Flowing Drilling Apparatus and Flow Drilling Process

Abstract

A flowing drilling apparatus having a feed drive for producing a feed of a flow drill in an axial direction and having a rotary drive for producing a rotational movement of the flow drill. The flowing drilling apparatus includes a control device that is configured and adapted to control the feed drive and/or the rotary drive in accordance with a first set of parameters up to a defined switchover point and to control it/them in accordance with a second set of parameters differing from the first set of parameters, from the defined switchover point onward.

Claims

1-29. canceled

30. A flowing drilling apparatus, comprising: a feed drive for producing a feed of a flow drill in an axial direction to selectively place the flow drill in contact with a workpiece; a rotary drive for producing a rotational movement of the flow drill, and a control device that is configured and adapted to control at least one of the feed drive and the rotary drive in accordance with a first set of parameters up to a defined switchover point and to control at least one of the feed drive and the rotary drive in accordance with a second set of parameters differing from the first set of parameters from the defined switchover point onward, wherein the flow drill when operated under the first set of parameters plasticizes a portion of material of the workpiece, and the flow drill when operated under the second set of parameters shapes the portion of material of the workpiece.

31. The flowing drilling apparatus in accordance with claim 30, wherein a second set of parameters differs from the first set of parameters with respect to its values.

32. The flowing drilling apparatus in accordance with claim 30, further comprising an input device by means of which at least one of the first set of parameters and the second set of parameters can be input.

33. The flowing drilling apparatus in accordance with claim 30, farther comprising an input device by means of which the switchover point can be input.

34. The flowing drilling apparatus in accordance with claim 30, further comprising a display device by means of which at least one of the first set of parameters and the second set of parameters can be displayed to a user.

35. The flowing drilling apparatus in accordance with claim 30, wherein the control device is connected to at least two separate measurement devices for monitoring a respective parameter.

36. The flowing drilling apparatus in accordance with claim 30, further comprising a feed path measurement device that is connected to the control device.

37. The flowing drilling apparatus in accordance with claim 30, wherein the control device is configured and adapted to control the rotational speed of the rotary drive.

38. The flowing drilling apparatus in accordance with claim 30, further comprising a rotational speed measurement device that is connected to the control device.

39. The flowing drilling apparatus in accordance with claim 30, wherein the control device is configured and adapted to control a feed force of the feed drive.

40. The flowing drilling apparatus in accordance with claim 30, further comprising a feed force measurement device that is connected to the control device.

41. The flowing drilling apparatus in accordance with claim 30, wherein the control device is configured and adapted to control a feed speed of the feed drive.

42. The flowing drilling apparatus in accordance with claim 30, further comprising a feed speed determination device that is configured and adapted to transmit determined speed data to the control device.

43. The flowing drilling apparatus in accordance with claim 30, further comprising a process duration measurement device that is configured and adapted to transmit the process duration of an operating mode to the control device.

44. The flowing drilling apparatus in accordance with claim 30, wherein the first set of parameters comprises at least one of the following parameters: feed path, rotational speed, feed force, maximum feed speed, minimal process time, maximum process time.

45. The flowing drilling apparatus in accordance with claim 30, wherein the second set of parameters comprises at least one of the following parameters: feed path, rotational speed, feed force, maximum feed speed, minimal process time, maximum process time.

46. The flowing drilling apparatus in accordance with claim 30, wherein the control device is configured and adapted to control at least one of the feed drive and the rotary drive in accordance with the second set of parameters up to a second defined switchover point and to control at least one of the feed drive and the rotary drive in accordance with a third set of parameters differing from the second set of parameters from the second defined switchover point onward.

47. The flowing drilling apparatus in accordance with claim 30, wherein the first set of parameters and the second set of parameters have at least two parameters that are the same.

48. A flow drilling process, the flow drilling process comprising the steps of: controlling at least one of a feed drive to produce a feed of a flow drill in an axial direction to selectively contact a workpiece with the flow drill and a rotary drive to produce a rotational movement of the flow drill up to a defined switchover point in accordance with a first set of parameters, and controlling at least one of the feed drive and the rotary drive from the defined switchover point onward in accordance with a second set of parameters differing from the first set of parameters, wherein the flow drill when operated under the first set of parameters plasticizes a portion of material of the workpiece, and the flow drill when operated under the second set of parameters shapes the portion of material of the workpiece.

49. The flow drilling process in accordance with claim 48, wherein at least one of the first set of parameters and the second set of parameters is input by means of an input device.

50. A flowing drilling apparatus, comprising: a feed drive for producing a feed of a flow drill in an axial direction to selectively place the flow drill in contact with a workpiece; a rotary drive for producing a rotational movement of the flow drill, and a control device that is configured and adapted to control at least one of the feed drive and the rotary drive in accordance with a first set of parameters up to a defined switchover point and to control at least one of the feed drive and the rotary drive in accordance with a second set of parameters differing from the first set of parameters from the defined switchover point onward, wherein the switchover point is defined by a value of a measured variable which is characteristic for the change of a physical state of material of the workpiece.

