Patent Application
20220324051
The present disclosure relates to friction welding, and particularly to friction element welding.
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
During assembly line manufacturing, a friction element weld (FEW) process can be an energy and cost efficient process to join dissimilar materials such as aluminum or aluminum alloys to steel. For example, and with reference to
The present disclosure addresses the issues of variations in panels being joined together via a FEW process, among other issues related to FEW processes.
This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.
According to one form of the present disclosure, a method of installing a friction element includes driving the friction element through at least a top panel and welding the friction element to a bottom panel using a friction element weld (FEW) machine. Also. The method includes controlling at least one key FEW controlled parameter of the FEW machine during installation of the friction element, monitoring at least one key FEW monitored parameter of the FEW machine during installation of the friction element, and adjusting the at least one key FEW controlled parameter of the FEW machine in real-time as a function of and in response to the at least one key FEW monitored parameter exhibiting completion of at least one key FEW process characteristic such that the friction element is adaptively installed based on the adjusting of the at least one key FEW controlled parameter of the FEW machine. In some variations, the at least one key FEW controlled parameter is at least one of RPM of the friction element and applied insertion force on the friction element and the at least one key FEW monitored parameter is at least one of torque of an electric motor rotating the friction element, time during installation of the friction element, energy consumption during installation of the friction element, electric current of the electric motor during installation of the friction element, and electric current of a servo-motor during installation of the friction element.
In at least one variation, the driving and welding of the friction element comprises rotating, with an electric motor, and applying an insertion force to, with a servo-motor, a bit that is engaged with the friction element.
In some variations, the at least one key FEW characteristic is at least one of movement of the friction element shaft through the top panel, penetration of a distal end of the friction element through the top panel, cleaning debris from the bottom panel with the distal end of the friction element, removing a coating on an upper surface of the bottom panel with the distal end of the friction element, welding of the friction element to the bottom panel, and deformation of the friction element after welding during insertion.
In at least one variation, the method further includes comparing the at least one key FEW monitored parameter with at least one stored key FEW monitored parameter and adjusting the at least one key FEW controlled parameter in real-time as a function of the comparison. In such variations, the at least one stored key FEW monitored parameter can be provided from a remote database.
In some variations, the method further includes installing a plurality of friction elements and collecting and storing the at least one key FEW controlled parameter during the installation of the plurality of friction elements in a remote database.
In at least one variation the method further includes installing a plurality of friction elements and collecting and storing the at least one key FEW monitored parameter during the installation of the plurality of friction elements in a remote database.
In some variations, the method further includes generating an alert in response to the at least one key FEW monitored parameter signaling a failure to complete the at least one key FEW process characteristic. In such variations the at least one key FEW monitored parameter can include the torque not increasing during a predefined portion of the installation of the friction element.
In at least one variation, the method further includes generating an alert in response to the at least one key FEW monitored parameter signaling overfilling of an underhead of the friction element. In such variations the at least one key FEW monitored parameter signaling overfilling of an underhead of the friction element can include a spiked increase in energy consumption during installing of the friction element.
In some variations, the driving and friction welding of the friction element comprises rotating a bit engaged with the friction element with an electric motor and applying an insertion force onto the bit with a servo-motor and the at least one key FEW process characteristic comprises at least one of movement of the friction element shaft through the top panel, penetration of a distal end of the friction element through the top panel, cleaning debris from the bottom panel with the distal end of the friction element, removing a coating on an upper surface of the bottom panel with the distal end of the friction element, welding of the friction element to the bottom panel, and deformation of the friction element during insertion. In such variations the exhibiting completion of the at least one key FEW process characteristic can be a change in the torque and the RPM of the bit can be adjusted in real-time as a function of the change in torque. Also, the applied insertion force on the bit can be adjusted in real-time as a function as of the change in torque.
In another form of the present disclosure, a method of installing a friction element includes driving the friction element through at least a top panel and welding the friction element to a bottom panel using a FEW machine using an electric motor to rotate the friction element at one or more predefined RPMs and a servo-motor to apply one or more axial insertion forces to the friction element. The FEW machine controls at least one key FEW controlled parameter of the FEW machine during installation of the friction element and the at least one key FEW controlled parameter is at least one of RPM of the friction element and applied insertion force on the friction element. The FEW machine also monitors at least one key FEW monitored parameter of the FEW machine during installation of the friction element, and the at least one key FEW monitored parameter is at least one of torque of the electric motor rotating the friction element, time during installation of the friction element, energy consumption during installation the friction element, electric current of the electric motor during installation of the friction element, and electric current of the servo-motor during installation of the friction element. The FEW machine adjusts the at least one key FEW controlled parameter of the FEW machine in real-time as a function of and in response to the at least one key FEW monitored parameter exhibiting completion of at least one key FEW process characteristic such that the friction element is adaptively installed based on the adjusting of the at least one key FEW controlled parameter of the FEW machine, and generates an alert in response to the at least one key FEW monitored parameter signaling a failure to complete the at least one key FEW process characteristic.
In some variations, the method further includes generating an alert in response to the at least one key FEW monitored parameter signaling overfilling of an underhead of the friction element. And in such variations, the at least one key FEW monitored parameter signaling overfilling of an underhead of the friction element includes a spiked increase in energy consumption during installing of the friction element.
