Active Vibration Avoidance Method for Variable Speed Welding in Robotic Friction Stir Welding Based on Constant Heat...

Area of Science:

• Manufacturing Engineering
• Robotics
• Materials Science

Background:

• Robotic Friction Stir Welding (RFSW) is crucial in aerospace, shipbuilding, and automotive industries.
• High-speed rotation in RFSW and low robot stiffness cause significant vibrations, impacting weld quality.
• Existing research lacks comprehensive analysis of RFSW-induced vibrations and effective control strategies.

Purpose of the Study:

• To investigate vibration patterns and their impact during the RFSW process.
• To propose and validate an active vibration avoidance control method for RFSW.
• To maintain constant heat input during variable speed welding in RFSW.

Main Methods:

• Developed a simplified dynamic model for the RFSW robot system.
• Implemented an active vibration avoidance control strategy using spindle speed feedback.
• Integrated a thermal equilibrium equation to adjust welding speed for constant heat input.

Main Results:

• The proposed method effectively adjusts spindle speed to avoid robot modal frequencies.
• Variable welding speed control successfully maintains constant heat input.
• Simulation experiments validated the feasibility and effectiveness of the active control strategy.

Conclusions:

• The study provides a novel solution for mitigating vibrations in RFSW.
• The active control method enhances process stability and weld quality.
• This research offers new insights for RFSW control and optimization in advanced manufacturing.