Friction Welding Apparatus with Three-Stage Adaptive Feeding Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for friction welding between plates of different materials, such as steel and light metal, lack the ability to adjust operation parameters like rotational speed and pressure to ensure a strong connection, particularly when the supporting plate has higher strength than the supported plate.
Innovation Solution
The apparatus incorporates a measurement device in the rotational feeder unit to adjust the feeding motion in three sequential stages, allowing for adaptive control of rotational speed and pressure based on material thickness and type, ensuring precise penetration and friction welding between the plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a connecting element is pressed onto a supported plate with high pressure to melt the material and form a friction welding connection, then the connection strength is improved, but the risk of damaging the supporting plate or over-penetration increases
Solution Approach 1:
The feeding motion is divided into three sequential stages (penetration stage, friction welding stage, and final pressing stage) with different pressure and speed parameters for each stage, allowing controlled material melting and connection formation without over-penetration
Solution Approach 2:
The rotational speed and axial feeding speed are dynamically adjusted during the three stages, with the rotational feeder unit adaptively changing parameters based on the current stage to optimize connection strength while preventing damage
2Ease of operation
If the rotational speed and pressure are kept constant during friction welding, then the process is simple to operate, but the connection quality varies when connecting plates of different materials and thicknesses
Solution Approach 1:
The system dynamically adjusts rotational speed and axial feeding speed during the three sequential stages based on material thickness and type, enabling consistent connection quality across different materials while maintaining ease of operation through automated control
Solution Approach 2:
Different combinations of rotational speed and axial feeding speed parameters are applied in each of the three stages, with parameters being changed according to the specific material properties and thickness to ensure optimal connection quality
3Strength
If the connecting element penetrates deeply into the supported plate to ensure strong friction welding, then the connection strength is improved, but the process time increases
Solution Approach 1:
The penetration and welding process is segmented into three stages with optimized duration for each, allowing sufficient penetration depth for strong connection while minimizing total process time through efficient time allocation to each stage
Solution Approach 2:
The rotational feeder unit applies periodic action with different rotational speeds and feeding rates in each stage, optimizing the balance between penetration depth and process time by adjusting the periodic motion characteristics
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 enables controlled friction welding by adjusting the rotational feeder's motion according to the plates' thickness and material, ensuring a strong and reliable connection between plates of varying strengths, including steel and light metal, and allows for surface cleaning during the process.
Implementation Method 1
by means of the therein encountered frictional heating between the bolt and the plate, melting of the bolt in the area of contact with the plate as well as melting of the surface of the plate is encountered at this location
Implementation Method 2
melting of the bolt in the area of contact with the plate as well as melting of the surface of the plate is encountered at this location whereby the process of friction welding is started
Implementation Method 3
the rotational feeder unit is provided with a measurement device which measures an axial force exerted by the rotational feeder unit
Data Source
AI summary
Apparatus for connecting at least two plates (1, 2) of which a supporting plate (1) comprises a higher strength than a supported plate (2) posed thereon. By means of a connecting element (5) rotated by a rotational feeder unit (11), the connecting element with a collar (6) presses the supported plate (2) onto the supporting plate (1). With a shaft (10) a friction welding connection to the supporting plate (1) is made. The rotational feeder unit (11) is provided with a measurement device with measures an axial force exerted by the rotational feeder unit as well as a respective feeding motion and which indicates, upon abutment of the shaft of the connecting element onto the supporting plate, the pressure increase encountered therein, which, thereby, advances the rotational feeder unit, the feeding motion of which is adjustable to at least three sequential connecting stages. Therein, the first stage is adjusted to the penetration of the supported plate, the second stage is adjusted to the friction welding of the shaft with the supporting plate. The third stage completes the friction welding process by putting up the axial force of the connecting element onto the supporting plate 1.