Friction Stir Welding Tool Retaining Mechanism
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Solution Overview
Problem
Existing friction stir welding technologies face inefficiencies in changing rotational tools and controlling pressing forces, leading to reduced productivity and complex force management during the welding process.
Innovation Solution
A friction stir welding apparatus with a retaining mechanism featuring mounting passages and a biasing system that ensures the machine tool remains securely attached, allowing for easy control of pressing force and automated tool changing without manual operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hand operation is used to change the rotational tool, then the tool can be replaced when worn out, but the efficiency is significantly reduced
Solution Approach 1:
The system uses a sensor to detect when the rotational tool has worn out and automatically triggers the tool changing process, eliminating the need for manual inspection and operation. The apparatus serves itself by monitoring its own tool condition and initiating replacement automatically.
Solution Approach 2:
The manual hand operation for tool changing is replaced with an automated mechanical system that uses sensors, actuators, and a changing mechanism to automatically replace the rotational tool when wear is detected, substituting human mechanical action with an automated system.
2Productivity
If the machine tool is pulled out from materials after welding, then the welding process can be completed, but the tool may come off the retaining means
Solution Approach 1:
The biasing means is pre-configured to apply a constant biasing force to the retaining means before the tool pulling out occurs. This preliminary application of force ensures that the tool remains securely retained during the welding process and when being pulled out, preventing accidental detachment.
Solution Approach 2:
The biasing means applies a counteracting force to prevent the tool from coming off the retaining means. By applying this preliminary anti-action force, the system counteracts any forces that might cause the tool to detach during the welding and pulling out operations.
3Productivity
If automated tool changing is implemented, then productivity is improved, but the device complexity increases
Solution Approach 1:
The automated tool changing system is divided into separate functional modules: a sensor for detecting tool wear, a biasing means for applying retention force, and a mounting/dismounting mechanism. This segmentation allows each component to perform its specific function independently, making the overall complex system more manageable and maintainable.
Solution Approach 2:
The mounting means is designed to universally accommodate different rotational tools through standardized mounting passages and biasing mechanisms. This multi-functionality allows the same apparatus to handle various tool types while maintaining automated changing capability, reducing the need for multiple specialized systems.
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 continuous friction stir welding by preventing tool detachment and simplifying force control, enhancing productivity through automated tool management and reduced mechanical stress on components.
Implementation Method 1
a biasing means configured to exert a force on the retaining means in a direction from the other end portion toward the one end portion of the retaining means
Implementation Method 2
a mounting means having a plurality of mounting members which are respectively inserted through the opening ends of the plurality of mounting passages and are respectively fitted to tip end portions of the plurality of mounting passages
Data Source
AI summary
A rotational tool retaining member unit 37 is mounted at one end portion thereof to a FSW gun body 26. The rotational tool retaining member unit 37 is provided at the other end thereof with a fitting hole 61 and a plurality of mounting passages 60 which are formed on a peripheral surface thereof such that the mounting passages 60 open on the opposite side of the one end portion and are spaced apart from each other in the circumferential direction. A mounting member unit 38 has a plurality of pin members 67. The mounting member unit 38 is mounted to the rotational tool retaining member unit 37 in such a manner that the pin members 67 are moved from the openings to the tip end portions of the mounting passages 60 and fitted thereinto. A rotational tool 33 is inserted into the mounting member unit 38. The rotational tool 33 has one end portion thereof a tie-in portion which is fitted to the fitting hole of the retaining means. The mounting member unit 38 is provided with a biasing means 69 for exerting a force on the rotational tool retaining member unit 37 to inhibit the pine members 67 from coming off the tip end portions.