Friction Stir Welding Origin Alignment Using Pin and Shoulder Displacement
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Solution Overview
Problem
Existing friction stir welding methods face challenges in safely and efficiently aligning the origin points of the pin and shoulder members, leading to inefficiencies and safety concerns during manual alignment processes.
Innovation Solution
A control method and device that automatically aligns the origin points of the pin and shoulder members by storing positions, determining movement and displacement conditions, and adjusting positions to ensure accurate alignment, followed by re-execution if conditions are not met.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual origin point alignment is performed by an operator, then flexibility and adaptability are maintained, but safety risks increase and work efficiency decreases
Solution Approach 1:
The system performs origin point alignment automatically through control units that coordinate movement of the pin member and shoulder member without operator intervention. The control unit autonomously executes the alignment sequence, eliminating manual safety risks while maintaining operational flexibility
Solution Approach 2:
The patent replaces manual mechanical alignment operations with an automated control system that uses control units to manage the alignment process. This substitution of mechanical/manual operations with automated control improves both safety and efficiency
2Ease of operation
If manual origin point alignment is performed by an operator, then adaptability is maintained, but productivity decreases due to time-consuming procedures
Solution Approach 1:
The automated control system performs origin point alignment without operator intervention, significantly reducing the time required for this preparatory operation. The control unit autonomously executes the alignment sequence, eliminating manual time consumption while maintaining operational flexibility
Solution Approach 2:
The system performs origin point alignment automatically as a preliminary step before welding operations begin. By automating this preparatory action, the system ensures proper alignment is achieved quickly and accurately before production welding starts, improving overall productivity
3Reliability
If automated origin point alignment is implemented, then safety and productivity are improved, but device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it controls the movement of both the pin member and shoulder member, manages the alignment sequence, and coordinates the welding operations. This multi-functionality reduces the need for separate control systems, thereby limiting the increase in device complexity while achieving automated safe alignment
Data Source
AI summary
In a state where a shoulder member is in contact with a contact surface, a pin member is brought into contact with the contact surface to specify a pin movement amount, which is a distance from an initial position of the pin member to the contact surface, and specify a shoulder displacement amount, which is a displacement amount when the shoulder member is retreated as a result of the contact of the pin member. When both a first condition that the pin movement amount is included in a first range and a second condition that the shoulder displacement amount is included in a second range are satisfied, the pin member is retreated from the contact surface by a predetermined return amount, and furthermore, origin point alignment of the pin member and the shoulder member is performed on the basis of positions of the pin member and the shoulder member.