Patent ID: 12220778

DESCRIPTION OF EXAMPLE EMBODIMENTS

In view of the aforementioned deficiencies in the conventional design, the present invention is directed towards a two-stage device or tool100(shown inFIGS.1-2) configured to both pierce an aperture through a substrate ‘S’ as well as clinch a fastener ‘F’ (e.g., a self-attaching fastener) to said substrate ‘S’ in separate actions, albeit all in the same device and without repositioning the substrate ‘S’. The embodiment described herein is made with reference to a substrate (e.g., a metal panel) and a fastener (e.g., a clinch bolt). It is to be understood that the substrate may be any other type of panel and that the fastener may be any other type of fastener (e.g., nut, etc.).

The tool100includes a punch device102, a loader104, and a die device106. As shown, the punch device102, the loader104, and the die device106are vertically aligned with respect to one another (i.e., along a vertical, punch/clinch axis ‘X,’ shown inFIG.2), wherein the loader104is disposed vertically between the punch device102and the die device106. It is contemplated that the tool100need not have a vertical orientation, but instead can have any other alignment/orientation (e.g., horizontal, diagonal, etc.) necessary to perform the piercing/clinching operations.

With reference toFIG.2, the punch device102includes a movable frame108that houses an actuator110therein. As will be discussed further below, the actuator110provides a driving force for both piercing an aperture within the substrate ‘S,’ and (separately) clinching the fastener ‘F’ to the substrate ‘S’. In one embodiment (as shown), the actuator110is a nitrogen gas spring that drives a piston112(via pressurization of nitrogen gas within a cylinder) to provide said driving force (e.g., 40 kilonewtons to 200 kilonewtons). However, it is contemplated that the actuator110may be any other type of mechanism configured to provide a driving force (in some non-limiting examples, pneumatics, hydraulics, electric motors, etc.). Further, the punch device102includes a pressure monitor114to enhance operation of the tool100. For example, if fluid pressure of the actuator110is too low or too high (i.e., outside of a predetermined operational value range), then the tool100may be shut down or otherwise restricted from operating. That is, the tool100may be shut down via electrical signals from an on-board controller (not shown), or mechanically restricted.

The punch device102further includes a punch116extending outwards from the frame108and which is drivable via the actuator110. The punch116includes an inner (pierce) pin118and an outer pin120. As shown, the inner pin118is nested within the outer pin120and is coaxial therewith (i.e., both being aligned on the axis ‘X’). More specifically, the outer pin120is hollow such that the inner pin118is received within and circumferentially surrounded by the outer pin120. As further shown, the outer pin120has a chamber119formed therein (i.e., at an end closest to the frame108) and the inner pin118has a head121(i.e., a lip or radial protrusion formed at an end closest to the frame108) received within the chamber119.

Notably, in a particular state of the punch device102(described in further detail below), the inner pin118is movable independently of the outer pin120, and is held in a home or retracted position (as shown inFIG.2) via a spring122. In the depicted embodiment, the spring122is a compression spring received within the chamber119of the outer pin120and circumferentially surrounds the inner pin118. Moreover, a first end of the spring122acts on an inner wall of the chamber, and an opposite, second end of the spring122acts on the head121of the inner pin118such that respective contact surfaces (configured to physically engage the substrate ‘S’) of the inner and outer pins118,120are coplanar or otherwise aligned in the retracted position, as shown. As further shown, magnet(s)123(i.e., a single magnet or a plurality of magnets) are provided at an end of the outer pin120(i.e., at or adjacent its contact surface) and are configured to magnetically hold the fastener ‘F’ in a desired orientation during transportation to the substrate ‘S,’ as will be discussed below.

Of note, the ability of the inner pin118to move (i.e., translate) with respect to the outer pin120is dependent on a pair of punch locks124that are actuatable (i.e., repositionable) via respective pneumatic cylinders126. In the depicted embodiment, the locks124are movable in a direction orthogonal to the axis ‘X’ to transition the punch device102between a first (pierce) state (as shown inFIG.2) and a second (clinch) state (as shown inFIG.7, discussed below). As will be further discussed below, when the punch device102is in the first (pierce) state, the inner pin118is movable (i.e., translatable along the axis ‘X’) independently of the outer pin120. Alternatively, when the punch device102is in the second (clinch) state, the inner pin118is unable to move independently of the outer pin120. That is, as will be explained below, the inner pin118and the outer pin120move in concert during the entire clinching stage or action. Of note, while the discussed embodiment depicts the locks124being movable via respective pneumatic cylinders126, it is contemplated that the locks124may be movable in any other manner.

