Friction Stir Welding Tool Self-Adjusting Shoulder Gap
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Solution Overview
Problem
Friction stir welding devices require complex control systems to adjust welding pressure due to non-uniform plate thickness, increasing costs and complexity.
Innovation Solution
A friction-stir welding tool with a simple structure where the front and rear shoulders rotate relative to each other, with a threaded engagement mechanism that automatically adjusts to maintain constant gap and suitable welding pressure without a complex control device, using screwing forces and reaction forces to balance the pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a control device is added to adjust welding pressure according to plate thickness changes, then welding quality is improved, but device complexity and cost increase
Solution Approach 1:
The patent implements self-adjustment of welding pressure through the mechanical interaction between the front and rear shoulders. The rear shoulder automatically moves closer to the front shoulder in response to friction forces during welding, maintaining constant welding pressure without requiring external control devices or sensors. This self-service mechanism eliminates the need for complex control systems while ensuring consistent welding quality across varying plate thicknesses.
Solution Approach 2:
The patent incorporates a feedback mechanism where the friction force acting on the rear shoulder during welding provides real-time information about the welding conditions. This friction force automatically adjusts the gap between the front and rear shoulders, creating a closed-loop control system that maintains optimal welding pressure without requiring external sensors or control algorithms.
2Adaptability or versatility
If hydraulic pressure control is used to adjust the gap between shoulders, then adaptability to plate thickness changes is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex hydraulic control systems with a simple mechanical interaction between the front and rear shoulders. The mechanical friction force during welding directly adjusts the gap between shoulders, eliminating the need for hydraulic cylinders, pressure control valves, and associated control systems. This mechanical substitution maintains full adaptability to plate thickness variations while dramatically simplifying the device structure.
3Ease of manufacture
If the gap between shoulders is manually adjusted, then manufacturing simplicity is improved, but adaptability to varying plate thickness deteriorates
Solution Approach 1:
The patent transforms the static gap between shoulders into a dynamic, self-adjusting parameter. The gap automatically changes during welding based on the friction force generated, allowing the system to adapt to varying plate thicknesses in real-time. This dynamic adjustment mechanism is achieved through simple mechanical interaction rather than complex control systems, maintaining manufacturing simplicity while providing full adaptability.
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 friction stir welding with reduced costs and complexity by maintaining consistent welding pressure across varying plate thicknesses, ensuring high-quality welds without the need for intricate control systems.
Implementation Method 1
a first screw part (8) provided on the probe (7) and a second screw part (11) provided on the front side shoulder (6), in which the state of threaded engagement between the first screw part (8) and the second screw part (11) is changed
Implementation Method 2
a friction force is applied to a portion between the rear side shoulder and the plate materials during the welding. If the friction force from the plate materials is applied to the rear side shoulder, the rotation of the rear side shoulder is suppressed by the friction force
Data Source
Figure 1
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Figure 4
AI summary
A friction-stir welding tool provided with: an axially extending front-side shoulder (6); a reverse-side shoulder (5) in contact with plate materials so as to sandwich the abutment portion of the the plate material pair; and a probe (7) disposed so as to penetrate the plate materials between the front-side shoulder (6) and the reverse-side shoulder (5), the probe (7) linking the front-side shoulder (6) and the reverse-side shoulder (5) to each other; wherein the probe (7) has a first screw part (8) provided on at least one axial end section, and the front-side shoulder (6) and/or the reverse-side shoulder (5) has a second screw pan (11) in threaded engagement with the first screw part (8), the threaded engagement changing so that the reverse-side shoulder (5) and the front-side shoulder (6) approach each other along the axial direction as the front-side shoulder (6) and the reverse-side shoulder (5) rotate relat-ive to each other, the threaded engagement with the first screw part linking the reverse-side shoulder (5) and/or the front-side shoulder (6) with the probe.