Friction Stir Welding Assembly for Large Panel Edge Alignment
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Solution Overview
Problem
The existing methods for edge-to-edge assembly of large metal panels using friction stir welding are cumbersome and costly due to the need for precise edge alignment and complex mechanical equipment, which is difficult to achieve with large panels as the edges tend to deform and lose the required clearance during the assembly process.
Innovation Solution
A method involving overlapping panels and using a reflective chute with notches to guide precise laser cutting of connection edges, allowing for friction stir welding without repositioning the panels, utilizing a laser cutting method to create edges within the permissible clearance, thereby simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If panels are positioned on a bearing structure with raw edges facing each other, then the panels can be locked on the structure, but the edges deform and move away from each other, exceeding the maximum permissible clearance for friction stir welding
Solution Approach 1:
The patent applies preliminary action by performing the cutting operation before the friction stir welding. The connection edges are cut to the precise required dimensions and clearance while the panels are in the overlapping position on the bearing structure. This preliminary cutting ensures that when friction stir welding is performed, the edges are already at the correct alignment, eliminating the need for complex repositioning equipment and control systems.
2Manufacturing precision
If complex mechanical equipment with control systems is used to mill edges and reposition panels, then edge alignment can be achieved, but the implementation becomes particularly long and costly
Solution Approach 1:
The cutting step is performed as a preliminary action before welding, when the panels are already positioned in the correct overlapping configuration on the bearing structure. This eliminates the need for time-consuming operations with complex milling equipment and repositioning systems, reducing both assembly time and cost while maintaining the required edge clearance precision for friction stir welding.
Solution Approach 2:
The patent extracts the cutting operation from the traditional sequence and performs it independently as a separate preliminary step. By taking out the cutting operation and performing it before welding, the process eliminates the need for complex mechanical equipment and control systems that would otherwise be required to achieve precise edge alignment during or after positioning.
3Ease of manufacture
If panels are brought closer together to position connection edges against each other, then friction stir welding can be implemented, but complex handling and positioning operations are required
Solution Approach 1:
The connection edges are cut to the correct dimensions and clearance as a preliminary action while the panels are in the overlapping position on the bearing structure. This preliminary cutting ensures that when the panels are brought closer together for welding, the edges are already properly aligned, eliminating the need for complex positioning equipment and multiple handling operations.
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 method enables precise and efficient edge-to-edge welding of large panels by eliminating the need for repositioning and reducing the complexity of mechanical operations, resulting in cost savings and improved geometric compliance of the welding seams.
Implementation Method 1
a step of jointly cutting the first panel and the second panel in the overlap area
Implementation Method 2
a local softening of the matter resulting from the heating generated by the friction of the pin against the material of the panels
Data Source
AI summary
A method for edge-to-edge welding of a first sheet metal panel to a second sheet metal panel on a bearing structure. The method comprises positioning and fixing the first panel to the bearing structure, positioning and fixing the second panel to the bearing structure with the second panel overlapping a raw edge of the first panel, jointly cutting the first panel and the second panel in the overlap area to form a connection edge of the first panel and a connection edge of the second panel, withdrawing scrap cuttings from the first panel and scrap cuttings from the second panel, and friction stir welding the connection edges.