Compact Friction Stir Welding Apparatus with Nested Linear Actuator
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Solution Overview
Problem
Existing friction stir welding equipment is large and costly, limiting its applicability for spot and stitch welding applications, particularly in industries like automotive where compact and affordable solutions are needed.
Innovation Solution
A compact, low-cost servo-driven friction stir welding apparatus with a linear actuator module, inline spindle, and guide assembly, featuring hollow core motors and a nesting design to minimize size and facilitate linear movement, integrated with a "C" gun assembly and industrial robot for precise control and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional friction stir welding equipment is used, then welding capability is achieved, but equipment size and cost become excessively large
Solution Approach 1:
The patent implements nesting by placing the linear actuator module inside the spindle housing. The actuator's motor and lead screw mechanism are contained within the spindle's internal cavity, allowing the actuator to be retracted into the spindle when not in use. This nested configuration significantly reduces the overall equipment volume while maintaining both welding capability and linear movement functionality.
Solution Approach 2:
The patent merges the linear actuator module and the spindle into a single integrated assembly. The actuator is mounted within the spindle housing, and both components share common mounting structures and support mechanisms. This merging eliminates the need for separate actuator housings and mounting fixtures, thereby reducing equipment size while preserving welding capability.
2Reliability
If conventional friction stir welding equipment is used, then welding capability is achieved, but equipment cost becomes excessively high
Solution Approach 1:
The patent designs the spindle to serve multiple functions: it houses the rotating tool for welding, contains the linear actuator module for positioning, and provides structural support for the entire assembly. The motor mounting structures and housing elements are designed to fulfill multiple roles simultaneously. This multi-functionality reduces the number of separate components needed, lowering manufacturing complexity and cost while maintaining welding capability.
3Volume of moving object
If compact design is implemented, then equipment size is reduced, but stability and balance may be compromised
Solution Approach 1:
The patent incorporates counterbalancing weights within the spindle housing to offset the weight of the linear actuator module and moving components. These weights are strategically positioned to maintain the center of gravity and ensure stable operation during welding. The counterweight mechanism allows for compact design while preserving stability and balance.
4Volume of moving object
If linearly compact design is implemented, then equipment size is reduced, but movement precision may be compromised
Solution Approach 1:
The patent replaces traditional mechanical positioning systems with a servo-driven lead screw mechanism. The servo motor provides precise rotational control, and the lead screw converts this rotation into accurate linear movement of the tool. This substitution enables compact design while maintaining high movement precision through electronic control and mechanical advantage.
Solution Approach 2:
The patent incorporates feedback mechanisms including encoders on the servo motor and position sensors on the linear actuator. These sensors continuously monitor the position and movement of components, providing real-time feedback to the control system. This feedback enables precise positioning and movement control within the compact apparatus, ensuring manufacturing precision is maintained despite reduced equipment size.
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 apparatus provides a compact, cost-effective solution for friction stir spot and stitch welding, ensuring stability and precision through independent motor control and thermal compensation, reducing equipment size and operational costs while maintaining accuracy.
Implementation Method 1
a linear actuator module having a motor, a lead screw, a nut and a thrust member or tube
Implementation Method 2
a linear actuator module having a motor, a lead screw, a nut and a thrust member or tube
Implementation Method 3
The process involves applying a rotating tool or tool head of various configurations to the abutting faces of two or more workpieces, thereby generating frictional heat
Data Source
AI summary
A friction stir weld apparatus having a linear drive actuator and a separate friction stir weld device. The linear actuator and the friction stir weld device are driven by concentric motors. In the preferred embodiment, the thrust member of the actuator is connected to the friction stir weld device within or adjacent to the friction stir weld device motor to advance and retract the friction stir weld device along a linear axis concentric with the actuator and friction stir weld device motors.