of a checking device within the setting device, featuring a sensor unit with first and second contact sections for electrical conductivity measurements to determine the quality of the connection between the functional element and the workpiece, allowing for real-time quality assessment and documentation, and optionally issuing warning signals for faulty connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If random laboratory testing is used to ensure connection quality, then reliability of quality assurance is improved, but productivity is worsened due to time-consuming and expensive testing
Solution Approach 1:
The patent applies preliminary action by performing the quality check immediately after the setting process within the same device, rather than conducting separate post-production laboratory testing. The sensor unit measures electrical conductivity right after the functional element is attached to the workpiece, ensuring quality verification is built into the production flow before parts move to the next stage.
Solution Approach 2:
The patent replaces mechanical destruction testing with electrical measurement. Instead of physically testing connections in the laboratory, the system uses a sensor unit to measure electrical conductivity between the functional element and workpiece, substituting a non-destructive electrical field-based measurement for traditional mechanical testing methods.
2Measurement precision
If extensive laboratory testing is performed on each connection, then measurement precision is improved, but loss of time is worsened
Solution Approach 1:
The patent implements continuity of useful action by making the quality measurement an uninterrupted part of the setting process. The sensor unit is integrated into the setting device, allowing continuous measurement of electrical conductivity as each connection is made, eliminating idle time between production and quality verification.
Solution Approach 2:
The patent uses electrical conductivity as a proxy or copy indicator for connection quality. Instead of directly measuring mechanical bond strength, the system measures electrical conductivity between contact sections, which correlates with connection quality, providing a faster indirect measurement method.
3Ease of operation
If visual inspection is used to check connections, then ease of operation is improved, but measurement precision is worsened due to limited information
Solution Approach 1:
The patent introduces electrical conductivity measurement as an intermediary parameter to assess connection quality. The sensor unit measures electrical properties that serve as a mediator between the physical connection and quality assessment, providing objective quantitative data that bridges visual inspection limitations and direct mechanical testing complexity.
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 improved and cost-effective quality assurance by providing reproducible and comparable measurement data, allowing for immediate identification of faulty connections and reducing the need for extensive laboratory testing.
Implementation Method 1
an electrical measurement can be used to determine the quality of the connection between the functional element and the workpiece
Data Source
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AI summary
The present invention relates to a setting device (10) for attaching a functional element (16) to a workpiece (18), in particular to a sheet metal component. The setting device (10) comprises a die (20) for receiving and supporting the workpiece (18), a setting head (12) with a setting punch (14) that interacts with the functional element (16) and by which the functional element (16) can be attached to the workpiece (18) in an axial setting motion. The setting device (10) further comprises a testing device (22) for determining the quality of a connection between the functional element (16) and the workpiece (18), wherein the testing device has a sensor with a first contact section (24) that can be electrically connected to the functional element (16) and with a second contact section (26) that can be electrically connected to the workpiece (18).The present invention also relates to a corresponding method for attaching a functional element (16) to a workpiece (18).