CN105281173B - 在铝构件上形成接地点的方法 - Google Patents

在铝构件上形成接地点的方法 Download PDF

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CN105281173B
CN105281173B CN201510354190.1A CN201510354190A CN105281173B CN 105281173 B CN105281173 B CN 105281173B CN 201510354190 A CN201510354190 A CN 201510354190A CN 105281173 B CN105281173 B CN 105281173B
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德拉甘·B·斯托伊科维克
迈克尔·威廉·丹由
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16BDEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B25/00Screws that cut thread in the body into which they are screwed, e.g. wood screws
    • F16B25/001Screws that cut thread in the body into which they are screwed, e.g. wood screws characterised by the material of the body into which the screw is screwed
    • F16B25/0021Screws that cut thread in the body into which they are screwed, e.g. wood screws characterised by the material of the body into which the screw is screwed the material being metal, e.g. sheet-metal or aluminium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033Deforming tubular bodies
    • B21D26/035Deforming tubular bodies including an additional treatment performed by fluid pressure, e.g. perforating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D28/00Shaping by press-cutting; Perforating
    • B21D28/24Perforating, i.e. punching holes
    • B21D28/28Perforating, i.e. punching holes in tubes or other hollow bodies
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21JFORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/063Friction heat forging
    • B21J5/066Flow drilling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60RVEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/06Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements for removing electrostatic charges
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/66Connections with the terrestrial mass, e.g. earth plate, earth pin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00Making other particular articles
    • B21D53/88Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16BDEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B25/00Screws that cut thread in the body into which they are screwed, e.g. wood screws
    • F16B25/10Screws performing an additional function to thread-forming, e.g. drill screws or self-piercing screws
    • F16B25/106Screws performing an additional function to thread-forming, e.g. drill screws or self-piercing screws by means of a self-piercing screw-point, i.e. without removing material
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16BDEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B37/00Nuts or like thread-engaging members
    • F16B37/005Nuts or like thread-engaging members into which threads are cut during screwing
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16BDEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/02Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of fastening members using screw-thread

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  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
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  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
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Abstract

本发明公开了一种在铝构件上形成接地点的方法。提供了一种在机动车辆的铝结构构件上设置电气接地点的方法。将所述构件液压成型为产生闭合的截面,之后在所述构件的壁中形成由凸缘包围的孔。凸缘通常为截头圆锥形的形状并朝向构件的内部延伸。具有附着到其的接地线的自攻丝的紧固件插入孔中,以在凸缘中切削出螺纹并将接地线固定到所述构件。在没有另外所需要的任何进入到构件的中空内部的情况下,自攻丝的紧固件使得接地连接实现。

