C-Shaped FSW Frame Control for Bending Compensation
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Solution Overview
Problem
Friction stir welding (FSW) devices face challenges in achieving accurate and reliable joining of complex and narrow portions due to bending of the pressing force receiving portion (carrying table) caused by the joining tool, which existing techniques fail to adequately correct, especially in applications with reduced C-shaped frame size and thickness.
Innovation Solution
A friction stir welding apparatus and method that includes a C-shaped frame with vertical movement drive mechanisms to correct the holding position of the C-shaped frame in real-time, using a control device to adjust the depth or range of the joined portion based on the bending of the pressing force receiving portion, ensuring constant joining conditions throughout the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the C-shaped frame size and thickness are reduced to allow joining of narrower portions, then the adaptability to complicated shapes is improved, but the rigidity of the pressing force receiving portion deteriorates causing bending
Solution Approach 1:
The patent applies dynamics by making the C-shaped frame's holding position adjustable during the welding process. The frame is connected to the apparatus main body via a vertical movement drive mechanism that can dynamically change the holding position in the vertical direction based on detected bending amounts, transforming a static rigid structure into a dynamic adaptable one that compensates for reduced rigidity.
Solution Approach 2:
The patent implements feedback by using a detection mechanism to monitor the bending state of the pressing force receiving portion in real-time during welding. The control device receives this detection signal and automatically adjusts the holding position to compensate for the bending, creating a closed-loop control system that maintains joining accuracy despite frame flexibility.
2Device complexity
If the C-shaped frame size and thickness are reduced, then the device complexity is reduced, but the manufacturing precision of the joined portion deteriorates due to bending
Solution Approach 1:
The patent implements feedback by using a detection mechanism to monitor the bending state of the pressing force receiving portion in real-time during welding. The control device receives this detection signal and automatically adjusts the holding position to compensate for the bending, creating a closed-loop control system that maintains joining accuracy despite frame flexibility.
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting the vertical position parameter of the C-shaped frame during the welding process. Based on the detected bending amount, the control device changes the holding position parameter to compensate for deformation, ensuring consistent joining depth and quality throughout the welding operation.
3Manufacturing precision
If a highly rigid C-shaped frame is used to prevent bending, then the manufacturing precision is improved, but the adaptability to narrow and complicated portions deteriorates
Solution Approach 1:
The patent applies dynamics by making the C-shaped frame's holding position adjustable during the welding process. The frame is connected to the apparatus main body via a vertical movement drive mechanism that can dynamically change the holding position in the vertical direction based on detected bending amounts, transforming a static rigid structure into a dynamic adaptable one that compensates for reduced rigidity.
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 highly accurate and reliable joining of complex and narrow portions by minimizing the effect of bending, maintaining consistent joining quality even with reduced frame rigidity, thus enhancing the reliability of FSW processes.
Implementation Method 1
Friction stir welding (FSW) joins target materials by softening the target materials with frictional heat generated by rotation of a cylindrical joining tool
Data Source
AI summary
Provided are a friction stir welding apparatus and a friction stir welding method that achieve highly accurate and highly reliable joining while minimizing an effect of bending of a pressing force receiving portion (carrying table) as a result of a press by a joining tool unit. The friction stir welding apparatus joins joining target members by friction stir welding. The friction stir welding apparatus is characterized by including: an apparatus main body; a control device that controls an operation of the friction stir welding apparatus; a C-shaped frame connected to the apparatus main body via a first vertical movement drive mechanism unit; a holder unit connected to one end of the C-shaped frame via a second vertical movement drive mechanism unit; and a joining tool held by the holder unit. The C-shaped frame includes a held portion connected to the apparatus main body via the first vertical movement drive mechanism unit, a holder unit holding portion connected to the holder unit via the second vertical movement drive mechanism unit, and a pressing force receiving portion connected to the other end of the C-shaped frame and receiving a pressing force from the joining tool. The control device includes a first joining mode that performs friction stir welding based on a joining command signal that determines a joining condition of the joining tool, and a first holding position determining signal that determines a first holding position of the first vertical movement drive mechanism unit, and a second joining mode that performs friction stir welding based on the joining command signal and a second holding position determining signal obtained by correcting the first holding position determining signal such that a depth or a range of a joined portion becomes constant in accordance with a state of the pressing force receiving portion. The first joining mode and the second joining mode are included in one joining pass from insertion of the joining tool into the joining target members to extraction of the joining target members.