Friction Stir Welding Device Rack Gear Rigidity
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Solution Overview
Problem
Friction stir welding devices face challenges in maintaining uniform welding quality due to non-uniform movement speed and rotational shaking caused by large welding reaction forces, which require enhanced rigidity in both the moving and rotational directions.
Innovation Solution
The friction stir welding device incorporates a moving device with a pair of racks and rack meshing gears that deviate by half-pitch, providing symmetrical support and alternating strong and weak meshing positions to enhance rigidity, and a probe with rotational symmetry to minimize vibration resonance, ensuring consistent movement and rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional moving device is used to move the welding device body along the welding line, then the device can perform friction stir welding, but the large welding reaction forces cause non-uniform movement speed and rotational shaking, deteriorating welding quality
Solution Approach 1:
The moving device is segmented into multiple independent moving units, each equipped with its own drive mechanism. This segmentation allows each unit to independently compensate for reaction forces and maintain stable movement, preventing the non-uniform motion and shaking that would otherwise occur during friction stir welding.
Solution Approach 2:
The invention changes the motion parameters by implementing a moving device that can dynamically adjust its movement characteristics. The device maintains a constant movement speed despite large welding reaction forces by using independent drive mechanisms for each moving unit, thereby ensuring uniform welding quality throughout the welding line.
2Ease of manufacture
If the moving device lacks sufficient rigidity in the movement direction, then the device structure can be more flexible and easier to manufacture, but the movement speed becomes non-uniform under welding reaction forces
Solution Approach 1:
The moving device is divided into multiple independent moving units with individual drive mechanisms. This segmentation provides sufficient rigidity in the movement direction for each unit to maintain constant speed under welding reaction forces, while the modular structure remains flexible and manufacturable.
Solution Approach 2:
The invention implements a dynamic moving device where each moving unit can independently adjust its motion characteristics. The independent drive mechanisms allow each unit to dynamically compensate for external disturbances, maintaining uniform movement speed while preserving structural flexibility through the modular design.
3Device complexity
If the moving device lacks sufficient rotational rigidity, then the device can be simpler in structure, but rotational shaking occurs under welding reaction forces, deteriorating welding quality
Solution Approach 1:
The moving device is segmented into multiple independent moving units, each with its own drive mechanism. This segmentation provides sufficient rotational rigidity for each unit to resist shaking under welding reaction forces, while the overall device structure remains relatively simple and modular.
Solution Approach 2:
The invention changes the structural parameters by implementing a modular moving device with independent drive mechanisms for each unit. This configuration provides the necessary rotational rigidity to prevent shaking and maintain welding quality, while keeping the overall device complexity manageable through standardization and modularity.
4Device complexity
If a single drive mechanism is used for the moving device, then the device structure is simpler, but the rigidity in both movement and rotational directions is insufficient under large welding reaction forces
Solution Approach 1:
The drive mechanism is segmented into multiple independent units, each responsible for driving a specific moving unit. This segmentation distributes the load and provides sufficient rigidity in both movement and rotational directions to withstand large welding reaction forces, while the modular structure keeps overall complexity manageable.
Solution Approach 2:
The invention combines multiple independent drive mechanisms into a coordinated system where each drive unit operates independently but contributes to the overall movement. This combination provides the necessary rigidity and strength to handle welding reaction forces while maintaining a relatively simple modular structure that is easier to manufacture and maintain.
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 configuration enhances the rigidity of the moving device in both the travel and rotational directions, preventing non-uniform movement and shaking, resulting in improved welding quality along the entire welding line.
Implementation Method 1
a plurality of rack meshing gears that individually mesh with the respective racks
Implementation Method 2
raising the temperature of the welded part between the workpieces due to the frictional heat generated by the contact between the rotating probe and the workpieces
Data Source
AI summary
A friction stir welding device includes a pair of workpiece surface plates between which a gap extending along a welding line between workpieces is formed; a welding device body including a rotatable friction stir welding tool protruding upward from the gap; and a linear guide mechanism and a moving device for the welding device body. The moving device has a configuration in which a pair of pin racks extending in a direction along the gap are disposed at symmetrical positions on both sides in a width direction with a position immediately below a tool movement path of the friction stir welding tool as a symmetrical axis, and pin gears that individually mesh therewith are provided in the welding device body so as to be rotatably driven. Respective sets of a pin rack and a pin gear are alternately brought into a strong meshing state during the movement of the welding device body by causing the locations of pins and teeth thereof to deviate from each other by a half pitch.