Spring-Loaded Spot Weld Punch for Drill-Free Panel Separation
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Solution Overview
Problem
Existing methods for removing spot welds from sheet metal panels often damage the drills or the underlying metal, making it difficult to separate the panels without causing damage.
Innovation Solution
A spot weld removal punch is designed with a punch body, centering pin, venting roll pin, and compression spring, which allows for the separation of sheet metal panels by center punching and displacing the weld slug without drilling through, using an impact gun and optionally a replaceable impact head with radial venting to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If drilling is used to remove spot welds, then the spot welds can be separated, but the drills are damaged after only a dozen or less spot welds and the underlying metal may be damaged if done improperly
Solution Approach 1:
The patent replaces the drilling mechanical system with a punch-out mechanical system. Instead of using rotating drills that cut through spot welds, the invention uses a punch tool that delivers controlled impact forces to dislodge the weld slug through a pre-formed dimple, eliminating drill wear and damage while maintaining productivity
Solution Approach 2:
The patent introduces a dimple as an intermediary feature before the punch-out operation. The dimple, formed by a center punch or drill without penetrating the spot weld, serves as a stress concentration point that facilitates the punch-out process, reducing the force required and preventing damage to both the tool and underlying metal
2Productivity
If drilling is used to remove spot welds, then the spot welds can be separated, but the underlying metal is damaged if done improperly
Solution Approach 1:
The patent performs a preliminary action by forming a dimple at the spot weld location before the actual removal. This dimple, created by a center punch or shallow drill, concentrates stress at the weld interface, allowing the subsequent punch-out to remove the weld slug without requiring excessive force that would damage the underlying metal
Solution Approach 2:
The patent replaces the drilling system with a punch-out system that applies localized impact force through a punch tool. This mechanical substitution eliminates the risk of drill bit breakage penetrating through to damage the underlying metal, as the punch tool operates from the opposite side of the weld
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 the safe and effective separation of sheet metal panels without damaging the metal or tools, allowing for efficient repair of vehicles by removing spot welds without causing damage to the metal or equipment.
Implementation Method 1
A compression spring is inserted into the pin bore. The centering pin is pushed into the pin bore, such that the compression spring is compressed.
Implementation Method 2
The impact gun is actuated, until a slug of material is displaced from the spot weld by repeated hammering of the impact end.
Data Source
AI summary
A spot weld removal punch preferably includes a punch body, a centering pin, a venting roll pin and a compression spring. The punch body preferably includes a punch shank, a body portion and a punch flange. The punch shank extends from one end of the punch flange and the body portion extends from an opposing end of the punch flange. A pin bore is formed in the end of the body portion to receive the centering pin and the compression spring. The venting roll pin is transversely inserted into the pin bore to retain the centering pin. A second embodiment of a spot weld removal punch preferably includes a punch body, a centering pin, a pin retention device, a replaceable impact head and a compression spring. The replaceable impact head may be replaced when thereof wears out.