Joining apparatus and method for loading a joining element

Abstract

Joining apparatus for joining joining elements onto workpieces, comprising a joining element holding device, which is configured to radially hold a joining element, and comprising a loading pin arrangement, which is configured to slide a joining element axially into a holding position in the joining element holding device, and/or to axially support the joining element during a joining process, wherein the loading pin arrangement has a loading pin, which is slidable by means of a loading pin actuator arrangement in the direction of the joining element holding device. The loading pin arrangement is here designed to variably establish a loading pin stroke of the loading pin between at least two stages, so that in a first stage the loading pin is displaceable less far in the direction of the joining element holding device than in a second stage.

Claims

1. A joining apparatus for joining a joining element onto workpieces, the joining apparatus comprising: a joining element holding device, which is configured to radially hold the joining element; and a loading pin arrangement including a loading pin actuator arrangement and a loading pin with a front end, wherein the loading pin-is slidable by means of the loading pin actuator arrangement in the direction of the joining element holding device, and wherein the loading pin arrangement is operable to establish one of a first loading pin stroke and a second loading pin stroke, and the first loading pin stroke is in the direction of the joining element holding device from a feed position to a first joining position, while the second loading pin stroke is from the feed position to a second joining position, and wherein the first loading pin stroke is less long than the second loading pin stroke and the front end of the loading pin is displaceable less far in the direction of the joining element holding device than in the second loading pin stroke; and wherein the loading pin arrangement further includes a housing and the joining element holding device is axially fixed relative to the housing; and wherein the loading pin actuator arrangement includes: a loading pin cylinder located in and axially displaceable within the housing of the loading pin arrangement, the loading pin cylinder includes a first cylinder chamber and a second cylinder chamber, and a partition divides the loading pin cylinder into the first cylinder chamber and the second cylinder chamber; a first piston coupled with a rear end of the loading pin and is displaceable in the first cylinder chamber of the loading pin cylinder which defines a first piston stroke; and a second piston is located in the second cylinder chamber of the loading pin cylinder.

2. The joining apparatus according to claim 1, wherein the second piston is fixed in relation to the housing.

3. The joining apparatus according to claim 1, wherein the first piston and the second piston have the same diameter.

4. The joining apparatus according to claim 1, wherein the loading pin arrangement is configured such that, in the feed position (SP) of the loading pin, in which the loading pin frees a feed channel for the joining element which is to be fed into the joining element holding device, the first piston and the second piston are disposed adjacent to the partition.

5. The joining apparatus according to claim 1, wherein the loading pin arrangement includes a stroke fine adjustment device.

6. The joining apparatus according to claim 5, wherein the stroke fine adjustment device includes a nut as a screw adjustable stroke-limiting stop between the housing and the loading pin cylinder.

7. A joining tool for joining a fastener onto a workpiece, the joining tool comprising: a housing defining a bore with a longitudinal axis and including a first end and a second end opposed to the first end; a receiver fixedly connected to the housing at the first end and including: a joining element holding device including a plurality of holding tongues arranged around a joining axis; and an inlet opening through which the fastener is fed radially inward then axially downward via a feed channel to the joining element holding device; a loading pin extends inside the housing along the joining axis coaxially to the joining element holding device and is movable along the joining axis from a feed position to a first joining position or a second joining position; and a loading pin actuator including: a loading pin cylinder mounted in and axial displaceable within the bore of the housing and including a first axial end, proximate to the joining element holding device, and a second axial end, distal from the joining element holding device; a partition transverse to the joining axis divides the loading pin cylinder into a first chamber, proximate to the joining element holding device, and a second chamber distal from the joining element holding device; a first piston is disposed within the first chamber of the loading pin cylinder and is connected to and axially movable with the loading pin which extends into the loading pin cylinder through the first axial end; and a second piston is disposed within the second chamber and is connected to the second end of the housing via a piston rod which extends through the second axial end of the loading pin cylinder.

8. The joining tool according to claim 7 wherein the first cylinder chamber defines a first piston stroke and the second cylinder chamber defines a second piston stroke, which is smaller than the first piston stroke.

9. The joining tool according to claim 8 wherein the loading pin cylinder moves axially within the housing a cylinder stroke distance between a first cylinder position, when the loading pin is in the first joining position, and a second cylinder position, when the loading pin is in the second joining position, and the cylinder stroke distance is adjustable.

