Friction Stir Welding Zero Alignment Using Pin-Shoulder Contact Detection
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Solution Overview
Problem
Existing methods for origin point alignment of pin and shoulder members in friction stir welding devices are unsafe and inefficient, relying on manual visual alignment which lacks accuracy and poses safety risks.
Innovation Solution
A method and device for automated origin point alignment using a friction stir welding device with a controller that executes precise zeroing control of the pin and shoulder members, ensuring accurate alignment through coordinated movement and contact with a backing member, utilizing servomotors and encoders for precise positional adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual visual alignment is used for origin point alignment, then the operator can perform the alignment work, but the safety and work efficiency are poor
Solution Approach 1:
The patent replaces manual visual alignment with an automated detection and control system. The alignment detection unit automatically detects the positions of the pin member and shoulder member, and the control unit calculates and executes the origin point alignment, substituting manual mechanical operations with automated systems to improve both safety and efficiency
Solution Approach 2:
The patent introduces an alignment detection unit as an intermediary between the manual operation and the alignment result. This intermediary automatically measures positions and provides data to the control unit, eliminating the need for manual visual estimation and improving alignment accuracy
2Manufacturing precision
If manual alignment is performed by moving pin member in teaching mode, then origin points can be matched visually, but the work efficiency is low and safety risks exist
Solution Approach 1:
The system performs self-alignment through automated detection and control. The alignment detection unit automatically measures the positions of pin and shoulder members, the control unit calculates the required adjustments, and the system executes the alignment without requiring manual intervention, thereby improving both accuracy and efficiency
Solution Approach 2:
The patent implements a feedback mechanism where the alignment detection unit continuously monitors the positions of the pin and shoulder members, provides position data to the control unit, and allows for verification of alignment accuracy. This feedback loop ensures high precision while automating the process to improve efficiency
Data Source
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AI summary
In a state where a shoulder member (12) is in contact with a contact surface, a pin member (11) is additionally 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 (11) to the contact surface, and specify a shoulder displacement amount, which is a displacement amount when the shoulder member (12) is retreated as a result of the contact of the pin member (11). 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 (11) is retreated from the contact surface by a predetermined return amount, and furthermore, origin point alignment of the pin member (11) and the shoulder member (12) is performed on the basis of positions of the pin member and the shoulder member in this state.