Description

在铝构件上形成接地点的方法
技术领域
本公开涉及诸如在皮卡车的制造过程中使用的中空铝结构构件。具体地,本公开涉及一种形成与这种中空铝构件电气接地连接的方法。
背景技术
皮卡车是具有前乘客区(通常被称作驾驶室)和顶部打开式的后部货物区(通常被称作货厢(box))的机动车辆。车箱通常具有实质上的平坦的机架(bed),其中,两侧壁和前互连接的前部板(headboard)从该平坦的机架向上延伸。皮卡车还可使用底部铰接的车门(通常被称作后挡板),该车门铰接在机架的后边缘上并且是可关闭的,以提供用于货物区的第四个(后)壁。驾驶室和车箱可以是独立的组件或者相同的一体式结构的部件。皮卡车非常受欢迎,这是因为车箱允许人们以非常多种不同的方式使用(包括运输多种类型的货物和拖挂各种类型的拖车(trailer))。
传统地,皮卡车的大部分车身结构已经由钢合金形成。经过多年的经验,皮卡车设计者已经获知如何设计经受多种需求的皮卡车应用的钢的货车车身部件。当前的监管和经济环境增大了使皮卡车更节省燃料以及功能更多且更耐用的重要性。降低车辆的燃料消耗的一种方式是降低车辆结构重量。
铝合金通常具有比钢合金高的强度与重量比。因此,用铝替代钢提供了降低重量的潜能。然而,铝的弹性模量通常低于钢的弹性模量。另外,对钢部件起良好作用的连接部件的制造技术和方法可能不会对同样的铝部件起良好作用。由于这些和其它差异,简单的材料替换不一定产生合意的设计。
已经发现液压成型是一种用于形成铝结构构件的有效且经济的方法,该铝结构构件具有高强度与低重量之间的需要的平衡。
机动车辆的电气系统、电路和组件必须为了适当和安全的运转而电气接地。接地点可合宜地设置在车辆的金属结构组件上,例如,设置在框架或车身组件上。在典型的机动车应用中,与接地的电气组件或电路连接的接地线、电缆或带终止于金属圈(eyelet)或类似的元件,金属圈或类似的元件使用螺栓和螺母固定到金属组件上的接地点。
当结构组件由钢形成时,通常可实现为将螺母焊接到结构构件的壁并与壁上的孔对齐,所述结构构件的壁位于接地螺栓的插入方向相反的表面上。然后,螺栓穿过接地金属圈、插入构件的壁中的接地孔并拧紧为与卡式螺母(captive nut)螺纹接合,从而使接地金属圈抵靠着壁夹紧。接地金属圈具有足够的表面面积并利用足够的力抵靠着金属组件夹紧(通过将螺栓拧紧到螺母中的方式)以建立良好的电气连续性。
在提供接地点的结构构件具有中空或闭合的截面的情况下,如果在构件的与形成接地孔的壁相对的壁中形成检修孔(access hole),则螺母仅能固定在必要的位置上(中空部的内侧,位于具有接地孔的壁的后侧上)。这样的检修孔可削弱构件,并且形成检修孔可需要额外的制造和装配步骤,这增大了车辆装配工艺的成本和复杂性。
第6,931,901B1号美国专利教导在钢部件仍处于液压成型模具腔中的同时在液压成型的钢部件上形成螺纹孔。这需要穿过部件的壁进行冲孔、在使孔扩张到期望直径的同时迫使或挤压壁材料以形成从部件向内延伸的环形区域并且随后在环形区域的内部切削出螺纹的工具。这种过程需要专门的固定装置和冲孔/定尺/螺纹加工工具,因此使构件的制造成本增大相当多。这种过程还不太适合铝结构构件,这是由于在紧固件插入为与螺纹接合时的螺纹错扣和/或螺纹滑扣的可能性相对高。
将期望提供一种用于设置电气接地的方法,所述方法更适于由液压成型的铝的构件并消除对进入闭合的截面的中空内部的需要。
发明内容
在最先公开的实施例中,一种将接地线固定到机动车辆的铝结构构件的方法包括:将所述构件液压成型为形成闭合的截面;在所述构件的壁中形成具有截头圆锥形的凸缘的孔,所述凸缘朝向所述构件的内部延伸;将自攻丝的紧固件插入所述孔以接合所述凸缘,并在凸缘中切削出螺纹。紧固件具有固定到紧固件的接地线,然后,接地线可附着到接地的电路或装置。在没有另外所需要的任何进入到构件的中空内部的情况下,自攻丝的紧固件使得接地连接实现。
在另一公开的实施例中,一种在机动车辆的铝构件上设置电气接地点的方法包括:将机动车辆的铝构件液压成型为产生闭合的截面;在铝构件的壁中形成通过凸缘包围的孔,所述凸缘朝向铝构件的内部延伸;将自攻丝的紧固件插入所述孔中以在所述凸缘中切削出螺纹,紧固件具有附着到紧固件的接地线。
附图说明
利用附加的权利要求中的特征列举了在此描述的本发明的实施例。然而,通过参照下面结合附图的详细的描述,其它特征将变得更清楚并且可更好地理解实施例,其中:
图1是具有闭合截面的铝结构构件和通过接地螺栓附着到铝结构构件的接地线的局部透视图;
图2是沿图1的线2-2截取的截面;
图3是截取插入螺栓之前的框架构件的放大截面;
图4是截取安装在孔中的自攻丝的紧固件的截面视图;
图5是通过流钻固定装置保持的框架构件的简化示意图;
