Differential Displacement Control for Plastic Friction Welding
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Solution Overview
Problem
Conventional friction welding devices are inadequate for setting plastic setting elements in plastic components due to surface deformation during the process, as they rely on absolute feed measurement, which is insufficient for ensuring precise penetration depth and timely completion of the setting process.
Innovation Solution
A device equipped with a differential travel measuring device to measure the relative movement between the setting element and the component, coupled with a control unit to manage the rotary feed unit based on measured differential travel, ensuring accurate penetration depth and preventing unwanted displacement of molten material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If absolute feed measurement is used in conventional friction welding devices, then the measurement system is simple, but the penetration depth precision deteriorates due to surface deformation of the component
Solution Approach 1:
The patent introduces a marker as an intermediary element between the rotary feed unit and the component surface. The marker is attached to the component surface and serves as a reference point for measuring differential displacement. This mediator allows the measurement system to track relative movement between the setting element and the component surface without being affected by surface deformation, thereby maintaining measurement simplicity while improving penetration depth precision
Solution Approach 2:
The patent replaces the conventional absolute feed measurement system with a differential displacement measurement system that uses optical or electromagnetic sensors to track the position of the marker. This substitution eliminates the need for complex mechanical measurement mechanisms while achieving precise penetration depth control despite component surface deformation
2Strength
If the setting process continues until complete penetration, then the connection strength is maximized, but molten material protrudes laterally to the surface
Solution Approach 1:
The patent implements a feedback control system where the differential displacement measuring device continuously monitors the penetration depth in real-time. The control unit receives this feedback and automatically terminates the setting process when the predetermined penetration depth is reached. This feedback mechanism ensures that the setting process stops at the optimal point, achieving sufficient connection strength without allowing molten material to protrude laterally to the surface
Solution Approach 2:
The patent uses the differential displacement measuring device to preliminarily determine the correct penetration depth before the setting process begins. By pre-establishing the target penetration depth based on component thickness and material properties, the system can control the setting process to stop exactly at the desired depth, preventing molten material displacement while ensuring adequate connection strength
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
Enables reliable and reproducible friction welding of plastic setting elements by precisely controlling the penetration depth and preventing lateral protrusion of molten material, ensuring a secure and integral connection.
Implementation Method 1
a rotary feed unit by which the setting element can be rotated about an axis of rotation and at the same time an axial force acting in the direction of the axis of rotation can be exerted on the setting element in order to drive the setting element into the component while generating a friction weld connection between the setting element and the component
Implementation Method 2
the device comprises a differential displacement measuring device for measuring the differential displacement between a surface of the component and a surface of the driven setting element
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The invention relates to a device for setting a setting element having a first plastic material in a component having a second plastic material, comprising a rotational advancing unit, by means of which the setting element can be rotated about an axis of rotation and simultaneously an axial force acting in the direction of the axis of rotation can be applied to the setting element in order to drive the setting element into the component, a friction welding joint thereby being produced between the setting element and the component, a differential-distance measuring apparatus for measuring the differential distance between a surface of the component and a surface of the driven setting element, and a control unit for controlling the rotational advancing unit in dependence on the measured differential distance.