As further shown inFIG.2, the loader104includes a movable caddy128that is slidable (i.e., translatable) in a direction orthogonal to the axis ‘X’. The caddy128includes a reception slot130therein that is configured to receive a fastener ‘F’ (i.e., a self-attaching fastener) and maintain an orientation of that fastener ‘F’ during transportation, as discussed below. The caddy128is slidable via a pneumatic cylinder132, but may be actuated in a different manner. The loader104further includes a hopper134configured to receive and store multiple fasteners ‘F’ therein. In particular, the hopper134includes a collar136to which a tube (carrying multiple fasteners ‘F’, not shown) may be removably connected for delivering fasteners ‘F’ to the hopper134from a storage bin/area. Alternatively, the hopper134may be hand-fed. Still in other embodiments, the hopper134may be fed in any other conventional manner.

The loader104further includes a guide138having first and second clamshells (only the first clamshell140being shown inFIG.2) that are pivotable (e.g., via a hinged connection) so as to move between a first (closed) position and a second (open) position. Of note, the first and second clamshells are biased into the first (closed) position. Moreover, when the first and second clamshells are in the first (closed) position (as partially shown inFIG.2) the guide138provides a reception area configured to receive a fastener ‘F’. Alternatively, when the first and second clamshells are in the second (open) position (as partially shown inFIG.5), the first and second clamshells are pivoted outwards and away from one another (via translation of the punch116) so as to permit the punch116to translate along the axis ‘X’ in a direction towards the substrate ‘S’. As mentioned above, and as will be discussed further below, the caddy128is configured to transport a single fastener ‘F’ from the hopper134to the guide138.

Now with reference toFIG.3, the die device106includes a die button142provided at a top (or outer end) of a body144. The die button142has an engagement surface146on which the substrate ‘S’ rests (i.e., physically sits) during operation of the tool100. Further, the die button142includes an aperture148(i.e., through-hole) formed therein that is coaxial with the axis ‘X’. The aperture148is in fluid communication with a channel150provided in the body144, which is in fluid communication with a vacuum source (not shown).

The die device106further includes a guide pin152received within a passage154of the body144that is coaxial with the aperture148of the die button142. Notably, the guide pin152is movable (i.e., translatable) along the axis ‘X’ via a pneumatic cylinder (not shown). It is contemplated that the guide pin152may be movable in a manner other than by a pneumatic cylinder. Notably an outer diameter of the guide pin152is smaller than a diameter of the aperture148formed in the die button142such that the guide pin152is movably receivable within the aperture148during operation, as discussed further below. Moreover, the guide pin152has a bore156formed therein configured to receive a portion of the fastener ‘F’ (e.g., the shank of the clinch bolt) during operation, as discussed below.

Operation of the tool100will now be discussed with respect to its separate, two-stages. The first stage (or piercing action) begins with a substrate ‘S’ being received on the engagement surface146of the die button142(as shown inFIGS.2and3). Further, in the first stage, the locks124are oriented such that the punch device102is in the first (pierce) state (as shown inFIG.2). Now with reference toFIG.4, the punch device102begins to translate along the axis ‘X’ in a direction towards the die device106(i.e., in the depicted embodiment, the punch device102translates vertically downwards). Notably, the punch device102is movable (i.e., translatable along the axis ‘X’) via a press, or other known device, not shown. As the punch device102translates, the guide138of the loader104receives an engaging end of the punch116(i.e., the respective contact surfaces of the inner and outer pins118,120). With respect toFIG.5, further continual movement of the punch device102(i.e., towards the die device106) results in forcibly moving (i.e., pivoting) the first and second clamshells of the guide138against their bias to the second (open) position, thereby permitting the punch device102(i.e., the punch116) to continue translating towards the substrate ‘S’.

As shown inFIG.5, the punch device102continues to translate until the engaging end of the punch116(i.e., the respective contact surfaces of the inner and outer pins118,120) reaches (i.e. disposed adjacent and/or making physical contact with) the substrate ‘S’. With reference toFIG.6, with the locks124being oriented such that the punch device102is in the first (pierce) state, and as the actuator110provides the drive force (via the piston112), the inner pin118continues to translate (along the axis ‘X’) towards the die device106, whereas the outer pin120of the punch116remains stationary. That is, with the punch device102in the first (pierce) state, after the outer pin120engages (e.g., physically contacts) the substrate ‘S’, the outer pin120is restricted from further movement (i.e., towards the die device106), whereas the inner pin118is able to continue translating (independently) of the outer pin120(via the driving force of the actuator110) to thereby pierce an aperture in the substrate ‘S’. Notably, the removed material ‘M’ (i.e., the pierced piece) of the substrate ‘S’ falls into the aperture148of the die button142and is guided into the channel150of the body144via the vacuum source (not shown).