图6A-图6C是流钻钻孔工艺(flow-drilling bit process)的简化示意图;
图7是在液压成型模具组中成型后的构件的总的示意图;
图8是示出流钻钻头40在构件中形成孔和凸缘的图7中的部分8的详细视图。
具体实施方式
参照附图公开了示出的实施例。然而,将理解的是,公开的实施例仅意图是示例,示例可以以多种和可选形式实施。附图不一定按比例绘制,一些特征可被夸大或最小化以示出特定组件的细节。公开的具体结构和功能细节不被解释为限制,而仅作为用于教导本领域技术人员如何实践公开的原理的代表性基础。
在图1中,铝构件10是在机动车辆的制造过程中使用的结构组件。构件10可以是(例如)皮卡车的框架、机架或驾驶室结构的组件。用于车辆的电气组件或电路(未示出)的电气接地点通过经由自攻丝的紧固件14将接地线12固定到构件10而设置在构件10上。在公开的实施例中,接地线12包括终止于金属圈12b的导体12a和穿过该金属圈的紧固件14。导体12a的远离金属圈12b的端部附着到接地的电气组件或电路(未示出)。导体12a可包括本领域所熟知的电线、电缆或带。
接地的金属圈12b可具有与其一体地形成的防旋转接片12c,当金属圈通过紧固件14夹紧构件时,接片接合构件10中的相应的槽、凹入或孔16。
如图2中最佳示出的,构件10具有(例如)可以以液压成型工艺(如本领域所熟知的)形成的闭合的截面形状。在公开的实施例中,构件10的截面大致为矩形。由于本方法适合于任何中空或闭合形状的构件,所以这仅作为示例。在此所使用的术语“闭合截面”指中空形状,从而在很大程度上阻止接入构件的中空内部。由于在构件的一个或更多个壁中开设孔、槽、窗口或其它开口可能是出于构件的适合的设计功能和/或制造的原因的需要,所以该术语不否定在构件的一个或更多个壁中可开设有孔、槽、窗口或其它开口的可能性。
从图2将清楚的是,在与紧固件14相对的壁10b中没有开口,该开口将允许通过将螺母焊接或另外地固定到壁10a和/或允许螺母与螺栓螺纹接合所需要的工具(未示出)进入壁10a的后侧/内侧。
现在参照图3,构件10的一部分的放大截面示出了在容纳自攻丝的紧固件之前的形成在构件10的壁10a中的孔20。环形凸缘24围绕孔20并从壁10a的后侧r突出到构件的中空内部中。凸缘24具有截头圆锥形的截面,在其根部(凸缘的与壁10a相邻的端部)处具有最大厚度tmax并且朝向凸缘的远离壁10a的端部的厚度逐渐减小。当形成孔20时,凸缘24由壁10a的向内移动的材料形成。孔20和凸缘24的内表面具有一样的直径并且大体上平滑(没有螺纹)。最大凸缘厚度tmax大体上比壁10a的厚度tw小。
如在图4中所看出的,自攻丝的紧固件14从构件10的外部插入到孔20中,在紧固件14插入时紧固件14在孔20和凸缘24的内表面上切削出螺纹,从而紧固件接合壁和凸缘以保持金属圈12b与壁10a的前表面f接触。相对于仅壁的厚度tw可用而言,凸缘24的轴向长度l提供额外的螺纹接合长度,从而在紧固件与构件10之间提供更牢固的机械连接和更好的电气连续性(由于增大了接触表面面积)。
在构件10仍保留在液压成型模具腔中时或在构件10从液压成型模具移除之后所执行的独立的机械加工步骤或多个步骤中,可形成孔20和凸缘24。液压冲孔和流钻(也被称为热摩擦钻削和流体冲孔成型)被认为是合适的工艺。优选地,用于形成孔20和凸缘24的工艺不会产生与构件10分离的任何碎片或小块。
图5是在中空框架构件100已从液压成型模具(未示出)移除之后固定在机械加工固定装置102上的中空框架构件100的简化、示意性描绘。双钻头式流钻床(dual-bit flow-drill press)104被定位为形成两个紧密相邻的接地孔。
图6A-图6C(以简化、示意的形式)示出在构件100中形成具有向内突出的凸缘124的孔的流钻钻位头106。
图7和图8是液压成型模具组的简化示意性描绘,液压成型模具组包括上模具32、下模具34、第一端塞子36和第二端塞子38。构件10示出为在液压成型之后被包含在模具腔中。示出流钻钻头40通过上模具32中的导向轴插入。流钻钻头40通过钻床(未示出)旋转并前进以在构件的壁中形成孔。
公开的方法消除对在构件的与接地点相对的壁中形成检查孔的需要,而在卡式螺母(captive nut)保持接地紧固件时需要形成该检查孔。还消除对在插入紧固件之前在铝构件中形成螺纹的需要,这降低制造成本和复杂性,并且还在紧固件插入时降低螺纹错扣和/或螺纹损坏的可能性。
上面描述的实施例是特定的示例,所述特定的示例没有描述本公开的所有可能形式。说明的实施例的特征可组合以形成公开的原理的进一步实施例。在说明书中使用的词语是描述性的词语而非限制性的词语。权利要求的范围比明确公开的实施例的范围宽,并还包括示出的实施例的变型。

