Quick-Connect Refill Friction Stir Spot Welding Tool Change
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Solution Overview
Problem
Refill friction stir spot welding tools require labor-intensive and time-consuming replacement, leading to costly downtime due to conventional attachment methods that are cumbersome and time-consuming.
Innovation Solution
A quick connect system for refill friction stir spot welding tools featuring radially-projecting mounting tabs and a stadium-shaped mounting head, allowing for attachment and detachment through less than 360 degrees, enabling rapid tool exchange by rotating the clamp, friction sleeve, and friction pin relative to the weld head and spindle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional attachment methods are used for refill friction stir spot welding tools, then the tools can be securely attached to the weld head, but the replacement process becomes labor-intensive and time-consuming
Solution Approach 1:
The tool assembly is divided into separable components (clamp, friction sleeve, friction pin) that can be independently attached and detached. The clamp contains mounting tabs that engage with mounting slots in the weld head, allowing the entire tool assembly to be quickly replaced as a unit or individual components to be swapped independently, dramatically reducing replacement time from conventional methods
Solution Approach 2:
Mounting tabs and mounting slots serve as intermediary coupling elements between the tool components and the weld head/spindle. These standardized interface features enable rapid connection and disconnection through simple rotational motion, eliminating the need for complex fastening mechanisms while ensuring secure attachment during operation
2Strength
If conventional attachment methods are used for refill friction stir spot welding tools, then the tools can be firmly secured, but the replacement process becomes labor-intensive and costly
Solution Approach 1:
The attachment system is segmented into discrete mounting tabs on the clamp and separate mounting slots in the weld head. This segmentation allows the tool to be firmly secured through multiple engagement points while enabling simple, tool-free replacement by rotating the clamp to disengage the tabs from the slots, reducing both labor intensity and cost
Solution Approach 2:
Instead of using complex fastening mechanisms that require tools for tightening, the design inverts the approach by using a simple rotational insertion where the mounting tabs slide into mounting slots and lock automatically. The attachment is secured by the geometry of the tabs and slots themselves, eliminating the need for additional fasteners or complex assembly procedures
3Ease of operation
If standard rotation attachment is used (360 degrees or more), then the mounting tabs can engage the mounting slots, but the tool replacement time increases
Solution Approach 1:
The mounting tabs are designed to engage with mounting slots through less than 360 degrees of rotation. The tabs are positioned and dimensioned so that a partial rotational motion (e.g., 90-180 degrees) is sufficient to bring the tabs into engagement with the slots and secure the tool. This partial action approach dramatically reduces attachment and detachment time while maintaining secure connection during welding operations
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
Facilitates tool replacement in under two minutes, significantly reducing downtime and labor costs compared to the conventional 20-minute process, while maintaining the tools' operational efficiency.
Implementation Method 1
a sleeve and a pin within the sleeve are pressed against one of the workpieces and rotated to heat the workpieces
Data Source
AI summary
A quick connect refill friction stir spot welding tool includes a clamp having a first radially-projecting mounting tab configured for engaging a first mounting slot in a refill friction stir spot welding weld head. A friction sleeve is located coaxially within the clamp and has a second radially-projecting mounting tab configured for engaging a second mounting slot in the refill friction stir spot welding weld head. The second radially-projecting mounting tab is located higher along an axis of the tool than the first radially-projecting mounting tab, and radially inward thereof. A friction pin is located coaxially within the clamp and friction sleeve. The clamp and friction sleeve are attachable to and detachable from the refill friction stir spot welding weld head by rotations through less than 360 degrees.