Inflatable Workpiece Support Rings for Modular Friction Welding
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Solution Overview
Problem
Conventional friction welding techniques require multiple dedicated welding heads and controllers for assembling large, high-value components like rocket fuel tanks, leading to high costs and space consumption.
Innovation Solution
A modular friction welding head system that can be moved between stations and controlled by a single controller, reducing the need for multiple welding heads and controllers, and utilizing inflatable rings for supporting workpieces during welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple dedicated welding heads and controllers are used for friction welding operations, then welding reliability and precision are improved, but device complexity and cost increase
Solution Approach 1:
The patent implements a single welding head and controller that can perform multiple welding operations on different workpieces by using inflatable rings with adjustable configurations. The inflatable rings can be inflated to different pressures and configurations to accommodate various workpiece sizes and shapes, allowing one welding head to replace multiple dedicated welding heads while maintaining welding reliability through programmable control
2Manufacturing precision
If multiple dedicated welding heads and controllers are used, then welding precision is improved, but space consumption increases
Solution Approach 1:
The inflatable ring support system allows a single welding head to accurately position and weld different workpieces by adjusting the inflation pressure of individual segments. This eliminates the need for multiple dedicated welding stations, reducing space consumption while maintaining welding precision through programmable positioning and inflatable ring configuration
3Reliability
If conventional friction welding techniques are used, then welding quality is maintained, but cost increases
Solution Approach 1:
The patent reduces manufacturing cost by implementing a single reusable welding head and controller system that can perform multiple welding operations. The inflatable rings are made from flexible material that can be repeatedly inflated and deflated, and the system uses programmable control to maintain welding quality across different workpieces, eliminating the need to purchase multiple expensive dedicated welding systems
4Manufacturing precision
If inflatable rings are used to support workpieces, then workpiece support uniformity is improved, but device complexity increases
Solution Approach 1:
The patent uses inflatable rings with multiple independently controllable segments that can be inflated to different pressures to provide uniform support for workpieces of various sizes and shapes. The pneumatic system allows precise control of support forces through pressure regulation, and the inflatable structure naturally distributes pressure uniformly across the contact surface, achieving workpiece support uniformity while the modular design keeps device complexity manageable
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
The modular system decreases the cost and space requirements for friction welding operations by allowing a single head and controller to perform various tasks, while the inflatable rings provide efficient and uniform support for workpieces, reducing the risk of misshapen products and simplifying the manufacturing process.
Implementation Method 1
Each of the plurality of inflatable members can be independently inflated radially inwardly to engage the workpiece
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
Inflatable rings for supporting friction welding workpieces, and associated systems and methods. A support assembly (874) for joining multiple workpieces in a representative embodiment includes two drive rings (875), each carried by a corresponding drive ring carriage (876). Each drive ring (875) can include a generally cylindrical body (890) carrying one or more inflatable members (880) that extend around some or all of the circumference of the region enclosed by the drive ring (875). Each of the inflatable members (880) can be inflated with a suitable fluid (e.g., a gas or liquid) so as to expand radially inwardly (as indicated by arrows I) to engage the outer circumference, periphery or other outwardly-facing surface of a workpiece.