Friction Welding Fast Forwarding Distance Control
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Solution Overview
Problem
The existing friction welding methods face productivity issues due to dimension errors in works, leading to prolonged cycle times and reduced productivity as they require longer slowly forwarding distances to prevent impacts during the fast forwarding stage.
Innovation Solution
A method and apparatus for friction welding that involves measuring the dimensions of the works, calculating a fast forwarding distance based on the measured dimensions, and executing the fast forwarding for that distance, allowing for a shorter slowly forwarding distance and decelerating the slowly forwarding speed to prevent damage and optimize the timing of the rotation driving source activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the slowly forwarding distance is set longer to prevent work impact during fast forwarding, then work damage is prevented, but the cycle time is prolonged and productivity is reduced
Solution Approach 1:
The invention measures the work dimension before the friction welding process and uses this information to calculate and set the appropriate fast forwarding distance in advance. This preliminary measurement and calculation allows the system to optimize the forwarding parameters specifically for each work piece, preventing both work damage and excessive cycle time by setting the slowly forwarding distance only when necessary based on actual dimensional data.
Solution Approach 2:
The invention dynamically adjusts the fast forwarding distance based on the measured work dimension. Rather than using a fixed conservative slowly forwarding distance for all cases, the system calculates the optimal fast forwarding distance using the formula: fast forwarding distance = measured work dimension + safety margin. This dynamic adjustment allows the system to minimize the slowly forwarding distance while still preventing work impact, thereby reducing cycle time without compromising reliability.
2Reliability
If the slowly forwarding distance is set longer to account for dimension errors, then work impact during fast forwarding is avoided, but the fabrication time increases
Solution Approach 1:
The invention introduces a feedback mechanism where the work dimension is measured and this measurement feeds back into the control system to determine the fast forwarding distance. The control unit uses the measured dimension to calculate the appropriate forwarding parameters, creating a closed-loop system that adapts to actual work piece variations. This feedback approach replaces the open-loop conservative estimation with precise, measurement-based control, reducing unnecessary waiting time while ensuring work impact avoidance.
Solution Approach 2:
The invention changes the parameter used to determine fast forwarding distance from a fixed conservative value to a dynamic value based on measured work dimension. By using the formula: fast forwarding distance = measured work dimension + safety margin, the system optimizes the forwarding parameters for each specific work piece. This parameter change allows the system to minimize fabrication time by reducing the slowly forwarding distance while maintaining reliable work impact avoidance through the safety margin.
3Productivity
If the fast forwarding distance is increased to reduce cycle time, then productivity improves, but the risk of work impact during fast forwarding increases
Solution Approach 1:
The invention performs preliminary measurement of the work dimension and calculates the optimal fast forwarding distance before executing the friction welding process. This preliminary action allows the system to set the maximum safe fast forwarding distance specific to each work piece, enabling the system to maximize productivity by using the largest possible fast forwarding distance without exceeding safety limits, thereby minimizing the proportion of time spent in slower forwarding modes.
Solution Approach 2:
The invention changes the fast forwarding distance parameter from a conservative fixed value to a dynamic value calculated as: fast forwarding distance = measured work dimension + safety margin. This parameter change allows the system to increase the fast forwarding distance (and thus productivity) while maintaining reliability through the safety margin that prevents work impact. The safety margin acts as a buffer that allows aggressive fast forwarding while still protecting against dimensional variations.
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 reduces the cycle time for manufacturing one product by increasing the relative proportion of the fast forwarding distance, preventing work damage, and minimizing power consumption while ensuring proper contact and bonding, thereby enhancing productivity and product quality.
Implementation Method 1
measuring a dimension of at least one of the first work and the second work
Implementation Method 2
relatively rotating the pair of the works while the end surfaces of the works are in contact with each other to generate friction heat on the end surfaces
Data Source
Figure 1
Figure 2
Figure 3~3c
AI summary
[Problems] To provide a method of friction welding and an apparatus of friction welding in which a length of time for manufacturing one product is reduced as much as possible regardless of the dimension errors of works. [Means of solving problems] The fast forwarding distance Lx1 is calculated for the fast forwarding by using the results of measuring the dimensions of works W1, W2 under the condition of the constant slowly forwarding distance Lx2, Thereby, for the work of a legitimate dimension and even for the work having a dimension smaller than the legitimate dimension, the elongation of the slowly forwarding distance is prevented compared with the work having the longer dimension than the legitimate dimension, and the relative proportion of the fast forwarding distance Lx1 is increased by making shorter the specified slowly forwarding distance.