Friction Stir Joint Height Sensing to Prevent Poor Joining
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Solution Overview
Problem
The height positions of metal members vary due to warping, twisting, and deformations, leading to potential poor joining, and foreign objects or defective clamping can interfere with the joining process, affecting the quality of friction stir joining.
Innovation Solution
A joining device and method that includes a measuring part to measure the height near the joint portion, a setting part to set the rotating tool's height position based on these measurements, and a friction stir body to move the tool along the joint portion, ensuring accurate alignment and depth control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the height positions of metal members are not controlled, then the joining process can proceed without additional measurement and adjustment steps, but poor joining quality occurs due to warping, twisting, and deformations
Solution Approach 1:
The measuring part measures the height position of the first metal member before the joining operation begins. This preliminary measurement allows the system to compensate for warping, twisting, and deformations in advance, ensuring accurate depth control during the actual joining process without adding complexity to the core friction stir mechanism
Solution Approach 2:
The setting part receives measurement data from the measuring part and automatically sets the depth of the rotating tool based on the measured height position. This closed-loop feedback system adjusts the joining parameters in real-time according to the actual state of the metal members, maintaining high joining quality while automating the control process
2Manufacturing precision
If the height position of the rotating tool is not accurately controlled, then the joining process is simpler to operate, but poor joining occurs due to inconsistent depth and alignment
Solution Approach 1:
The system automatically measures the height position and sets the rotating tool depth without requiring manual intervention. The measuring part and setting part work together to self-adjust the joining parameters, eliminating the need for operators to manually calculate or adjust depth settings, thus maintaining ease of operation while achieving precise depth and alignment control
3Manufacturing precision
If foreign objects or defective clamping are not detected, then the inspection process is faster and simpler, but poor joining quality results from interference during the joining process
Solution Approach 1:
The measuring part performs height position measurement and foreign object detection before the joining operation begins. This preliminary inspection identifies potential issues such as foreign objects or defective clamping in advance, allowing the system to prevent poor joining before it occurs. The measurement process is integrated into the setup phase, so no additional inspection time is added to the main production cycle
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 prevents poor joining by maintaining consistent depth and alignment of the rotating tool, reducing the likelihood of defects and enhancing the quality of the joint.
Implementation Method 1
a measuring part that measures a height near a joint portion, which serves as a part for joining formed by a first metal member and a second metal member placed in a positional relationship for joining by abutting or overlapping
Implementation Method 2
a friction stir body that relatively moves the turning rotating tool along the joint portion based on the height position
Data Source
AI summary
The present invention aims to provide a joining method that can prevent poor joining. The present invention provides a joining method including: a measuring step that measures a height near a joint portion, which serves as a part for joining formed by a first metal member and a second metal member placed in a positional relationship for joining by abutting or overlapping, and obtains measured values; a setting step that sets a height position of a rotating tool based on the measured values obtained by the measuring step; and a friction stir step that relatively moves the turning rotating tool along the joint portion based on the height position set by the setting step.