A system and method for drilling a hole in a vehicle structure and installing a fastener in the hole. A drill plate having openings and associated machine-readable elements is positioned on the structure. A drill gun is positioned in a particular opening and reads hole information from the associated element, and a computer determines whether the drill gun is properly set-up to drill the hole. A fastener insertion gun is positioned in the particular opening and reads fastener information from the element, and the computer determines whether the hole has been drilled and, if so, whether the fastener insertion gun is properly set-up to insert the fastener. A fastener delivery subsystem stores, tracks, and delivers fasteners to the fastener insertion gun. A system computer monitors the drilling of every hole, the insertion of every fastener, and the overall operation of the fastener delivery subsystem.

A fastening apparatus die cartridge comprises a main body defining a cavity configured to receive a plurality of dies; and an opening through which dies received by the cavity can be removed from the cavity; and an engagement portion configured to engage with a complementary engagement portion of a die changer of a fastening apparatus.

The invention relates to a functional element, in particular to a bolt element, for attachment to a workpiece, in particular a sheet metal part. The functional element comprises a fastening section that has a reshaping section that can be reshaped to fasten the functional element to the workpiece, in particular wherein the reshaping section is a rivet section, and a functional section having a functional region, wherein the functional section is connected, in particular is rotationally fixedly connected, to the fastening section. The fastening section and the functional section are produced from different materials.

A punch for a staking/riveting device having a workpiece receiving opening formed on a pressing surface of the punch to make a workpiece, projecting from a contacting surface, that is at least partially introducible into the receiving opening in response to the pressing surface of the punch approaching the contacting surface and is deformable in conformity with an inner contour of the receiving opening; at least a partial surface of the inner contour being formed in a spherical/ellipsoidal cap shape; and the inner contour of the receiving opening having an inner-contour intermediate surface between a rim of the inner contour on the pressing surface and the spherical or ellipsoidal cap-shaped partial surface that is a cylinder truncated cone jacket-shaped. A staking/riveting device, a joining partner for cooperating with the punch or with the staking/riveting device, a device having at least one staked/riveted workpiece, and a method for staking/riveting a workpiece.

A punch for a staking/riveting device having a workpiece receiving opening formed on a pressing surface of the punch to make a workpiece, projecting from a contacting surface, that is at least partially introducible into the receiving opening in response to the pressing surface of the punch approaching the contacting surface and is deformable in conformity with an inner contour of the receiving opening; at least a partial surface of the inner contour being formed in a spherical/ellipsoidal cap shape; and the inner contour of the receiving opening having an inner-contour intermediate surface between a rim of the inner contour on the pressing surface and the spherical or ellipsoidal cap-shaped partial surface that is a cylinder truncated cone jacket-shaped. A staking/riveting device, a joining partner for cooperating with the punch or with the staking/riveting device, a device having at least one staked/riveted workpiece, and a method for staking/riveting a workpiece.

A self-piercing rivet joint, having at least two components made of formable metallic materials having a strength up to 300 MPa, which are connected to one another in a riveting procedure, in which a self-piercing rivet pierces the first, stamp-side component with a setting force and is driven into the second, die-side component, specifically while maintaining a residual base thickness in the second component and while spreading out the self-piercing rivet to a spreading diameter in the second component. The self-piercing rivet is compressed after the riveting procedure down to 60% of its starting length and the spreading diameter is enlarged up to 140% to 150%, in particular to up to 140% of the rivet shaft diameter, specifically without damaging the self-piercing rivet by self-piercing rivet material cracks.

A process monitoring method for monitoring the joining of at least two workpieces by means of a self-piercing riveting device having a joining gun including a) a total sheet metal thickness, a rivet length and a bending constant of the joining gun are detected for a plurality of joining operations for each operation before joining; b) a punch path for a certain force, an end force, a path end value for the end force, a setting path of the rivet, and a rivet head end position are detected for the plurality of joining operations; c) a force/path window for the joining operations is determined; and d) a determined force/path window of one additional joining operation is compared to the force/path window of the joining operations determined in step c), and the additional joining operation is monitored so that any joining-related defects are identified.

A die for deforming a workpiece material in a joining tool comprises a head with a top side partially defining a cavity in which the workpiece material is to be deformed, a bottom side opposite the top side, a lateral side arranged between the top side and the bottom side, and a stem which extends along a longitudinal axis from the bottom side of the head. The die further comprises an identification tag, preferably an RFID tag, having an antenna for receiving and/or transmitting a signal, and a storing element for storing information, and the antenna is wrapped circumferentially around the head, such that the antenna entirely surrounds the head. The head may also include a groove extending around the head on the lateral side with the antenna arranged in the groove. Additionally, the die may include a recess with the storing element located in the recess.

Systems and methods that provide an improved mechanism for attaching a sensor wire to a bus bar in a battery module are disclosed. A battery module according to the present disclosure may include a bus bar comprising a rivet hole and a plurality of battery cells electrically coupled to the bus bar. The battery module may also include a sensor wire comprising a terminal end, as well as a blind rivet passing through the rivet hole of the bus bar and coupling the bus bar to the terminal end of the sensor wire. Attaching the sensor wire to the bus bar with a blind rivet may provide one or more of the following mechanical advantages: fast assembly, robustness for low power applications, elimination of the need to wait for an adhesive to cure, and elimination of the need for double-sided access of the bus bar.

Systems and methods that provide an improved mechanism for attaching a sensor wire to a bus bar in a battery module are disclosed. A battery module according to the present disclosure may include a bus bar comprising a rivet hole and a plurality of battery cells electrically coupled to the bus bar. The battery module may also include a sensor wire comprising a terminal end, as well as a blind rivet passing through the rivet hole of the bus bar and coupling the bus bar to the terminal end of the sensor wire. Attaching the sensor wire to the bus bar with a blind rivet may provide one or more of the following mechanical advantages: fast assembly, robustness for low power applications, elimination of the need to wait for an adhesive to cure, and elimination of the need for double-sided access of the bus bar.