Two-Stage Press-In Device for Reliable Anti-Rotation Locking
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Solution Overview
Problem
Existing press-in methods for forming connections between press-in nuts and prepunched components often require deformation of both the nut flange and the component, which can be inefficient and may not ensure reliable antirotation locking, especially in applications where different press-in functional regions are needed.
Innovation Solution
A two-stage press-in method using a die mandrel and die ring with different spring forces, where the die mandrel acts as a pilot pin and reshaping element, allowing for precise centering and deformation of the nut flange, while the die ring forms antirotation locks with varying press-in forces, eliminating the need for active control elements and ensuring reliable decoupling of press-in stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-stage press-in operation is used to form connections between press-in nuts and prepunched components, then the process is simpler and faster, but reliable antirotation locking and proper deformation of both the nut flange and component cannot be ensured
Solution Approach 1:
The press-in operation is divided into two distinct stages: first stage forms antirotation locks by pressing antirotation lock elements into the component, and second stage deforms the nut flange to form axial locking means. This segmentation allows each stage to be optimized independently, ensuring both antirotation locking reliability and proper deformation while maintaining efficient production.
2Strength
If the nut flange is deformed during press-in operation, then axial locking is achieved, but the threaded hole in the press-in nut may be damaged
Solution Approach 1:
The die mandrel is designed with a pilot section that protrudes beyond the die ring to perform preliminary centering and positioning of the press-in nut before the actual deformation process. This preliminary action ensures proper alignment and prevents misalignment-induced damage to the threaded hole during the subsequent flange deformation stage.
Solution Approach 2:
The die mandrel serves as an intermediary element between the press-in punch and the press-in nut. It provides a controlled deformation interface that distributes the deformation forces evenly, preventing concentrated stresses that could damage the threaded hole while still achieving the necessary flange deformation for axial locking.
3Reliability
If different press-in forces are applied for antirotation locking and axial locking, then reliable connection is achieved, but the press-in device complexity increases
Solution Approach 1:
The die mandrel is designed with spring elements that allow it to move dynamically between the die ring and the press-in punch during the press-in operation. This dynamic capability enables the system to automatically apply different press-in forces for the two stages: a first force for antirotation locking and a second, different force for axial locking, without requiring complex external control mechanisms.
Solution Approach 2:
The press-in device utilizes changes in the mechanical parameters of the die mandrel position and spring compression to differentiate between the two press-in stages. By controlling the displacement and force parameters through the spring-loaded mandrel mechanism, the system achieves reliable connection with distinct press-in forces while maintaining relatively simple device structure.
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 a reliable two-stage press-in operation with distinct antirotation and deformation stages, enhancing the security and efficiency of the press-in connection by differentiating press-in forces and avoiding damage to the threaded nut, thus improving the axial locking and antirotation capabilities.
Implementation Method 1
the die mandrel and the die ring (12) are each mounted so as to be displaceable in the axial direction counter to a spring force
Data Source
AI summary
In order to reliably ensure a press-in connection between joining elements, in particular a press-in nut and a pre-punched component, a press-in device contains a die which has a die ring and a die mandrel. The die mandrel is mounted counter to a spring force in the manner of a pilot pin. In addition, the die ring is also mounted counter to a spring force such that a two-stage press-in operation is carried out. Preferably, during a first press-in stage an anti-rotation lock is formed between the press-in nut and the component and in a second press-in stage an axial pull-out prevention measure is formed. To this end, the die mandrel deforms a nut flange.