Friction Stir Welding Device Corrects Junction Deviation
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Solution Overview
Problem
Small and lightweight friction stir welding devices struggle to accurately move the joining tool along the joint line due to the Coriolis force, leading to misalignment and reduced welding quality, as existing solutions do not effectively correct junction deviation caused by this force.
Innovation Solution
A friction stir welding device equipped with a joining head attached to a multi-axis robot main body, a control device that supplies motor drive current to the joining tool, and a deviation detection system to correct misalignment by outputting position correction signals, ensuring the joining tool moves accurately along the joint line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a small and lightweight friction stir welding device is used, then the device portability and ease of operation are improved, but the joining tool cannot be moved accurately along the joint line due to Coriolis force, resulting in junction deviation
Solution Approach 1:
The patent employs a feedback control mechanism where a deviation detection device continuously monitors the position of the joining tool relative to the joint line. When junction deviation is detected, the control device automatically generates and outputs a position correction signal to the drive device, which adjusts the tool's position in real-time. This closed-loop feedback system enables lightweight devices to maintain high positioning accuracy despite Coriolis force effects.
Solution Approach 2:
The patent replaces purely mechanical positioning systems with an integrated control system that combines sensors, controllers, and actuators. Instead of relying solely on the mass and mechanical rigidity of the device to resist Coriolis force, the system uses electronic sensing and control to detect and correct position deviations, enabling lightweight construction without sacrificing precision.
2Manufacturing precision
If the mass of the joining tool and peripheral apparatus is increased to restrain Coriolis force, then the position accuracy is improved, but the device becomes large and heavy, reducing portability
Solution Approach 1:
The feedback control system with deviation detection and automatic correction allows the use of lightweight components while maintaining positioning accuracy. The electronic control mechanism compensates for the lack of mechanical mass, eliminating the need to increase device weight to resist Coriolis force.
Solution Approach 2:
The patent substitutes mechanical mass-based stabilization with an electronic control-based stabilization system. Instead of using heavy components to physically counteract Coriolis force, the system uses sensors and controllers to detect and correct position deviations, achieving the same effect with much lighter components.
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 configuration enables precise movement of the joining tool and improves the quality of friction stir welding by correcting junction deviation, ensuring high-quality joint formation even with small and lightweight devices.
Implementation Method 1
a friction stir welding device which generates, with a rotating joining tool, a plastic flow in members to be joined and thus joins together the members to be joined
Implementation Method 2
generates, with a rotating joining tool, a plastic flow in members to be joined
Implementation Method 3
an external force (Coriolis force) directed in a direction away from the joint line acts on the joining tool moving along the joint line
Data Source
AI summary
A friction stir welding device includes: a control device which causes a pin part to be inserted into members to be joined while causing a joining tool to rotate and which causes a joining head to move along a joint line via a robot main body; and an image pickup device which detects a junction deviation that is a deviation between the joining head and a direction along the joint line. Also, when a junction deviation is generated, this control device causes the joining head to move in a direction toward the joint line and thus resolves the junction deviation.