Patent Application
20150034214
This disclosure relates to the manufacture of metallic components with bends, and more particularly to reinforcing the bends of metallic components for extended use.
Modern internal combustion engines are controlled by an engine control module (ECM). Generally, the ECM includes various electronic components that control the operation of the internal combustion engine, as well various sub-systems operatively coupled to the internal combustion engine. In automotive applications, the ECM is housed on a vehicle along with the internal combustion engine. Due to the potentially corrosive environment in which the ECM and internal combustion engine operate, conventional ECMs include a protective housing in which the electronic components are housed. Typically, the protective housing is made from a metal, such as aluminum, that is formed by bending a metallic sheet into a desired enclosed shape defining the interior of the ECM. Further, seams of the protective housing are sealed such that the interior of the ECM is sealed off from potentially harmful contaminants. Generally, the protective housing of an ECM is configured to remain permanently closed during its life cycle.
However, for various reasons, such as refurbishment or repair of the electronic components, the protective housing of an existing ECM is forcibly opened to expose the interior of the housing. Conventionally, an existing protective housing is opened by bending the metallic sheet along edges or corners of the housing in a direction opposite that used to bend the housing into its enclosed shape. When refurbishment operations on the interior of the housing are complete, the housing is again bent along the edges or corners into the original enclosed shape. Such reverse bending and re-bending of the housing tends to weaken the material along the bent edges or corners due to the formation of cracks. In some cases, the cracking is severe enough that housing can be completely severed along the bent edges or corners. Generally, after the original manufacture of an ECM, a conventional protective housing can be opened and closed no more than two times before the integrity of the housing fails, which severely limits the useful life of the ECM.
The subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to the problems and needs associated with the refurbishment or repair of ECMs for internal combustion engines. Accordingly, the subject matter of the present application has been developed to provide an apparatus, system, and method for reinforcing the housing of an ECM to extend the useful life of the ECM, which overcomes at least some of the above-discussed shortcomings of prior art.
According to one embodiment, an apparatus for reinforcing a metallic material includes a rotatable tool that is insertable into the metallic material. The rotatable tool is configured to plastically deform the metallic material. The apparatus also includes a coolant delivery mechanism that is coupled to the rotatable tool. The coolant delivery mechanism is configured to deliver a coolant to the metallic material. The metallic material can include a bend, and wherein the rotatable tool can be insertable into the bend and configured to plastically deform the bend.
In some implementations of the apparatus, the coolant delivery mechanism delivers coolant to the metallic material before the rotatable tool plastically deforms the metallic material. The rotatable tool plastically deforms the metallic material to create a plastically deformed zone in the metallic material. The coolant delivery mechanism can deliver coolant to the plastically deformed zone or to the material before it's plastically deformed. The coolant delivery mechanism can deliver coolant to a heat affected zone adjacent the plastically deformed zone. The coolant delivery mechanism can deliver coolant to the rotatable tool.
According to certain implementations of the apparatus, the coolant is a fluid, and the coolant delivery mechanism can be configured to spray the fluid onto the metallic material. The fluid may include at least one of liquid nitrogen and compressed air.
In certain implementations of the apparatus, the metallic material includes a first surface and an opposing second surface. The rotatable tool penetrates the first surface and does not penetrating the second surface. The apparatus can additionally include a metallic strip positioned along the second surface. The metallic strip positioned along the second surface can be made from a metal that is different than the metallic material. The apparatus might further include a metallic strip positioned along the first surface, where the rotatable tool penetrates the metallic strip. The metallic strip positioned along the first surface can be made from a metal that is the same as the metallic material.
According to some implementations of the apparatus, the coolant delivery mechanism includes a hollow ring that encircles the rotatable tool. The hollow ring includes a plurality of apertures through which the coolant is delivered. The plurality of apertures may include at least one first aperture oriented to direct coolant onto the metallic material before the rotatable tool plastically deforms the metallic material and at least one second aperture oriented to direct coolant onto the metallic material after the rotatable tool plastically deforms the metallic material. The plurality of apertures may include at least one third aperture oriented to direct coolant onto the metallic material at a location adjacent a plastically deformed portion of the metallic material created by the rotatable tool. Further, the plurality of apertures can include at least one fourth aperture oriented to direct coolant onto the rotatable tool. In certain implementations, the coolant delivery mechanism includes a plurality of nozzles each coupled to the hollow ring in alignment with a respective one of the plurality of apertures.
In yet another embodiment, a method for reinforcing a metallic material includes friction stir processing the metallic material along a targeted area in a first direction using a tool. The method also includes applying a coolant onto the targeted area upstream of the tool as the tool moves along the targeted area in the first direction. Further, the method includes applying a coolant onto the targeted area downstream of the tool as the tool moves along the targeted area in the first direction.
In some implementations, the method also include applying a coolant onto the metallic material adjacent the targeted area as the tool moves along the targeted area in the first direction, and applying a coolant onto the tool as the tool moves along the targeted area in the first direction.
