Friction Stir Welding Shoulder Angle Control Without Delay
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Solution Overview
Problem
Conventional friction stir welding systems lack the capability for a rapid and precise change in the angle of attack of the welding shoulder, which is necessary due to varying geometric arrangements and material unevenness during the welding process.
Innovation Solution
A system with a vertically adjustable friction welding head and a welding shoulder receptacle that can be adjusted to any angle using pull and push rods with piezo fine adjustment devices, allowing for almost instantaneous changes in the welding direction by employing a disk-shaped welding shoulder receptacle with a gimbal suspension and actuating units, enabling pitching and tilting movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional friction stir welding systems are used, then the welding process is simple and cost-effective, but the welding shoulder angle cannot be changed rapidly or precisely
Solution Approach 1:
The welding shoulder is made dynamically adjustable through a gimbal suspension system with multiple degrees of freedom, allowing real-time angle changes during the welding process. The cardanic suspension enables the welding shoulder to pivot and tilt dynamically, transforming a static component into a dynamic one that can adapt to varying welding requirements.
Solution Approach 2:
A gimbal suspension system acts as an intermediary mechanism between the fixed tool holder and the welding shoulder. This intermediate structure with cardanic joints transmits motion and force while enabling precise angular adjustments, serving as a mediator that decouples the fixed mounting from the required angular mobility.
2Reliability
If the welding shoulder angle is changed frequently to adapt to geometric arrangements and material irregularities, then the weld quality improves, but the adjustment time increases
Solution Approach 1:
The welding shoulder angle is made dynamically adjustable through a gimbal suspension system with multiple degrees of freedom, allowing real-time angle changes during the welding process. The cardanic suspension enables the welding shoulder to pivot and tilt dynamically, transforming a static component into a dynamic one that can adapt to varying welding requirements.
Solution Approach 2:
Conventional mechanical adjustment mechanisms are replaced with a gimbal-based cardanic suspension system that utilizes spherical joints and leverage principles. This substitution enables smoother, faster, and more precise angular transitions by replacing complex mechanical linkages with the inherent mobility of gimbal structures.
3Adaptability or versatility
If a fixed welding shoulder angle is used, then the system is simple to operate, but it cannot adapt to varying geometric arrangements and material irregularities
Solution Approach 1:
The welding shoulder system is designed with multi-functionality through the gimbal suspension, enabling it to perform both fixed-angle welding and dynamic angle adjustment functions. The same structure serves as both a stable mounting platform and a flexible adjustment mechanism, allowing the system to adapt to various welding configurations without requiring separate dedicated devices.
Solution Approach 2:
The cardanic gimbal suspension enables the welding shoulder to self-adjust its angle automatically in response to geometric variations and material irregularities. The inherent mechanical properties of the gimbal system allow it to pivot and tilt as needed, providing self-adaptation without requiring complex external control mechanisms.
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 precise and rapid adjustments of the welding shoulder, improving the quality of the weld seam by allowing for optimal alignment with joining partners, reducing friction, and ensuring smoother weld surfaces, while maintaining low operational costs and high automation potential.
Implementation Method 1
pull and push rods (16) have piezo fine adjustment devices (22)
Implementation Method 2
friction stir welding (FSW)
Data Source
Figure 1
Figure 2~2b
Figure 3~3b
AI summary
The invention relates to a device and a method for changing the welding direction of the welding shoulder of a system for a friction stir welding process virtually without delay when required by the geometric arrangement of the joint partners to be welded or by a material unevenness, having the following method features: a) a main part (1) with a horizontally movable bridge support (5) has a friction welding head (12) which can be vertically adjusted together therewith and which has a pin receiving area (13) for mounting and driving a welding pin tip (14), wherein the welding shoulder (18) has a welding shoulder receiving area (17) which is supported at multiple points, and b) the welding shoulder receiving area (17) can be adjusted to any angle of attack relative to the joint partners by means of different push-pull rods (16) during the welding process.