Single-Motor Spot-Joining Apparatus with Multifunctional Transmission
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Solution Overview
Problem
Existing spot-joining machines and methods that utilize friction stir softening require two actuators for rotary and linear motion, increasing cost, bulk, and weight, which limits their performance and maintenance, and makes them less suitable for robotic applications and reaching small spaces.
Innovation Solution
A spot-joining apparatus with a single motor that uses a multifunctional transmission to produce both rotary and linear motion, along with a transmission control apparatus to adjust the degree of engagement, allowing for efficient and flexible operation, and an upsetting die that can selectively rotate to enhance frictional heating control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two actuators are used to produce rotary and linear motion, then the required motion functions are achieved, but the cost, bulk, and weight of the apparatus increase
Solution Approach 1:
The patent combines two separate actuators (one for rotary motion and one for linear motion) into a single actuator that can produce both types of motion. This is achieved through a mechanism where the actuator's piston rod is constrained to move along a curved path, converting linear actuator motion into both rotary and linear components needed for the punch operation.
Solution Approach 2:
The single actuator is designed to perform multiple functions: it generates both the rotary motion needed for friction stir softening and the linear motion needed for driving the punch into the workpiece. This multi-functional design eliminates the need for separate actuators, reducing overall system weight while maintaining full motion control capability.
2Adaptability or versatility
If two actuators are used to produce rotary and linear motion, then the required motion functions are achieved, but the bulk of the apparatus increases
Solution Approach 1:
The patent merges two separate actuator systems into one compact actuator assembly. By using a single actuator with a curved path constraint mechanism, the overall volume required for housing two actuators and their associated mounting structures is significantly reduced, making the apparatus more compact.
Solution Approach 2:
The mechanism employs a nested arrangement where the curved path constraint is integrated within the actuator assembly itself. The guide rails or constraint structures are positioned within the actuator's operational envelope, allowing the rotary and linear motion generation components to occupy overlapping spatial volumes, thereby reducing total apparatus bulk.
3Adaptability or versatility
If two actuators are used, then the required motion functions are achieved, but the service life and maintenance cost are adversely affected
Solution Approach 1:
By consolidating two actuators into one, the patent reduces the total number of moving parts, seals, bearings, and electrical connections that can fail. Fewer components mean fewer potential failure points, improved reliability, and reduced maintenance requirements while still achieving both rotary and linear motion control through the integrated mechanism.
4Adaptability or versatility
If two actuators are used, then the required motion functions are achieved, but the cost of the apparatus increases
Solution Approach 1:
The patent reduces apparatus cost by eliminating one entire actuator system and its associated components. The single actuator design with curved path constraint is simpler and less expensive to manufacture, install, and commission than a dual-actuator system, while maintaining full functionality for both rotary and linear motion generation.
5Volume of moving object
If the apparatus is made more compact, then it can reach smaller spaces, but the transmission mechanism complexity increases
Solution Approach 1:
The curved path constraint mechanism is nested within the actuator assembly, with guide rails and constraint structures integrated into the actuator's operational space. This nested arrangement allows the transmission of both rotary and linear motion through a compact configuration without requiring external transmission mechanisms, thus reducing overall apparatus bulk while controlling 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
The single-motor system reduces cost and bulk, improves service life, and allows for more versatile and efficient operation, enabling the apparatus to reach smaller spaces and handle various materials effectively, while the upsetting die provides greater control over frictional heating for improved adherence and faster processing.
Implementation Method 1
a motor; a first transmission configured to transfer rotary motion of the motor to the punch
Implementation Method 2
a first transmission configured to transfer rotary motion of the motor to the punch when engaged
Implementation Method 3
a second transmission configured to convert rotary motion of the motor to linear motion of the punch
Implementation Method 4
Sliding friction between the probe and the workpiece layers causes the layers to soften and plasticise without melting
Implementation Method 5
the rotation of the probe displaces the material and causes the plasticised portions of the two layers to intermingle
Data Source
AI summary
A spot-joining apparatus comprises a motor, a punch for driving a fastener or performing a clinching or friction stir spot welding operation, a first transmission, a second transmission and a transmission control apparatus. The first transmission is configured to transfer rotary motion of the motor to the punch when engaged. The second transmission is configured to convert rotary motion of the motor to linear motion of the punch, and thereby drive the punch towards a workpiece, when engaged. The transmission control apparatus is arranged to selectively adjust the degree of engagement of at least one of the first and second transmissions. Further apparatus for spot joining, and methods of spot-joining, are also disclosed.