10. The joining tool according to claim 9 wherein the cylinder stroke distance is adjustable by an adjustment screw.

11. The joining tool according to claim 9 wherein the cylinder stroke distance is no longer than the second piston stroke.

12. The joining tool according to claim 7 wherein a front end of the loading pin selectably moves from the feed position to: the first joining position a first loading pin stroke distance; or the second joining position a second loading pin stroke distance; and the second loading pin stroke distance is longer than the first loading pin stroke distance.

13. The joining tool according to claim 7, wherein in the feed position: the first axial end of the loading pin cylinder is spaced an axial distance from the first end of the housing; the second axial end of the loading pin cylinder bears against the second end of the housing; the first piston and second piston are proximate to respective and opposite axial sides of the partition; and the loading pin is withdrawn from the joining element holding device so far that it is removed from the feed channel, and the fastener can be freely conveyed from the inlet opening to the joining element holding device.

14. The joining tool according to claim 7, wherein in the first joining position: the first axial end of the loading pin cylinder is spaced a first axial distance from the first end of the housing; the second axial end of the loading pin cylinder is adjacent to the second end of the housing; the first piston is proximate to the first axial end of the loading pin cylinder; the second piston is proximate to the partition; and the loading pin moved from the feed position into the joining element holding device a first loading pin stroke distance.

15. The joining tool according to claim 14, wherein in the first joining position a compressed air is fed between the partition and the first piston.

16. The joining tool according to claim 14, wherein in the first joining position a front end of the loading pin presses the fastener axially out of first fastener position within the holding device into a second fastener position.

17. The joining tool according to claim 14, wherein the first cylinder chamber defines a first piston stroke, and the first loading pin stroke distance is equal to the first piston stroke.

18. The joining tool according to claim 7, wherein in the second joining position: the first axial end of the loading pin cylinder is adjacent to the first end of the housing; the second axial end of the loading pin cylinder is spaced a second axial distance from the second end of the housing; the first piston is proximate to the first axial end of the loading pin cylinder; the second piston is distal from the partition and proximate to the second axial end of load pin cylinder; and the loading pin moved from the feed position into the joining element holding device a second loading pin stroke distance.

19. The joining tool according to claim 18, wherein in the second joining position a compressed air is fed between the partition and the second piston.

20. The joining tool according to claim 18, wherein the second cylinder chamber defines a second piston stroke.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) Illustrative embodiments of the invention are represented in the drawing and explained in greater detail in the following description, wherein:

(2) FIG. 1 shows a schematic representation of a joining system comprising an embodiment of a joining apparatus according to the invention, wherein a loading pin is in a feed position;

(3) FIG. 2 shows the joining apparatus of FIG. 1, wherein a loading pin is in a first joining position;

(4) FIG. 3 shows the joining apparatus of FIG. 1, wherein a loading pin is in a second joining position; and

(5) FIG. 4 shows an alternative embodiment of a joining apparatus, wherein a loading pin is in a first joining position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(6) In FIG. 1, a joining system for joining joining elements onto workpieces is represented schematically and denoted in general terms by 10.

(7) The joining system 10 has a joining head 12, which forms a joining apparatus. The joining head 12 is movable three-dimensionally in space, by way of example by means of a robot 14, wherein the joining head 12 is guided on one end of an arm 16 of the robot 14.

(8) The joining system 10 further contains a feed device 18. The feed device 18 has a separating device 20, in which the joining elements 48 are separated and are then conveyed via a feed system, for instance in the form of blow air, via a feed tube 22 to the joining head 12.

(9) The joining head 12 contains a joining element receiver 26, which contains an inlet opening 28, via which separated joining elements 48 are fed. The inlet opening 28 is connected via a feed channel 30 to a joining element holding device 32 of the joining head 12. The joining element holding device 32 has a plurality of holding tongues 34 arranged distributed over the periphery. The joining element holding device 32 is connected to the joining element receiver 26 by means of a fastening system in the form of a cap nut 36.

(10) The holding tongues 34 define a conical portion 38, which passes from an inner diameter, which corresponds to a maximum diameter of a joining element, to an inner diameter, which is smaller than a minimum diameter of the joining elements to be worked.