According to another embodiment, a system for reinforcing an engine control module (ECM) for an internal combustion engine along a bend formed in the ECM includes a friction stir processing tool. The friction stir processing tool includes a rotatable pin that is insertable into the bend formed in the ECM. The rotatable pin is movable along the bend in a first direction. Additionally, the rotatable pin is configured to plastically deform the bend. The system also includes a hollow annular ring that is fixedly positioned about the friction stir processing tool. The hollow annular ring includes at least one first aperture oriented to direct coolant onto the bend before the rotatable pin plastically deforms the bend. Also, the hollow annular ring includes at least one second aperture oriented to direct coolant onto the bend after the rotatable pin plastically deforms the bend. Further, the hollow annular ring includes at least one third aperture oriented to direct coolant onto the ECM at a location adjacent the bend. Additionally, the hollow annular ring includes at least one fourth aperture oriented to direct coolant onto the friction stir processing tool. The system also includes a coolant supply line in coolant providing communication with the hollow annular ring.
The described features, structures, advantages, and/or characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments and/or implementations. In the following description, numerous specific details are provided to impart a thorough understanding of embodiments of the subject matter of the present disclosure. One skilled in the relevant art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials, and/or methods of a particular embodiment or implementation. In other instances, additional features and advantages may be recognized in certain embodiments and/or implementations that may not be present in all embodiments or implementations. Further, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the subject matter of the present disclosure. The features and advantages of the subject matter of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the subject matter as set forth hereinafter.
In order that the advantages of the subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the subject matter and are not therefore to be considered to be limiting of its scope, the subject matter will be described and explained with additional specificity and detail through the use of the drawings, in which:
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. Similarly, the use of the term “implementation” means an implementation having a particular feature, structure, or characteristic described in connection with one or more embodiments of the present disclosure, however, absent an express correlation to indicate otherwise, an implementation may be associated with one or more embodiments.
Referring to
The housing 11 also includes one or more bends 18 that define the panels. For example, the housing 11 includes a bend 18 that separates the top panel 12 from the side panel 16, as well as couples the top and side panels together. The top panel 12 is coupled to the end panels 14, 15 and the side panel 17 along separate edges of the panel, which can be coupled together using any of various coupling techniques, such as bonding, welding, and fastening. The seams along the separate edges of the panels can be sealed using any of various sealing techniques.
During formation of the housing 11, the top panel 12 can be bent along the bend 18 and moved in a closing direction into a sealing position relative to the top edges of the end panels 14, 15 and side panel 17 as shown by directional arrow 26 in
As mentioned above, after forming and sealing the housing 11, in some instances, it may be desirable to physically access the interior 22 of the housing to refurbish or repair the components within the housing 11. Physical access to the interior 22 of the housing 11 is gained by breaking the seal along the seams between the top panel 12, end panels 14, 15, and side panel 17, and bending the top panel along the bend 18 in an opening direction away from the end panels and side panel as shown by direction arrow 24 in
After an initial refurbishment of the ECM 10, in yet some instances, it may be desirable to conduct one or more additional refurbishments of the ECM. Such additional refurbishments are performed in the same manner as the initial refurbishment by opening the top panel 12, refurbishing the electrical components within the housing 11, and closing the top panel. Each time the top panel 12 is opened and closed during an additional refurbishment, the strength of the housing 11 along the bend 18 diminishes. Ultimately, after a certain number of opening and closing operations, the strength of the material along the bend 18 is sufficiently diminished or the bend completely fails (e.g., the top panel 12 physically separates from the side panel 16 along the bend 18) such that the housing is rendered inoperable for its intended purpose. Due to the expense associated with ECMs and the associated housings, it is desirable to extend the life of the ECMs by increasing the number of times a single ECM can be refurbished.
Referring to
The friction stir processing operation facilitated by the plastic deformation tool 100 includes applying a downwardly directed force to the tool as indicated by arrow 115. The downwardly directed force 115 causes the pin 116 to penetrating the material of the bend 18, and causes the flat distal end 111 of the rotatable portion 110 to maintain contact with and apply pressure against an outer surface 19 of the bend. The contact between the rotatable portion 110 and the outer surface 19 of the bend 18 generates frictional heat as the rotatable portion rotates and the profile of the pin 116 stirs or mixes the heated material to create a plastic deformation zone 120 as the pin rotates (see, e.g.,
Because the strength of the material of the bend 18 is increased, the material forming the bend is less susceptible to cracking. Accordingly, the plastic deformation tool 100 can be used to not only strengthen the bend 18, but to resist cracking as well. For this purpose, the housing 11 of the ECM 10 can be friction stir processed as described above during its original manufacture, as opposed to after initial production or during a refurbishing event.
Further, the mixing of the material along the bend 18 repairs cracks formed in the bend. Accordingly, the housing 11 of the ECM 10 can be friction stir processed as described above after its original manufacture during a refurbishing event. In some implementations, a single housing 11 can be friction stir processed multiple times during multiple refurbishing events.