Description

[0053] The invention will be described in the following with reference to a purely exemplary embodiment and to the enclosed drawings. There are shown:

[0054] FIG. 1 a front view of a flowing drilling apparatus in accordance with the invention;

[0055] FIG. 2 a first side view of the flowing drilling apparatus of FIG. 1;

[0056] FIG. 3 a first perspective side view of the flowing drilling apparatus of FIG. 1;

[0057] FIG. 4 a second perspective side view of the flowing drilling apparatus of FIG. 1;

[0058] FIG. 5 a second side view of the flowing drilling apparatus of FIG. 1;

[0059] FIG. 6 a detail view of the flow drill of the flowing drilling apparatus of FIG. 1; and

[0060] FIG. 7 a flowchart to describe a control device of the flowing drilling apparatus of FIG. 1.

[0061] Different views of a flowing drilling apparatus 10 are shown in FIGS. 1 to 5. The flowing drilling apparatus 10 comprises a feed drive 12 for producing a feed of a flow drill 14 in an axial direction 16. In addition, the flowing drilling apparatus 10 comprises a rotary drive 18 for producing a rotational movement 20 of the flow drill 14.

[0062] The flowing drilling apparatus 10 further comprises a control device 22 for controlling the feed drive 12 and the rotary drive 18 in differing operating modes that change during a drilling process. So that a user can individually define the different operating modes, the flowing drilling apparatus 10 has an input device 24, for example an input keypad, and a display device 26, for example a display, that are connected to the control device 22. The input device 24 and the display device 26 can also be formed by a single module such as a touch display. A user can input a first set of parameters 28 and a second set of parameters 30 into the flowing drilling apparatus 10 by means of the input device 24. The first set of parameters 28 here defines a first individually settable operating mode 32 (see FIG. 7). The second set of parameters 30 defines a second individually settable operating mode 34. In addition, the user can define a first individually settable switchover point 36, for example a feed path X, by means of the input device 24, at which the control device 22 switches over from the first operating mode 32 to the second operating mode 34.

[0063] In the present example, the first set of parameters 28 comprises a rotational speed A, a feed force B, a maximum feed speed C, and a maximum process stage time D. Each of these parameters A, B, C, and D can be individually input by the user. In addition, the user can input the feed path X that defines how far the flow drill 14 should penetrate into a workpiece, not shown, before the flowing drilling apparatus 10 is to be switched over to the second operating mode 34. In the present case, a specific penetration depth of the flow drill 14 into a workpiece, not shown, thus serves as the switchover point 34, i.e. as the switchover criterion between the first operating mode 32 and the second operating mode 34. The switchover point 34 can be selected, for example, such that a tip of the flow drill 14 exits the workpiece, a metal sheet as a rule, at the switchover point 14.

[0064] The second set of parameters 30 is preferably selected such that the rotational speed A in the second operating mode 34 is smaller than the rotational speed A of the first operating mode 32. In addition, the feed force B of the second operating mode 34 should be selected as smaller than the feed force B in the first operating mode 32. It is recommended also to select the maximum feed speed C of the second operating mode as smaller than the maximum feed speed C of the first operating mode. A better surface quality of the passage is hereby achieved. The maximum permitted process stage time D of the second operating mode 34 can also be defined as shorter with respect to the maximum permitted process stage time of the first operating mode 32.

[0065] In addition, as shown in FIG. 7, the control device 22 can be configured and adapted to control the feed drive 12 and the rotary drive 18 in accordance with a third operating mode 38. In this case, the user defines a third set of parameters 40 and a second switchover point 42 via the input device 24. To check the input, the third set of parameters 40 and the second switchover point 42 as well as the first set of parameters 28, the second set of parameters 30, and the first switchover point 36 can be displayed to the user via the display device 26. As likewise shown in FIG. 7, a length L and/or a diameter of the flow drill can be able to be input by means of the input device 24 and can be displayed by means of the display device 26.

[0066] To be able to regulate the rotary drive 18 to a specific rotational speed and thus to operate it in accordance with the specified rotational speeds A, A, and A of the different operating modes, the flowing drilling apparatus 10 comprises a rotational speed measurement device 44 integrated in the rotary drive 18. The rotational speed measurement device 44 is connected to the control device 22 so that the control device 22 always provides the current rotational speed of the flow drill 14. The control device 22 can regulate the rotational speed of the flow drill 14 in accordance with the predefined rotational speeds A, A, or A by means of these data.