(11) The feed channel 30 extends from the inlet opening 28 in a curved path out of a radial feed direction into an axial feed direction and is connected to the rear end of the joining element holding device 32 in order hence to be able to feed joining elements via the feed channel 30 from the rear into the joining element holding device 32, until these come to a halt in the region of the conical portion 38 in the joining element holding device 32.

(12) In order to transfer a thus supplied joining element subsequently into a holding position, which in FIG. 1 is shown schematically at H, a loading pin arrangement 40 is provided.

(13) The loading pin arrangement 40 contains a housing 42, which is fixedly connected to the joining element receiver 26. In addition, the loading pin arrangement 40 has a loading pin 44, which extends along a joining axis 46, i.e. coaxially to the holding device 32. The loading pin 44 is movable between a feed position SP and two joining positions.

(14) In FIG. 1, the loading pin 44 is shown in the feed position SP. In this, the loading pin 44 is so far withdrawn from the joining element holding device 32 in the axial direction that it frees with its front end the feed channel 30, so that a joining element can be freely conveyed from a side of the loading pin 44 into the holding device 32.

(15) After this, the loading pin 44 can be transferred into one of the joining positions shown in FIGS. 2 and 3. As a result, a joining element 48 is pressed from the rear further into the joining element holding device 32 and finally into a holding position H, in which a part of the joining element 48 protrudes in relation to an axial end of the holding device 32, as is represented in FIG. 1.

(16) In FIG. 1 is shown that the joining element 48 has a shank portion 50, which in the holding position H is held on the outer periphery by the holding tongues 34, and a flange portion 52, which in the holding position H protrudes axially in relation to the holding device 32.

(17) For the performance of a joining operation, the flange portion 52 can then be mounted onto a workpiece 54 such as a metal sheet. After this, a welding current 56 can be conducted into the holding device 32, so that an electric current flows from the joining element 48 into the workpiece 54. Next the joining element 48 can be lifted off the workpiece 54 in order to draw an arc which fuses the mutual joining surfaces, after which the joining element 48 can be lowered onto the workpiece 54 in order to end the stud welding operation. The welding current is then short-circuited and shut off.

(18) The movements of the joining element 48 can here be effected by movements of the joining head 16 as a whole, either via a motor (not described in detail) on the joining head, or directly by means of the robot 14.

(19) Instead of a welding operation, a gluing operation or another joining operation can also be performed, however, with a joining apparatus according to the invention.

(20) In order to move the loading pin 44 between the feed position SP shown in FIG. 1 and one of the two joining positions FP1 and FP2 which are represented in FIGS. 2 and 3 respectively, a loading pin actuator arrangement 60 is provided.

(21) The loading pin actuator arrangement 60 has a loading pin cylinder 62, within which a loading pin piston 64 is disposed, to be precise within a first cylinder chamber 65 of the loading pin cylinder 62. The first cylinder chamber 65 defines a first piston stroke 66 for the loading pin cylinder 62.

(22) The loading pin itself or a therewith associated piston rod passes through a first axial end 68 of the loading pin cylinder 62 and is sealed at this place. The first cylinder chamber 65 is delimited by this first axial end 68 and by a partition 70 within the loading pin cylinder 62.

(23) The loading pin cylinder 62 itself is mounted in an axial displaceable manner within a bore 72 of the housing 42.

(24) Within the loading pin cylinder 62 is established a second cylinder chamber 74, which extends between the partition 70 and a second axial end 78 of the loading pin cylinder 62. Within the second cylinder chamber 74 is disposed a second piston 76, which is rigidly connected to the housing 42 via a second piston rod 82 (not described in detail) which passes rough the second axial end 78.

(25) The second cylinder chamber 74 is hence delimited by the partition 70 and by the second axial end 78 and establishes a second piston stroke 80, which is preferably smaller than the first piston stroke 66.

(26) As illustrated, the second piston 76 is connected to the housing 42 via the second piston rod 82, which passes through the second axial end 78. The second piston rod 82 is here fixed to an end cap 84 of the housing 42, which closes off an opening via which the loading pin cylinder 62 can be introduced into the bore 72 of the housing 42.

(27) A diameter of the cylinder chambers 65, 74 is shown in FIG. 1 at 86. The diameters are identical.

(28) In the feed position SP, the second axial end 78 bears against the end cap 84. In addition, the pistons 64, 76 bear against opposite axial sides of the partition 70.

