Friction Stir Welding Tool Embedded Sensor Temperature Control
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Solution Overview
Problem
Friction stir welding apparatuses struggle to accurately manage temperature at the welded portion, leading to variations in welding quality, especially when welding dissimilar materials, due to temperature sensors being positioned distant from the stir target region and heat input being constant throughout the process, causing temperature and quality inconsistencies.
Innovation Solution
A friction stir welding apparatus with temperature sensors embedded in the welding tool's protrusion portion, allowing for real-time temperature management by controlling the tool's rotation speed and movement speed to maintain a predetermined temperature range, ensuring consistent heat input and reduced temperature fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If temperature sensors are positioned distant from the stir target region, then the device structure is simpler, but the temperature management precision deteriorates
Solution Approach 1:
The temperature sensor is embedded within the protrusion portion of the welding tool, with the sensor positioned inside the tool structure rather than externally. This nested configuration allows the sensor to be located at the stir target region while maintaining a compact integrated design, resolving the contradiction between structural simplicity and measurement precision.
Solution Approach 2:
The protrusion portion serves as an intermediary structure that transmits the temperature measurement from the stir target region to the control system. By embedding the sensor in the protrusion portion, the system achieves accurate temperature monitoring at the critical location without requiring complex external sensor arrangements.
2Use of energy by moving object
If constant heat input is applied throughout welding, then the energy input is stable, but the welding quality uniformity deteriorates due to temperature variation
Solution Approach 1:
The welding system transitions from constant heat input to dynamic heat input control. The control device adjusts the rotation speed and/or movement speed based on real-time temperature feedback from the embedded sensor, allowing the heat input to vary dynamically throughout the welding process. This maintains the temperature within a predetermined range and ensures uniform welding quality across different positions.
Solution Approach 2:
The system implements a closed-loop feedback control mechanism where the temperature sensor continuously monitors the temperature at the stir target region, and the control device uses this feedback information to adjust the heat input parameters. This feedback loop enables the system to compensate for temperature variations and maintain consistent welding quality throughout the process.
3Device complexity
If temperature management is not implemented, then the process control is simpler, but the welding quality variation increases
Solution Approach 1:
The welding tool performs self-diagnosis and self-adjustment through the embedded temperature sensor and control device. The system automatically monitors its own temperature at the stir target region and adjusts its operation parameters accordingly, enabling self-regulated temperature management without requiring complex external control systems.
Solution Approach 2:
The temperature management function is merged into the welding tool itself by embedding the sensor in the protrusion portion. This integration combines the welding and temperature monitoring functions into a single unified system, achieving effective temperature management while avoiding the complexity of separate external monitoring 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
This approach enables uniform welding quality along the welded portion by maintaining the tool temperature within a set range, reducing variations and enhancing the strength and consistency of the weld, even when welding dissimilar materials.
Implementation Method 1
A friction stir welding apparatus (hereinafter referred to as an FSW apparatus) that applies friction heat with a rotating welding tool, generates a plastic flow phenomenon in members to be welded
Implementation Method 2
a temperature sensor which is embedded in the protrusion portion and detects a temperature at a stir target region
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A temperature sensor 13 is provided inside the protrusion portion 11 of the welding tool 1, and when welding is performed, the control device 5 controls a rotation speed, a movement speed, or both rotation speed and movement speed of the welding tool 1, and thus the temperature detected by the temperature sensor 13 is managed so as to fall within the predetermined management temperature range, and welding quality is equalized.