Friction Stir Welding Swing Control for Constant Weld Depth
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Solution Overview
Problem
Conventional friction stir welding methods struggle to maintain a consistent depth of the welded part due to variations in the position of the welding tool's leading end, which affects the quality of the weld, especially when dealing with composite materials like steel and aluminum.
Innovation Solution
A friction stir welding apparatus and method that incorporate a control device, a swing mechanism unit, and a holder unit with a multiaxial robot arm, allowing for precise control of the welding tool's depth and position through a combination of up/down motion drive mechanisms and revolving mechanisms, enabling constant depth control during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the welding tool is swung with a swing axis as fulcrum while fixing the hold position of the welding head, then the welding tool can perform friction stir welding along the welded part, but the leading end part of the welding tool draws an arc causing position variation and welding quality degradation
Solution Approach 1:
The invention transitions from a static hold position to a dynamic hold position that moves in synchronization with the swing mechanism. The hold position is no longer fixed but dynamically adjusts to compensate for the arc motion of the welding tool leading end, maintaining constant depth throughout the welding process.
Solution Approach 2:
The control device calculates the required hold position movement based on the swing mechanism's motion parameters (swing axis position, swing angle, swing speed). This feedback mechanism ensures the hold position adjusts precisely to counteract the arc drawing effect, maintaining welding tool leading end position accuracy.
2Productivity
If the hold position of the welding head is fixed during swing welding, then the swing mechanism can operate smoothly, but the depth of the welded part varies and cannot be maintained constant
Solution Approach 1:
The hold position transitions from a static fixed position to a dynamic moving position that synchronizes with the swing mechanism's motion. This dynamic adjustment maintains constant welding depth while preserving the continuity of the welding process.
Solution Approach 2:
The invention changes the parameter of hold position from a constant fixed value to a variable value that changes dynamically during welding. The control device calculates and adjusts the hold position based on swing mechanism parameters, transforming the static parameter into a dynamic one that adapts to process conditions.
3Ease of operation
If the welding tool leading end position is not accurately controlled, then the welding process is simpler to operate, but high welding quality cannot be maintained
Solution Approach 1:
The control device implements a feedback mechanism that automatically calculates and adjusts the hold position based on the swing mechanism's motion parameters. This eliminates the need for manual position adjustment while ensuring consistent welding quality through automated position control.
Solution Approach 2:
The system performs self-adjustment of the hold position automatically without requiring external intervention. The control device uses the swing mechanism's own motion parameters to calculate the required hold position adjustments, making the system self-regulating and maintaining welding quality autonomously.
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 ensures consistent depth of the welded part from start to finish, enhancing the reliability of the weld, particularly for composite materials like steel and aluminum, by accurately maintaining the Z-direction position of the welding tool, thereby improving the welding quality and preventing penetration through thin plates.
Implementation Method 1
Friction stir welding (FSW) which welds together welded materials by softening the welded materials with friction heat which is generated by rotating a columnar welding tool and stirring that part
Data Source
AI summary
A friction stir welding apparatus and method maintains a depth of a welded part constant without varying a depth-direction position of a welding tool leading end part relative to welded members. A control device controls an operation of the friction stir welding apparatus, and a holder unit is connected to a swing mechanism unit via a revolving mechanism section, and a welding tool is held to the holder unit. The control device has a first welding mode in which friction stir welding is performed on the basis of a welding condition signal for deciding a welding condition of the welding tool, a swing control signal for controlling the swing mechanism unit, a first hold position decision signal, and a second welding mode in which friction stir welding is performed on the basis of the welding condition signal, the swing control signal, and a second hold position decision signal.