Double-head double-sided high-efficiency friction stir welding device and welding method utilising such device
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Solution Overview
Problem
Friction stir welding of aluminum alloy profiles faces challenges such as welding deformation, reduced production efficiency, and increased costs due to the need for component polishing and overturning, as well as inefficiencies in double-sided welding processes.
Innovation Solution
A double-head double-sided high-efficiency friction stir welding device with a gantry structure, vision sensors, and anti-wear gaskets, allowing simultaneous welding of both surfaces with reduced wear rates and improved metal flow, along with a method that includes synchronized movement and rotation of welding heads and multiple worktables for continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional single-sided friction stir welding is used, then welding can be completed on one surface, but the component must be overturned and polished, reducing production efficiency and increasing costs
Solution Approach 1:
The welding process is segmented into two independent simultaneous operations: one welding head welds the first surface while the other welding head welds the second surface. This parallel segmentation eliminates the sequential overturning and polishing steps, directly resolving the time loss issue.
Solution Approach 2:
Two welding heads are combined into a single integrated device that operates simultaneously on both surfaces of the component. By merging the welding functions into one coordinated system, the process eliminates separate overturning and polishing operations, improving productivity.
2Productivity
If traditional friction stir welding is used, then welding can be completed, but welding deformation occurs that is hard to control
Solution Approach 1:
The welding process applies asymmetric heating and cooling patterns by welding both surfaces simultaneously rather than sequentially. This symmetric simultaneous approach balances thermal distribution, reducing differential thermal stresses that cause deformation.
Solution Approach 2:
The welding parameters are optimized by conducting simultaneous welding on both surfaces with controlled heat input distribution. This parameter change in the welding sequence and thermal management reduces cumulative deformation and improves dimensional control.
3Productivity
If double-sided welding is conducted with one set of component welding, then two surfaces can be welded simultaneously, but continuous operation scale is not achieved
Solution Approach 1:
The welding device is designed with universal functionality to handle multiple components through programmable control. The system can automatically sequence welding operations on different components, enabling continuous operation and scaling production without proportionally increasing device complexity.
Solution Approach 2:
The welding system maintains continuous useful action by implementing automated multi-component welding sequences. While one component is being welded, the system prepares or positions the next component, ensuring continuous operation and eliminating idle time, thus achieving production scale without excessive complexity.
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 solution enhances welding efficiency by eliminating the need for component overturning and polishing, achieving continuous operation, and reducing wear rates, resulting in improved production efficiency and cost-effectiveness.
Implementation Method 1
friction stir welding
Implementation Method 2
friction stir welding
Implementation Method 3
friction stir welding
Data Source
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AI summary
The present disclosure belongs to the technical field of friction stir welding devices. An objective of the present disclosure is to provide a double-head double-sided high-efficiency friction stir welding device, which comprises a base; a pair of columns arranged on the base; an upper beam connected with the top ends of the columns, wherein an upper head is arranged on the upper beam; a lower beam connected between the lower ends of the columns, wherein a lower head is arranged on the lower beam and corresponds to the upper head up and down, the columns, the upper beam and the lower beam form a gantry having an integrated structure, the upper head and the lower head can move by a drive device and a transmission mechanism along an X-axis, a Y-axis and a Z-axis and rotate along the Z-axis, movement of the upper head and the lower head along the X-axis and the Y-axis is driven by utilizing a linear motor or a motor-driven rack-and-pinion mechanism in a screw guide rail or rack-and-pinion guide rail transmission manner, movement of the upper head and the lower head along the Z-axis can utilize a manner such as servo electric cylinder transmission, hydraulic transmission, screw transmission, rack-and-pinion transmission and the like, rotation of the upper head and the lower head along the Z-axis can utilize a manner of combining an electric spindle or a mechanical spindle with a motor, and the motor can be a servo motor or an asynchronous motor.