After piercing the substrate ‘S,’ the first stage concludes with the punch device102returning to its original (i.e., home) position, as shown inFIG.7. Notably, while the punch116translates along the axis ‘X,’ (i.e., towards its home position) the force exerted on the first and second clamshells of the guide138will cease (i.e., as the punch116no longer engages with the guide138), thus resulting in the guide138reverting back to the first (closed) position in accordance with its bias. After the punch device102reaches its home position, the second stage (or clinching action) begins with the locks124being reoriented such that the punch device102is operably placed in the second (clinch) state, as depicted inFIG.7. As briefly mentioned above, when the punch device102is in the second (clinch) state (via the corresponding orientation of the locks124), the inner and outer pins118,120move in tandem. That is, unlike the first stage detailed above (i.e., wherein the drive force is applied only to the inner pin118), the drive force (via the actuator110) will be applied to both the inner and outer pins118,120during the second stage.

Next, as shown inFIG.8, the caddy128(loaded with a single fastener ‘F’) translatably slides (via the pneumatic cylinder132) until its reception slot130is aligned with (i.e., coaxial to) the guide138. Thereafter, the transported fastener ‘F’ falls (e.g., via gravity) into the guide138and is held in a correctly oriented position (i.e., coaxial with the axis ‘X’) via correspondingly-shaped, respective internal surfaces of the first and second clamshells, as depicted inFIG.9. Notably, while the caddy128transports the fastener ‘F’ to the guide138, the guide pin152simultaneously moves (i.e., translates) along the axis ‘X’ such that it is received within the aperture148of the die button142(as shown inFIGS.8-9). Moreover, as shown, an end of the guide pin152extends outwards of the aperture148of the die button142and passes through the previously formed aperture in the substrate ‘S’. This is an important step, as the guide pin152acts as an indicator as to whether an aperture has been properly formed in the substrate ‘S’ in the preceding stage. If no aperture is located (via the guide pin152) then an on-board controller may stop the remaining operations of the second stage, thus preventing part waste and/or machine downtime. As further shown inFIG.9, after one fastener ‘F’ has been received in the guide138, the caddy128returns to its original position and is reloaded (via the hopper134) with yet another fastener ‘F.’

After the fastener ‘F’ has been received in the guide138, the second stage continues with the punch device102translating (i.e., vertically downwards) towards the die device106. When the engaging end of the punch116(i.e., the respective contact surfaces of the inner and outer pins118,120) reaches the fastener ‘F’ (which is held captive in the guide138), the fastener ‘F’ is magnetically attracted thereto (i.e., via the magnet(s)123) and thus will remain in the correctly oriented position (i.e., aligned along the axis ‘X’). Subsequently, the first and second clamshells of the guide138are forcibly moved (i.e., pivoted) in the same manner as noted above, and the punch device102continues to translate towards the die device106. With reference toFIG.10, as the punch device102continues to translate, a portion of the fastener ‘F’ (e.g., the shank) will be inserted into the bore156of the guide pin152, and the punch device102(along with the guide pin152) will continue to translate (i.e., vertically downwards) until the fastener ‘F’ reaches (e.g., disposed directly adjacent, makes physical contact with, etc.) the substrate ‘S’ (as shown inFIG.11). Notably due to the coaxial alignment of the above-noted devices during both the first (piercing) and second (clinching) stages, the fastener ‘F’ is translated (via the punch device102) perfectly into the aperture formed previously in the substrate ‘S’.

Thereafter, as shown inFIG.11, the actuator110provides the drive force to the punch116(i.e., both the inner and outer pins118,120), resulting in the fastener ‘F’ being clinched to the substrate ‘S’ (e.g., a completed clinching part being shown inFIG.13). After clinching the fastener ‘F’ to the substrate ‘S,’ the punch device102returns to its home position for preparation in restarting the two-stage action of piercing and clinching. Notably, as shown inFIG.12, as the punch device102returns to its home position, the guide pin152translates (vertically downwards) such that the fastener ‘F’ (e.g., its shank) is no longer received within the bore156of the guide pin152.

Due to the respective dimensions of the guide pin152and the aperture148of the die button142, when the guide pin152retreats back to its original position, a spaced distance is provided between a circumferential wall that defines the aperture148and the fastener ‘F’ (i.e., the shank). This spaced distance improves efficiency when removing the completed part from the tool100(as shown inFIG.12). Indeed, removal of the completed part (i.e., as shown inFIG.13) is generally performed by a robot, thereby already exhibiting high efficiency and enhanced throughput. However, because the above-noted spaced distance exists, the robot does not need to be calibrated or programmed to be so precise as to extract the completed part coaxially along the axis ‘X.’

In sum, the above-described two-stage tool100and associated method reduces machine costs, saves floor space within a facility, and enhances both efficiency and accuracy (thereby reducing production costs). This is achieved by performing two separate operations (i.e., a pierce action and a clinch action) coaxially in a single machine. In other words, the manufacturer only needs one machine to perform two separate operations. Moreover, as the two-stage tool100performs both operations in-line (i.e., coaxially), there is no need to reposition the substrate (e.g., after piercing) in between those operations. Rather, the substrate remains in a single position during both operations, thereby reducing potential misalignment issues.

The invention has been described with reference to example embodiments. Modifications and alterations thereto will be evident to persons of skill in the art upon a reading and understanding this specification.