Referring to
In yet some implementations, a second strip 150 made from a metallic material can be placed against the outer surface 19 of the bend 18 during the friction stir processing operation of the tool 100. The second strip 150 can be made from a metallic material that is the same as the metallic material of the housing 11. For example, in one implementation, the second strip 150 and the housing 11 are made from aluminum. As shown in
The friction stir processing operation performed by the plastic deformation tool 100 to reinforce the bend or wall of a metallic structure generates heat. The heat generation is most intense within the plastic deformation zone 120. However, significant amounts of heat is generated in or transferred to a heat affected zone 121 immediately surrounding the plastic deformation zone 120. For applications where the metallic structure is an ECM, such as ECM 10, the heat from the plastic deformation zone 120 and heat affected zone 121 can affect the electronic components within the housing of the ECM. In other words, heat from the plastic deformation zone 120 and heat affected zone 121 can be transferred to the electronic components of the ECM, which heat can damage or negatively affect the performance of the electronic components.
To reduce or dissipate the heat generated by the friction stir processing operation, the plastic deformation tool 100 includes a coolant delivery mechanism 130. The coolant delivery mechanism 130 is fixedly coupled to a non-rotatable portion 101 of the tool 100. The non-rotatable portion 101 of the tool 100 is stationary relative to the rotatable portion 110. Accordingly, as the rotatable portion 110 rotates, the non-rotatable portion 101 and the coolant delivery mechanism 130 remains stationary relative to the rotatable portion. Generally, as shown in
As shown in
Referring to
The fluid can be any of various fluid coolants. In one embodiment, the fluid coolant is a combination of liquid nitrogen and compressed air. In some implementations, the fluid coolant is exclusively liquid nitrogen or exclusively compressed air. In yet some implementations, the fluid coolant can be other fluids, such as gases (e.g., nitrogen, air, hydrogen, inert gases, and the like) and liquids (e.g., water, glycol, cutting fluid, oils, freons, refrigerants, and the like).
According to some embodiments, the ring 131 includes respective pairs of upstream apertures 132A, lateral apertures 132B, downstream apertures 132C, and tool apertures 132D. The upstream apertures 132A are positioned spaced apart from each other on a leading portion of the ring 131. Further, the upstream apertures 132A are positioned on a lower surface of the ring 131 such that the upstream apertures face downwardly toward the outer surface 19 of the housing 11 upstream of the tool 100. The lateral apertures 132B are positioned on respective side portions of the ring 131, and on the lower surface of the ring, such that the lateral apertures face downwardly toward the outer surface 19 of the housing 11 laterally adjacent the tool. The downstream apertures 132C are positioned spaced apart from each other on a trailing portion of the ring 131. Further, the downstream apertures 132C are positioned on a lower surface of the ring 131 such that the downstream apertures face downwardly toward the outer surface 19 of the housing 11 downstream of the tool 100. The tool apertures 132D are positioned on respective side portions of the ring 131, and on the upper-side surface of the ring, such that the tool apertures face upwardly at an angle toward the rotatable portion 110 of the tool 100. In certain implementations, the tool apertures 132D can be positioned on the side surface or lower-side surface of the ring such that the tool apertures faced sideways or downwardly at an angle toward the rotatable portion 110 of the tool 100, respectively.
Referring to
Referring again to
Referring to
Referring again to
Although in the illustrated embodiments of
Additionally, although the ring 131 in the illustrated embodiments of
Further, although the hollow annular ring 131 in the illustrated embodiments of
Referring to
Each of the nozzles includes a hollow tubular structure that defines an elongate fluid conduit through which coolant exiting a corresponding aperture of the ring 231 flows. In this manner, the nozzles act to guide coolant from the apertures to a desired location on the housing 11. For example, the nozzles 232A each deliver a stream 270 of coolant onto the housing 11 upstream or in front of the tool 100 to cool the material of the bend 18 in preparation for plastic deformation by the tool. Similarly, the nozzles 232B each deliver a stream 272 of coolant onto the housing 11 to the sides of the bend 18 to cool the heat affected zone 121. The elongate fluid conduit of the nozzles can have a constant cross-sectional area in some implementations. In yet some implementations, the cross-sectional area of the elongate fluid conduit of the nozzles change along a length of the nozzles. For example, the elongate fluid conduits can converge in a coolant flow direction to accelerate the coolant.
In some embodiments, the plastic deformation tools 100, 200 can be used in a method for reinforcing a metallic material. According to one embodiment show in
Although in the illustrated embodiments, the bend that is processed by the plastic deformation tool 100 is between a top panel and side panel of a generally rectangular-shaped housing, in other embodiments any of various bends of an ECM housing having any of various shapes can be processed by the plastic deformation tool 100 in the manner described above. Additionally, it is recognized that the plastic deformation tool 100 can be used to reinforce a bend in a metallic structure other than the housing of an automotive ECM.
In the above description, certain terms may be used such as “up,” “down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an “upper” surface can become a “lower” surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise. Further, the term “plurality” can be defined as “at least two.”
Additionally, instances in this specification where one element is “coupled” to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, “adjacent” does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element.
Any schematic flow chart diagrams included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented apparatus, system, or method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.
As used herein, the phrase “at least one of”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of” means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.
The present subject matter may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
