Angle-Head Friction Stir Welding With Spindle Force Feedback
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Solution Overview
Problem
Existing methods and apparatuses for friction stir welding and other machining processes face challenges in achieving high efficiency and reliability, especially in poorly accessible positions where high forces can cause damage to tools and spindles due to exceeding permissible loads.
Innovation Solution
The method involves using an adapter, such as an angle head, to align the tool axis at an angle to the spindle axis, with force measurement and control systems to adjust parameters like advancing speed, normal force, and rotation speed based on measured spindle forces, preventing damage by maintaining permissible loads and allowing access to otherwise inaccessible positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an adapter is used to access poorly accessible positions, then accessibility is improved, but the risk of damage to tool and spindle increases due to high forces
Solution Approach 1:
The patent implements a force measurement system that continuously monitors forces acting on the spindle during machining operations. The measured forces are fed back to the control system, which automatically adjusts machining parameters (advancing speed, normal force, rotation speed) to prevent excessive loads. This feedback mechanism enables safe operation in poorly accessible positions by real-time monitoring and adaptive control, resolving the contradiction between accessibility and reliability.
2Productivity
If high forces are applied during friction stir welding, then welding efficiency is improved, but damage to tool and spindle occurs when permissible loads are exceeded
Solution Approach 1:
The patent employs dynamic parameter adjustment where machining parameters (advancing speed, normal force, rotation speed) are continuously adapted based on real-time force measurements. The control system modifies these parameters dynamically to maintain forces within safe limits while optimizing welding efficiency. This dynamic approach allows the system to operate at high efficiency when conditions permit while automatically reducing loads when approaching damage thresholds, resolving the contradiction between productivity and reliability.
Solution Approach 2:
The patent changes physical parameters (advancing speed, normal force, rotation speed) based on measured force conditions. When forces approach permissible limits, the system automatically adjusts these parameters to reduce loads. This parameter adaptation enables the system to maintain high welding efficiency under normal conditions while preventing damage when load limits are approached, resolving the contradiction between productivity and reliability.
3Reliability
If force measurement and control systems are implemented, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent integrates force measurement and control functions into the existing machining apparatus, making the system multi-functional. The same control system that manages basic machining operations also handles force monitoring and adaptive parameter adjustment. This universal approach improves reliability through force measurement while minimizing additional complexity by utilizing existing system components for multiple purposes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables reliable and efficient machining processes, including friction stir welding, in hard-to-reach areas by preventing tool and spindle damage through real-time force and moment monitoring and adjustment, ensuring the method operates within safe mechanical limits.
Implementation Method 1
whereby a force acting on the spindle is measured and the method is controlled depending on the force measured at the spindle
Data Source
AI summary
A method for joining or machining, in particular a friction stir welding method, using an apparatus, in which a tool, in particular a friction stir welding tool, is driven via a spindle with a spindle axis. To achieve high process reliability, even when the method is applied in poorly accessible positions, an adapter, in particular an angle head, is arranged between the spindle and the tool so that the tool axis about which the tool rotates does not coincide with the spindle axis. A force acting on the spindle is measured and the method is controlled depending on the force measured at the spindle. The apparatus for joining or machining, in particular for friction stir welding, includes a headstock with a spindle, which can be rotated about a spindle axis and a tool, in particular a friction stir welding tool, which can be driven about a tool axis by the spindle.