Linear Friction Welding Clamp Linkage for High Holding Force
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Solution Overview
Problem
The increase in size of metal components to be welded together in linear friction welding apparatuses leads to higher frictional forces, requiring increased clamp cylinder thrust and larger apparatus sizes, which complicates accurate pressure force measurement and application, affecting welding accuracy.
Innovation Solution
A linear friction welding apparatus with a link mechanism in the oscillation jig that extends and contracts to increase holding force without increasing clamp cylinder thrust, and a pressure mechanism that accurately measures and applies pressure using a load sensor, stabilizing the inertial forces during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the clamp cylinder thrust is increased to enhance holding force for larger metal components, then the clamping force is improved, but the apparatus size increases
Solution Approach 1:
The patent employs dynamic clamping where the clamp members are moved during the welding process. The oscillation table reciprocates in the oscillation direction, and the clamp members are positioned to hold the first metal component while allowing controlled movement. This dynamic approach enables adequate clamping force without requiring excessively large static clamping mechanisms.
Solution Approach 2:
The patent introduces a second degree of freedom by adding oscillation movement perpendicular to the pressure direction. The oscillation table moves in the oscillation direction (vertical in the drawings) while the pressure table moves in the pressure direction (horizontal). This dimensional separation allows the clamping force to be applied effectively without directly increasing the apparatus footprint in the pressure direction.
2Force
If the clamp cylinder size is increased to provide sufficient holding force, then the clamping capability is improved, but the sizes of oscillation jig base and oscillation table increase
Solution Approach 1:
The clamping function is segmented into multiple clamp members (first clamp member and second clamp member) that work together. The oscillation jig is divided into an oscillation jig base and an oscillation jig movable in the oscillation direction. This segmentation allows the clamping force to be distributed and applied more efficiently without requiring a single large clamp cylinder.
Solution Approach 2:
The oscillation table serves as an intermediary between the clamp members and the first metal component. It transmits the clamping force while adding oscillation movement in the vertical direction. This intermediary mechanism allows the clamp members to apply force without being directly connected to the component, reducing the size requirements of the oscillation jig base.
3Area of stationary object
If larger metal components are welded together, then the welded area increases, but the frictional force between weld joint surfaces increases
Solution Approach 1:
The patent employs dynamic oscillation of the first metal component in the oscillation direction perpendicular to the weld joint surfaces. This oscillation reduces the effective frictional resistance during the welding process by preventing the surfaces from sticking together, enabling welding of larger components with increased welded areas without requiring proportionally increased pressure forces.
Solution Approach 2:
The oscillation table reciprocates periodically in the oscillation direction, creating periodic movement of the first metal component relative to the second metal component. This periodic action maintains frictional heating necessary for welding while preventing excessive frictional force buildup that would require larger clamping 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 configuration enhances welding accuracy by maintaining a strong hold on the components without enlarging the apparatus, improving the precision of weld joint surfaces while reducing the overall size of the welding equipment.
Implementation Method 1
a frictional heat generated between the weld joint surfaces of the pair of the metal components
Implementation Method 2
a link mechanism provided in the oscillation jig base, composed of a plurality of links connected together, connected to the second clamp member, and caused to extend and contract in the oscillation direction
Data Source
Figure 1
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Figure 3
AI summary
An oscillation jig (39) includes: an oscillation jig base (65) connected to an oscillation table (25); a first clamp member (67) provided in the oscillation jig base (65); a second clamp member (69) located at a position opposed to the first clamp member (67) in an oscillation direction and configured to hold a first metal component (3) together with the first clamp member (67); a link mechanism (73) provided in the oscillation jig base (65), composed of a plurality of links (75, 77, 79) connected together, connected to the second clamp member (69), and caused to extend and contract in the oscillation direction; and a clamp actuator (89) configured to cause the link mechanism (73) to extend and contract in the oscillation direction. When the first clamp member (67) and the second clamp member (69) hold the first metal component (3), a connection center line (CL) connecting connection centers (CI, C2, C3) of the respective links (75, 77, 79) is made straight in the oscillation direction.