Method and device for anchoring an insert in a structure by using a vibration device
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Solution Overview
Problem
Existing methods for joining fibrous or porous materials, such as Woodwelding technology, face challenges in accurately positioning inserts due to reliance on reference members, which can lead to misalignment, especially when multiple inserts are attached, and struggle with precision on uneven or dusty surfaces.
Innovation Solution
A device with a vibration device and a contact sensor that moves together along the insertion direction, detecting contact with the structure to interrupt vibration and movement, ensuring precise positioning of the insert by controlling the transmission of vibrations and pressing force based on sensor contact, with a sensor design that maintains accuracy even on complex surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a reference member is used to control insert position, then positioning accuracy for single insert is improved, but reliability deteriorates when multiple inserts are attached due to misalignment issues
Solution Approach 1:
The reference member is divided into multiple separate reference members, each associated with a specific insert. This segmentation allows each insert to have its own independent reference, eliminating misalignment issues between multiple inserts while maintaining positioning accuracy for each individual insert.
Solution Approach 2:
A sensor is introduced as an intermediary between the reference member and the control system. The sensor detects the position of the reference member and provides feedback to the control system, enabling precise control of insert insertion depth and position without direct mechanical contact between the reference member and the insert positioning mechanism.
2Manufacturing precision
If a reference member is used for position control, then insert positioning is improved, but device complexity increases
Solution Approach 1:
The positioning function is extracted from the mechanical reference member and transferred to a sensor-based detection system. The reference member serves only as a position reference, while the sensor and control system handle the actual positioning control, simplifying the mechanical structure while maintaining precision.
Solution Approach 2:
The mechanical reference member system is supplemented with a sensor-based detection and control system. Instead of relying solely on mechanical reference members, the invention uses sensors to detect reference member positions and electronically controls the insertion process, replacing complex mechanical positioning mechanisms with more simple sensor-based systems.
3Strength
If vibration amplitude is increased to improve joining strength, then anchoring strength is improved, but manufacturing precision deteriorates due to insert position deviation
Solution Approach 1:
A sensor provides real-time feedback on the insert position during the vibration joining process. The control system monitors the sensor signals and adjusts the vibration amplitude and insertion depth dynamically to maintain positioning accuracy while achieving the required anchoring strength, preventing position deviation that would occur with high amplitude vibrations alone.
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 solution enables more accurate anchoring of inserts in fibrous or porous structures, improving precision and ensuring correct positioning, even on uneven or dusty surfaces, with the contact sensor providing reliable detection and control for precise placement.
Implementation Method 1
By applying mechanical vibration, e.g. by means of an ultrasonic vibration device, to the thermoplastic material friction forces will be generated causing heat generation and consequently melting of the thermoplastic material
Implementation Method 2
The vibration device is configured to transmit vibrations to the insert to cause at least partial liquefaction thereof
Implementation Method 3
a contact sensor connected to the vibration device and adapted to move together with the vibration device along the insertion direction, the contact sensor having a sensor body adapted for detecting contact with the structure
Data Source
AI summary
A device for joining material by anchoring an insert comprising a first material in a structure comprising a second material is provided. The first material is solid and comprises thermoplastic properties and the second material is solid and is penetrable by the first material when in a liquefied state. The device comprises a vibration device being configured to transmit vibrations to said insert to cause at least partial liquefaction thereof and being arranged to move, relative to said structure, along an insertion direction (ID) to insert said insert at least partly into said structure, a contact sensor being connected to the vibration device and being adapted to move together with the vibration device along the insertion direction (ID), the contact sensor having a sensor body being adapted to detect contact with said structure. A controller is further connected to the contact sensor and adapted for receiving a contact signal from the contact sensor indicating that the sensor body has come into contact with said structure.