Friction Stir Welding Tool Position Correction Under Load Deviation
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Solution Overview
Problem
Existing friction stir welding apparatuses are not effective in accurately correcting the welding tool position in a short time when the load factor exceeds a predetermined range, leading to suboptimal welding quality.
Innovation Solution
A friction stir welding apparatus and method that includes a first correction mode using a variable correction quantity calculated by a predetermined operational expression and a second correction mode using a preset fixed correction quantity, allowing for precise adjustment of the welding tool position in the Z-axis direction based on the state quantity deviation during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fixed correction value is used to correct the welding tool position when the load factor exceeds the predetermined range, then the correction is simple to implement, but the correction accuracy is insufficient when the exceeded quantity is small
Solution Approach 1:
The patent applies dynamics by switching from a static fixed correction value to a dynamic variable correction value that changes based on the load factor deviation. The correction value is calculated using an operational expression that adapts to the actual exceeded quantity, enabling precise correction for both small and large deviations while maintaining implementation simplicity through automated calculation.
Solution Approach 2:
The patent changes the parameter of correction value from a fixed constant to a variable determined by an operational expression. The correction value is dynamically adjusted based on the load factor deviation magnitude, allowing the system to provide appropriate correction amounts for different deviation scenarios, thereby improving correction accuracy without complicating the implementation process.
2Speed
If a large correction value is applied when the load factor exceeds the predetermined range, then the welding tool position returns to the reference range quickly, but the correction may overshoot to the opposite side
Solution Approach 1:
The patent uses dynamics by making the correction value adaptive rather than fixed. The operational expression calculates an appropriate correction value based on the actual load factor deviation, enabling the system to apply large corrections when needed for quick recovery while applying smaller corrections when the deviation is minor, thus preventing overshooting while maintaining fast correction speed.
Solution Approach 2:
The patent implements feedback by continuously monitoring the load factor and using the deviation information to determine the appropriate correction value. The operational expression processes the feedback signal (load factor deviation) to generate a proportional correction value, creating a closed-loop control system that prevents overshooting by adjusting the correction magnitude according to the actual system state.
3Productivity
If correction is only performed when the load factor exceeds the predetermined range by a large margin, then the correction process is efficient, but welding quality deteriorates when the load factor is within a small exceeded range
Solution Approach 1:
The patent applies partial action by implementing continuous correction monitoring across the entire exceeded range rather than waiting for large deviations. The operational expression calculates and applies appropriate correction values even for small exceedances, ensuring welding quality is maintained throughout the entire range while maintaining efficiency through automated proportional correction rather than intensive manual intervention.
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 accurate and rapid correction of the welding tool position, ensuring high-quality friction stir welding by maintaining the state quantity within the predetermined range, even when the load factor exceeds the threshold, thereby improving welding accuracy and quality.
Implementation Method 1
friction stir welding (FSW) in which welding target materials are welded to each other by softening the welding target materials by frictional heat generated by rotating a cylindrical welding tool
Data Source
AI summary
A friction stir welding apparatus includes a welding tool that includes a shoulder and a probe supported by the shoulder, is inserted into a plurality of welding target members, and moves while rotating to weld the plurality of welding target members, a spindle motor that is coupled to the welding tool to rotate the welding tool in a predetermined direction, a welding head that supports the spindle motor, and an apparatus body that supports the welding head, applies a drive signal to the spindle motor, and moves the welding tool along a welding line while rotating the welding tool. The apparatus body has a first correction mode in which a welding tool position indicating a position of the welding tool in a Z-axis direction is corrected based on a variable correction quantity calculated by a predetermined operational expression according to a fluctuation quantity of a state quantity indicating a control quantity of the welding head in a Z-axis upper direction or a Z-axis lower direction when friction stir welding is performed on the welding target members by the welding tool, and a second correction mode in which the welding tool position is corrected based on a preset fixed correction quantity according to the fluctuation quantity.