Claims (15)

1.一种将接地线固定到机动车辆的铝结构构件的方法,包括:
将所述构件液压成型为形成闭合的截面;
在所述构件的壁中形成孔,所述孔由朝向所述构件的内部延伸的凸缘包围,所述凸缘具有与所述壁的内表面相邻的第一厚度并且所述凸缘的厚度朝远离所述壁的端部逐渐减小;
将自攻丝的紧固件插入到所述孔中以接合所述凸缘,紧固件具有固定到紧固件的接地线。
2.根据权利要求1所述的方法,其中,在所述构件保留在液压成型模具组中的同时形成所述孔和所述凸缘。
3.根据权利要求1所述的方法,其中,在液压成型之后的机械加工步骤中形成所述孔和所述凸缘。
4.根据权利要求1所述的方法,其中,通过流钻形成所述孔和所述凸缘。
5.根据权利要求1所述的方法,其中,接地线包括终止于金属圈的导体,并且所述方法还包括:
在将紧固件插入到所述孔中之前将金属圈附着到紧固件,从而将紧固件插入到所述孔中使金属圈压抵靠所述构件的与所述孔相邻的表面。
6.一种将接地线固定到铝构件的方法,包括:
使铝构件液压成型为形成闭合的截面;
在铝构件的壁中形成无螺纹的孔,所述孔由朝向铝构件的内部延伸的截头圆锥形的凸缘包围;
将接地线连接至自攻丝的紧固件;
将自攻丝的紧固件插入到所述孔中,以在所述凸缘中切削出螺纹并促使接地线与铝构件接触。
7.根据权利要求6所述的方法,其中,在铝构件保留在液压成型模具组中时形成所述孔和所述凸缘。
8.根据权利要求6所述的方法,其中,在液压成型之后的机械加工步骤中形成所述孔和所述凸缘。
9.根据权利要求6所述的方法,其中,通过流钻形成所述孔和所述凸缘。
10.根据权利要求6所述的方法,其中,接地线包括终止于金属圈的导体,并且将接地线连接至紧固件的步骤包括将紧固件穿过金属圈。
11.一种在机动车辆的铝构件上设置电气接地点的方法,包括:
将铝构件液压成型为产生闭合的截面;
在铝构件的壁中形成通过凸缘包围的孔,所述凸缘朝向铝构件的内部延伸;
将自攻丝的紧固件插入到所述孔中以在所述凸缘中切削出螺纹,紧固件具有附着到紧固件的接地线。
12.根据权利要求11所述的方法,其中,在铝构件保留在液压成型模具组中时形成所述孔和所述凸缘。
13.根据权利要求11所述的方法,其中,在液压成型之后的机械加工步骤中形成所述孔和所述凸缘。
14.根据权利要求11所述的方法,其中,通过流钻形成所述孔和所述凸缘。
15.根据权利要求11所述的方法,其中,接地线包括终止于金属圈的导体,并且所述方法还包括:
在将紧固件插入到所述孔中之前将金属圈附着到紧固件,从而将紧固件插入到所述孔中使金属圈压抵靠铝构件的与所述孔相邻的表面。
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