Visual Inspection of Self-Pierce Riveting Systems for the Automotive Industry By Paul Johnson (p.johnson1@ljmu.ac.uk) Supervisors: Dr Francis Lilley, Professor David Burton.
Slide 2Self-Pierce Riveting Why SPR? SPR Problems Current Technology Problems Project Objectives Project Status Conclusions & Future Work An issue to tackle… (this implies you!) Overview
Slide 3Mechanical joining process/aluminum Handheld, platform or robotized High speed, single operation, no prep Fully penetrate best materials & somewhat puncture base material Self-Pierce Riveting Joint creation prepare.
Slide 4Self-Pierce Riveting A cross segment of an effective SPR joint. A semi-tubular bolt joining three sheets of aluminum . Enlivened Joint creation prepare. C-outline which suits the tooling.
Slide 5Self-Pierce Riveting Doidge Type 120 Riveting Machine affect riveting machine semi-tubular, tubular, bifurcated steel, metal, copper, aluminum and light composite semi-tubular steel bolts 3.1mm distance across/7.4mm length aluminum review 1200 (BS1470: 1987) Doidge Type 120 Riveting Machine
Slide 6Why SPR? lessen discharges lighter vehicles littler motors EU emanations regs order 70/220/EEC classification M 1 traveler vehicles 8 situate max EU Emissions Directive 70/220/EEC.
Slide 7Why SPR? Conventional joining/steel body new light weight vehicles (partner) RSW is unfeasible for aluminum bring down resistance than steel expends more vitality because of warmth misfortune SPR is a feasible arrangement bring down influence utilization makes an air/water tight joint rapid no inclusion opening and material arrangement puncture and secure in one operation Spot weld machine. Test spot weld.
Slide 8SPR Problems Poor joint get to/double get to C-outline, pass on, punch Quality control of the joint Predominantly dangerous (etching, pulling) Handheld ultrasonic test Physical Teardown One auto, ~5000 joints, two men, 30 days Time, cash, deferred quality control
Slide 9Current Technology Driven by… expanded mechanization unique materials Decline of gifted/modest work constrain HENROB Ltd Industry pioneer for SPR frameworks BMW, Audi, Jaguar, Volvo, Chrysler, Mercedes, Freightliner and Hyundai.
Slide 10SLIDES REMOVED FOR CONFIDENTIALITY
Slide 11Project Status (Rivet Status) Applying camera to sense about bolt status : bespoke programming distinguishes light force obliges alignment to surrounding lighting pre-prepare investigation point power values choice Intensity profile of a missing bolt. Power profile of a solitary bolt. Power profile of a twofold bolt.
Slide 12Project Status (Mat. Profundity) Applying camera and laser to distinguish material profundity physical channels picture handling recognizes laser stripe thickness in mm and px pre-prepare requires joint alignment focal point remove from material surrounding lighting/limit A 6mm pile of sheet aluminum. As above, with impartial thickness and red channels. Screenshot of the procedure checking programming. As above, with edge and laser line recognizable proof.
Slide 13SLIDES REMOVED FOR CONFIDENTIALITY
Slide 14Thank You!
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