(29) The axial mobility of the loading pin cylinder 62 within the housing 42 is adjustable via a fine adjustment device 90.

(30) The fine adjustment device 90 has a screw bolt 92, which protrudes from the first axial end 68 of the loading pin cylinder 62 in the direction of the holding device 32. Onto the screw bolt 92 is screwed a nut 94. The nut 94 can here form a stroke-limiting stop in relation to a stop face 96 of the housing 42.

(31) Hence a loading pin cylinder stroke 98 can be finely adjusted by twisting of the nut 94, which forms a screwing element. The loading pin cylinder stroke 98 is here preferably smaller than/equal to the second piston stroke 80.

(32) Starting from the feed position SP shown in FIG. 1, a first joining position FP1 can be established, as is represented in FIG. 2. To this end, compressed air is fed between the partition 70 and the loading pin piston 64, so that the loading pin piston is displaced to the fore in the measure of the first piston stroke 66, such that a front end of the loading pin 44 presses a joining element 48, such as the stud shown in FIG. 2, out of a position within the holding device 32 into the holding position H shown in FIG. 1 and FIG. 2.

(33) During the joining process, the loading pin can remain in the position to axially support the joining element.

(34) The hereby established first loading pin stroke 100 is preferably identical to the first piston stroke 66.

(35) This first loading pin stroke 100, corresponding to the first joining position FP1, is established when a joining element 48 has a first joining element length 102 which can lie within a specific first joining element length range.

(36) The position of the loading pin cylinder 62 within the housing 42 here remains unaltered in relation to the feed position SP shown in FIG. 1 and is shown schematically in FIG. 2 at first axial position 104.

(37) Insofar as a joining element 48′ having a second joining element length 108 which is smaller than the first joining element length 102 and which can lie within a second joining element length range is to be joined, such as, for instance, the spherical joining element 48′ shown in FIG. 3, the second stage of the loading pin actuator arrangement 60 is activated, in which stage compressed air is fed into the region between the partition 70 and the second piston 76, whereby the loading pin cylinder 62 is transferred out of the first axial position 104 shown in FIG. 2 into the second axial position 110 shown in FIG. 3, which latter position is established by the fine adjustment device having the nut 94 and the stop face 96.

(38) The hereby established second loading pin stroke 106 is larger than the first loading pin stroke 100.

(39) In FIG. 4 is represented an alternative embodiment of a joining apparatus 12′ located within housing 42′, which in terms of structure and working method corresponds generally to the joining apparatus 12 of FIGS. 1 to 3. Same elements are therefore identified by same reference symbols. The differences are substantially set out below.

(40) In contrast to the joining apparatus of FIGS. 1 to 3, the loading pin cylinder 62 has no partition between the loading pin piston 64 and the second piston 76. The ranges of movement of these pistons can be established in the same way as in the embodiment of FIGS. 1 to 3.

(41) For the establishment of the first joining position FP1, which is shown in FIG. 4, a first cylinder chamber 65′ between the loading pin piston 64′ and that axial end of the loading pin cylinder 62′ which is facing the loading pin 44 is pressureless (P.sub.1=0). In the further second cylinder chamber 74′ between the second piston 76′ and that axial end of the loading pin cylinder 62′ which is facing away from the loading pin 44 is contained fluid with a pressure P.sub.2.

(42) Finally, in a variable cylinder chamber 112 which is present between the pistons 64′, 76′ a pressure P.sub.3 is present. In the first joining position FP1, P.sub.2 is greater than P.sub.3. When the second joining position FP2 is due to be established, the second cylinder chamber 74′ is pressurelessly connected, so that the loading pin cylinder 62′ is transferred still further to the left in relation to the position shown in FIG. 4 until the second axial end 78 of the loading pin cylinder 62′ butts against the second piston 76′.

(43) Thus in the first joining position FP1: P.sub.2>P.sub.3>P.sub.1.

(44) In the second joining position FP2: P.sub.3>P.sub.1 AND P.sub.3>P.sub.2.

(45) In the feed position (corresponding to FIG. 1), the following applies:
P.sub.2>P.sub.1>P.sub.3.

(46) The said pressures apply to uniform impact surfaces or cross sections of the respective cylinder chambers. Insofar as the impact surfaces are different, the pressures shall be adapted accordingly.

(47) Although exemplary embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes may be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.