Torque-Limited Fastener Welding Parameter Control
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Solution Overview
Problem
Existing methods for producing torque-limited fastening devices, such as shear-off nuts or bolts, are inefficient in producing a wide range of limit torques without requiring geometric changes to components, leading to high production costs and storage needs.
Innovation Solution
The method involves varying welding parameters like voltage, current intensity, and temperature during the welding process to achieve different limit torques with the same component geometry, allowing for adaptable torque settings without altering the geometry of the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different limit torques are achieved by varying component geometry (shapes, dimensions, number of welding points), then different torque settings can be obtained, but production complexity and storage costs increase due to multiple component types
Solution Approach 1:
The patent applies parameter changes by varying welding parameters (current intensity, voltage, temperature, prestress) instead of changing component geometry. This allows the same head elements to produce different limit torques through controlled variations in the welding process parameters, thereby achieving adaptability without increasing device complexity
Solution Approach 2:
The patent makes the welding process universal by using the same head element design for multiple torque settings. The welding process can be adjusted to create different welded connections with varying strengths, allowing a single component design to serve multiple torque requirements, thus reducing the need for multiple component geometries
2Adaptability or versatility
If multiple component geometries are produced to achieve different limit torques, then various torque settings are available, but storage costs and production time increase
Solution Approach 1:
By changing welding parameters rather than producing multiple component geometries, the manufacturing process becomes more efficient. The same head elements can be welded with different parameters to achieve various torque settings in a single production line, eliminating the need for separate production lines or inventory management for different geometries
Solution Approach 2:
The welding parameters are made dynamic and adjustable during the production process. This allows the manufacturing system to adapt to different torque requirements on-the-fly without changing physical components, thereby improving productivity by eliminating setup changes and reducing inventory needs
3Ease of manufacture
If welding parameters are varied to achieve different limit torques with the same component geometry, then production cost and simplicity increase, but precise control of welding parameters is required
Solution Approach 1:
The patent systematically varies welding parameters (current intensity, voltage, temperature, prestress) to control the welded connection strength. While this requires precise parameter control, it simplifies manufacturing by using identical head elements and only adjusting process parameters, which can be controlled through standardized welding equipment and procedures
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
This approach enables cost-effective and simple production of torque-limited fastening devices with a wide range of torque settings, reducing storage costs and allowing for verification of correct torque application in anchors.
Implementation Method 1
a first head element and a second head element are each welded in a welding process to produce the welded connection
Implementation Method 2
the welded connection at the beginning of the fastening process. If a predetermined limit torque is reached at the end of the fastening process, the first head element shears off the second head element at the welded joint
Data Source
Figure 1~3
AI summary
The invention relates to a method for producing torque-limiting securing devices which have a first head element (11) with engaging means (31) for a securing tool and a second head element (12) which is connected to the first head element by means of a welded joint which separates at a predefined torque limit. According to the invention, a plurality of first head elements and second head elements with the same geometry are provided, and respectively, a first head element and a second head element are welded in a welding process thus producing a welded joint. According to the invention, at least two welding processes are carried out using at least one different welding parameter so that different torque limits are maintained with the same component geometry. The invention also relates to the use of a securing device on a concrete anchor (50).