Flexible Clamping for Backside Laser Welding of T-Shaped Stringers
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Solution Overview
Problem
The existing double-laser-beam double-sided synchronous welding process for T-shaped skin-stringer structures in aircraft manufacturing is hindered by apparatus and assembly interference, leading to unstable clamping, poor flexibility, low automation, and increased risk of welding defects such as pores and incomplete penetration, which reduces production efficiency and quality.
Innovation Solution
A flexible automatic clamping device and method for backside laser penetration welding, featuring a clamping system with adjustable components, ranging systems for precise positioning, and a control system to optimize clamping pressure, enabling stable, torsion-resistant, and releasable clamping of T-shaped structural parts, even with different sizes and positions, and ensuring post-welding shape retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional riveting process is used to connect T-shaped skin-stringer structures, then connection strength and safety are improved, but structural weight increases and production efficiency decreases
Solution Approach 1:
The patent replaces the traditional mechanical riveting system with a laser welding system. The laser beam melts and fuses the skin and stringer materials directly, eliminating the need for rivets and mechanical fastening. This substitution achieves both high connection strength through metallurgical bonding and improved production efficiency through continuous welding operation.
Solution Approach 2:
The patent changes the fundamental connection parameter from mechanical interlocking (rivets) to thermal fusion (laser welding). By controlling laser power, welding speed, and focal position, the process achieves optimal weld strength while eliminating the time-consuming rivet installation and hole machining operations.
2Manufacturing precision
If double-laser-beam double-sided synchronous welding is used, then welding quality is improved, but apparatus interference and assembly interference occur making it unattainable in some cases
Solution Approach 1:
The patent segments the welding process into two independent stages: first welding the skin to the stringer, then welding the cover plate to the stringer. This segmentation allows each welding operation to be optimized independently and eliminates the apparatus interference problem that occurs when attempting simultaneous double-sided welding, while still achieving high welding quality.
Solution Approach 2:
The patent employs dynamic positioning and clamping systems that can adapt to different workpiece configurations and sizes. The flexible fixture system with adjustable clamps and positioning devices enables the process to accommodate various assembly geometries, maintaining process versatility while ensuring consistent welding quality.
3Force
If rigid clamping process is used for laser welding, then clamping force is sufficient, but flexibility and automation degree are reduced leading to poor workpiece stability
Solution Approach 1:
The patent employs dynamic clamping systems with actuators that can automatically adjust clamping force and position. These programmable fixtures respond to workpiece dimensions and welding requirements, providing sufficient clamping force while enabling full automation. The system eliminates manual intervention through integrated sensors and control algorithms that adapt to each workpiece.
Solution Approach 2:
The patent implements self-adjusting clamping mechanisms that automatically compensate for workpiece dimensional variations and positioning tolerances. Sensors detect workpiece geometry and the control system autonomously adjusts clamp positions and forces, eliminating the need for manual setup while maintaining optimal clamping conditions for high automation operation.
4Adaptability or versatility
If manual clamping adjustment is used to accommodate different workpiece sizes, then adaptability is improved, but production efficiency decreases and production cycle increases
Solution Approach 1:
The patent replaces manual measurement and adjustment operations with automated optical measurement systems and programmable positioning mechanisms. Lasers and sensors automatically measure workpiece dimensions, and the control system calculates optimal fixture positions, eliminating time-consuming manual adjustments while maintaining full adaptability to different workpiece sizes.
Solution Approach 2:
The patent transforms the clamping system from manually-adjusted mechanical fixtures to programmable, motorized positioning systems. By storing workpiece dimension data and corresponding fixture parameters in databases, the system automatically retrieves and applies appropriate settings for each workpiece size, dramatically reducing setup time while maintaining versatility.
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
The solution enhances the stability and quality of weld seams, shortens production cycles, releases residual stress, and achieves high-quality, high-performance products by allowing flexible automation and precise clamping, addressing the limitations of traditional clamping methods.
Implementation Method 1
laser welding has been widely used in aerospace, engineering and other fields
Implementation Method 2
laser penetration welding
Data Source
AI summary
The disclosure relates to a flexible automatic clamping device and method for backside laser penetration welding of a T-shaped structure. The flexible automatic clamping device includes a clamping system, a ranging system and a control system. The ranging system outputs a position instruction to the control system, the control system outputs a movement instruction to the clamping system, so as to adjust the clamping system to an optimal position, then a stringer pressing plate fastens a stringer by means of a Y-shaped connecting rod, and a skin pressing plate fastens skin by means of a skin connecting rod. Based on the flexible automatic clamping device, the method includes prewelding clamping, backside laser penetration welding and postwelding shape retention. The disclosure implements accurate positioning, automatic clamping, backside laser penetration welding and postwelding shape retention of a T-shaped skin-stringer structure.