Friction Stir Welding Guide Rail with Multi-Position Roll Members
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Solution Overview
Problem
Existing friction stir welding methods face challenges in maintaining the locus of welding when performed multiple times on the same member due to the low rigidity of articulated robot arms, requiring frequent re-attachment of guide rails to adjust the welding tool's position.
Innovation Solution
A friction stir welding apparatus with a spindle housing and multiple roll members on a guide rail, arranged to maintain consistent distance variations for guiding the welding tool, allowing easy shifting of the welding locus without needing to re-attach the guide rail.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a guide rail is used to guide the welding tool during friction stir welding, then the welding locus can be maintained, but the guide rail needs to be re-attached multiple times when performing welding on the same member, increasing operation complexity and time loss
Solution Approach 1:
The guide rail is designed to be movable along the workpiece, allowing it to be repositioned without complete removal. The rolling members can engage with different positions on the guide rail, enabling dynamic adjustment of the welding locus while maintaining guidance accuracy throughout multiple welding operations on the same member.
Solution Approach 2:
The guide rail system is segmented into multiple engagement positions through the arrangement of rolling members at different distances from the welding tool axis. This segmentation allows selective engagement of different guide rail sections for different welding passes, enabling locus shifting without complete re-attachment.
2Stability of the object's composition
If the guide rail is fixed in position, then the welding locus is stable, but the welding tool cannot be easily repositioned for multiple welding passes on the same member
Solution Approach 1:
The system transforms the static guide rail into a dynamic guidance system where the rolling members can engage different positions on the guide rail. This allows the guide rail to maintain stability during each welding operation while enabling locus shifting between operations through repositioning of the rolling member engagement point.
Solution Approach 2:
The guide rail serves multiple functions: it provides stable guidance during welding, enables locus shifting for multiple passes, and accommodates different welding positions through the multi-position rolling member arrangement. This universal design allows the same guide rail structure to support both stability and adaptability requirements.
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
Enables multiple friction stir welds on the same member with high welding strength using less expensive equipment by maintaining the welding locus alignment, reducing the need for repeated guide rail attachment.
Implementation Method 1
a guide rail for guiding the welding tool in a predetermined direction by contacting any of the roll members among the plurality of roll members and a guide surface of the guide rail
Implementation Method 2
friction stir welding is performed in which a softened portion of a member to be joined is agitated by frictional heat generated by rotating a welding tool
Data Source
AI summary
A friction stir welding apparatus includes: a welding tool; a spindle housing covering a spindle connected to the welding tool; a plurality of roll members provided on the spindle housing; and a guide rail for guiding the welding tool in a predetermined direction by contacting any of the roll members among the plurality of roll members and a guide surface of the guide rail. Further, the plurality of roll members is arranged in a manner that, when viewed from an axial direction of the welding tool, a distance from an axis of the welding tool to a position where one of the roll members is in contact with the guide surface is different from a distance from the axis of the welding tool to a position where another roll member is in contact with the guide surface.