[0067] To be able to regulate the feed drive 12 to a specific feed force and thus to operate it in accordance with the specified feed forces B, B, or B of the different operating modes, the flowing drilling apparatus 10 has a feed force measurement device 46 in the form of a load cell. The feed force measurement device 46 transmits the measured data to the control device 22 so that the latter can regulate the feed drive 12 to the respective specified feed force B, B, or B.

[0068] As can be seen in FIG. 1, the flowing drilling apparatus 10 additionally comprises a feed sped determination device 48, here in the form of a feed speed calculation device. The feed speed calculation device 48 calculates the current feed speed of the flow drill 14 and provides the calculated data to the control device 22. The control device 22 monitors that the maximum feed speed C. C. or C of the currently present operating mode 32, 34, or 38 is not exceeded.

[0069] As can likewise be seen in FIG. 1, the flowing drilling apparatus 10 additionally comprises a process duration measurement device 50. The process duration measurement device 50 is part of the control device 22. The process duration measurement device 50 is configured and adapted to measure the process duration of each process stage and to provide the process duration for the control of the flowing drilling apparatus 10. The control device 22 determines whether a maximum process stage duration D, D, or D of the respective process stage has been reached with reference to the data produced by the process duration measurement device 50. If the maximum process stage duration D, D, or D has been reached, either the flowing drilling apparatus 10 can be switched off or a change can be made to the next process stage, i.e. to the next set of parameters.

[0070] As can be seen in FIG. 1, for example, the flowing drilling apparatus 10 additionally comprises a feed path measurement device 52 that lies on the workpiece, not shown, during the operating modes 32, 34, and 38. This makes it possible to measure the axial feed path of the flow drill 14 relative to the workpiece, not shown. The feed path measurement device 52 serves to determine whether a switchover to a different operating mode has to be made. For this purpose, the feed path measurement device 52 continuously transmits data to the control device 22 that then determines whether the next switchover criterion, i.e. the switchover point 36 or 42, has already been reached. If the switchover point 36, 42 has been reached, the control device 22 switches over to the next operating mode 34, 38. A switch-off point or a switch-off criterion 53 (FIG. 7) can be defined after the last operating mode. The feed path measurement device 52 preferably here also determines whether the switch-off point 53 has been reached. In other words, a specific path can serve as the switch-off criterion 53. If the switch-off criterion 53 has been reached, the process is ended.

[0071] A detail view of the flow drill 14 and of a clamping apparatus 54 for the flow drill 14 is shown in FIG. 6. The clamping apparatus 54 is configured as a collet chuck to simplify the tool change between different flow drills.

[0072] As a rule, the flow drill 14 first has to be moved toward the surface of a workpiece to be machined in flow drilling. During this operating mode, not shown, so-to-say the zeroth operating mode, the flowing drilling apparatus 10 is controlled using preset parameters fixed by the manufacturer. The flowing drilling apparatus 10 is, for example, operated with a preset feed and at a preset rotational speed until the feed path measurement device 52 detects that the flow drill 14 is just in front of the workpiece. This can be detected in that the feed path measurement device 52 contacts the workpiece. As soon as such a state is detected, the control device 22 can switch over the flowing drilling apparatus 10 to the first operating mode 32.

[0073] When the tip of the flow drill 14 exits the workpiece again, the flowing drilling apparatus 10 should switch over to the second operating mode 34 to shape the passage at a lower rotational speed A and with a lower feed force B. The first switchover point 36 should therefore be selected such that the plasticization takes place during the first operating mode 32, but the shaping of the passage is carried out in the second operating mode 34. When the passage has been shaped, the flowing drilling apparatus 10 should switch over to the third operating mode 38 to, for example, form a chamfer at the flow hole. The second switchover point 42 should therefore be selected such that the flowing drilling apparatus 10 switches over when the passage has been completely shaped and the hole should now be chamfered. At the end of the process, a switch-off point 53 should be defined at which the flowing drilling apparatus automatically switches off. A predefined feed path can likewise serve as the switch-off point 53.

REFERENCE NUMERAL LIST

[0074] 10 flowing drilling apparatus

[0075] 12 feed drive

[0076] 14 flow drill

[0077] 16 axial direction

[0078] 18 rotary drive

[0079] 20 rotational movement

[0080] 22 control device

[0081] 24 input device

[0082] 26 display device

[0083] 28 first set of parameters

[0084] 30 second set of parameters

[0085] 32 first operating mode

[0086] 34 second operating mode

[0087] 36 first switchover point

[0088] 38 third operating mode

[0089] 40 third set of parameters

[0090] 42 second switchover point

[0091] 44 rotational speed measurement device

[0092] 46 feed force measurement device

[0093] 48 feed speed determination device

[0094] 50 process duration measurement device

[0095] 52 feed path measurement device

[0096] 53 switch-off point

[0097] 54 clamping apparatus

[0098] A rotational speed

[0099] B feed force

[0100] C maximum feed speed

[0101] D maximum process stage duration

[0102] E minimal process stage duration