Spot-joining Apparatus Movable Alignment Bracket
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Solution Overview
Problem
Existing spot-joining techniques, such as self-piercing riveting, face challenges with alignment precision and frame durability due to high loading and accidental damage, leading to costly manufacturing and potential for incorrect joint formation.
Innovation Solution
A movable alignment bracket and actuator retention assembly with adjustable clamping mechanism, allowing for precise alignment and secure mounting without the need for tight lock-nuts, enabling adjustment and re-adjustment of the force reaction frame to maintain alignment and prevent warping or damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lock-nut is used to secure the actuator to the force reaction frame, then the actuator can be held in position, but the nut must be extremely tight which can crush the actuator and impair its function
Solution Approach 1:
A mounting plate is introduced as an intermediary component between the actuator and the force reaction frame. The mounting plate distributes the clamping force over a larger area, preventing the actuator body from being crushed while still securing it firmly in position. This mediator resolves the contradiction by providing a compliant interface that protects the actuator during tightening.
Solution Approach 2:
The mounting plate changes the physical parameters of the clamping interface by increasing the contact area and distributing stress. This parameter change allows the nut to be tightened sufficiently to prevent actuator movement without concentrating enough force to crush the actuator body, thus resolving the contradiction between securing reliability and component integrity.
2Manufacturing precision
If the force reaction frame is made very strong to withstand high loading, then alignment can be maintained, but the cost of manufacture increases significantly
Solution Approach 1:
The force reaction frame is segmented into modular components that can be manufactured to standard tolerances and then assembled with precise alignment features. The mounting plate and actuator positioning mechanisms are separate adjustable components that allow alignment to be achieved through assembly rather than requiring the entire frame to be manufactured to high precision, thereby reducing manufacturing cost while maintaining alignment precision.
Solution Approach 2:
The system incorporates adjustable and repositionable components (mounting plate, actuator positioning mechanisms) that allow alignment to be dynamically adjusted during assembly and maintenance. This dynamic approach replaces the need for expensive precision manufacturing with adjustable fixtures that can be tuned to achieve the required alignment precision.
3Manufacturing precision
If the force reaction frame is manufactured to great precision to maintain alignment, then correct joint formation is ensured, but the frame must be replaced if subjected to accidental impact
Solution Approach 1:
The force reaction frame is divided into modular, replaceable segments. If one component is damaged by accidental impact, only that specific module needs to be replaced rather than the entire frame. This segmentation maintains alignment precision through standardized interfaces while improving ease of repair by localizing damage replacement.
Solution Approach 2:
The modular design allows damaged components to be discarded and replaced with new or refurbished modules. The standardized interfaces enable quick recovery of the system by swapping out only the affected component, maintaining alignment precision through the standardized connection geometry while significantly improving ease of repair compared to replacing the entire frame.
4Power
If the actuator is pushed backwards with high force during rivet insertion, then the rivet is driven effectively, but the lock-nut may not supply sufficient axial force to prevent the shoulder from lifting off
Solution Approach 1:
The mounting plate serves as a mediator that provides a larger bearing surface between the actuator shoulder and the support structure. This intermediary distributes the high axial forces generated during rivet insertion over a wider area, preventing the actuator shoulder from lifting off or fretting while allowing the actuator to deliver its full driving force effectively.
Solution Approach 2:
The mounting plate changes the geometric parameters of the support interface by increasing the contact area and optimizing the distribution of axial loads. This parameter change enables the system to withstand the high forces generated during rivet insertion without compromising mounting stability, allowing the actuator to operate at full power.
Data Source
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AI summary
A mounting assembly for a spot-joining apparatus comprises a first support arm (24). The first support arm (24) has a mounting surface (26), and receiving portion configured to receive an actuator or an anvil. The mounting assembly also comprises an alignment bracket (28) configured to engage with said actuator or anvil. The alignment bracket (28) is movable between a plurality of locations on the mounting surface (26) of the first support arm (24). The mounting assembly further comprises a clamp assembly (52, 29, 66a, 66b, 70, 70b or 52, 29, 88, 92, 98, 90, 96) configured to secure the alignment bracket (28) in any of said plurality of locations.