In still another form of the present disclosure, a method of installing a friction element includes driving the friction element through at least a top panel and welding the friction element to a bottom panel using a friction element weld (FEW) machine using an electric motor to rotate the friction element at one or more predefined RPMs and a servo-motor to apply one or more axial insertion forces to the restriction element. The method also includes controlling at least one key FEW controlled parameter of the FEW machine during installation of the friction element, monitoring at least one key FEW monitored parameter of the FEW machine during installation of the friction element, and adjusting the at least one key FEW controlled parameter of the FEW machine in real-time as a function of and in response to the at least one key FEW monitored parameter exhibiting completion of at least one key FEW process characteristic such that the friction element is adaptively installed based on the adjusting of the at least one key FEW controlled parameter of the FEW machine. The at least one key FEW controlled parameter is at least one of RPM of the friction element and applied insertion force on the friction element, and the at least one key FEW monitored parameter is at least one of torque of the electric motor rotating the friction element, time during installation of the friction element, energy consumption during installation the friction element, electric current of the electric motor during installation of the friction element, and electric current of the servo-motor during installation of the friction element. In some variations, the method includes generating an alert in response to the at least one key FEW monitored parameter signaling a failure to complete the at least one key FEW process characteristic, and/or generating an alert in response to the at least one key FEW monitored parameter signaling overfilling of an underhead of the friction element.
In at least one variation, the at least one key FEW monitored parameter signaling overfilling of an underhead of the friction element comprises a spiked increase in energy consumption during installing of the friction element.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
During installation of a friction element to form a FEW joint between panels, a number of different key parameters of the FEW process can be controlled and/or monitored. Such parameters include but are not limited to revolutions per minute (RPM) of the friction element, insertion force applied to the friction element, distance traveled by the friction element into the panels, torque of an electric motor rotating the friction element, time during installing the friction element, energy consumption during installing the friction element, electric current of the electric motor rotating the friction element, and electric current of a servo-motor applying the insertion force on the friction element, among others. Also, the FEW process can be characterized by different “stages” such as penetration and movement of the friction element through a panel (e.g., a top or upper panel), cleaning debris from a panel (e.g., a bottom or lower panel) with a distal end of the friction element (via rotation and friction), removing a coating from a panel with the distal end of the friction element, welding of the friction element to the bottom or lower panel, and compression or deformation of the friction element during insertion, among others.
The present disclosure provides a method of installing a friction element via the FEW process. The method accommodates or adjusts in real-time for variations in panels and/or panel assemblies being joined. As used herein, the term “real-time” refers to measuring, monitoring, and adjusting parameters of the FEW process within milliseconds (e.g., less than 20 milliseconds or less than 10 milliseconds) such that the friction element is adaptively installed based on the adjusting of the at least one KEY control parament of the FEW machine 100.
Referring now to
The controller 102 controls an operation of the FEW machine 100, and in some variations an adaptive system 180 for adapting or adjusting the FEW machine 100 before, during and/or after installation for a given friction element 120 and/or a given top panel 130—bottom panel 140 assembly is included.
It should be understood that the friction element 120 is driven (i.e., rotated and moved downwardly with or by the insertion force) by a friction element driver 110 that is rigidly engaged with the spindle 106 and the friction element 120. Particularly, the friction element driver 110 includes a bit 112 and a head support 114 configured to mechanically engage and support the head 122 of the friction element 120 such that the friction element 120 rotates with the spindle 106. Also, the head 122 can include an underhead 123 configured to accept or gather the plastically deformed material 133 from the top panel 130 as shown in
The top panel 130 has a lower surface 134 and is disposed over a bottom (−z direction) panel 140 with an upper surface 142 and a lower surface 144. Also, the top panel 130 and the bottom panel 140 are supported by a support ‘S’ and a downholder 116 applies a downward (−z direction) stabilizing or clamping force ‘F’ onto the top panel 130 to inhibit vibration of the top panel 130 and the bottom panel 140 during installation of the friction element 120.
In some variations, the top panel 130 is a light metal or a light metal alloy such as magnesium, aluminum, titanium, and alloys thereof, among others. In such variations the bottom panel 140 can be a heavier metal or heavier metal alloy such as cast iron, steel, stainless steel, copper, and copper alloys, among others. In at least one variation the top panel 130 is an aluminum alloy and the bottom panel is a steel, e.g., an advanced high-strength steel. It should be understood that in such variations the friction element 120 can be formed from a steel. In other variations, the top panel 130 is a heavier metal or heavier metal alloy and the bottom panel 140 is a light metal or a light metal alloy. It should be understood that in such variations the friction element 120 can be formed from a light metal or light metal alloy.
Non-limiting examples of a thickness (z direction) of the top panel 130 include thicknesses between about 0.5 millimeter (mm) and 4.0 mm and non-limiting examples of a thickness of the bottom panel 140 include thicknesses greater than or equal to about 1 mm. And while
Referring to
Referring to
Referring to
As noted above, a plurality of parameters define installation of a given friction element 120 with non-limiting examples of key FEW parameters including RPM of the friction element 120 during stage I, II, III, and/or IV (referring to herein as “stages I-IV”), insertion force applied to the friction element 120 during stages I-IV, distance traveled (−z direction) by the friction element 120 during stages I-IV, torque of the electric motor 103 rotating the friction element 120 during stages I-IV, time during stages I-IV, energy consumption (also known as “process energy”) during stages I-IV, electric current of the electric motor 103 rotating the friction element 120 during stages I-IV, and electric current of the servo-motor 104 applying the insertion force on the friction element 120 during stages I-IV.
Each of the stages I-IV is executed controlling and monitoring one or more key FEW parameters of the FEW machine 100. For example, in some variations, the controller 102 directs the FEW machine 100 to execute a first RPM and a first target insertion force during stage I, a second RPM and a second target insertion force during stage II, a third RPM and a third target insertion force during stage III, and a fourth RPM and a fourth target insertion force during stage IV. In some variations, the parameters are the same during different stages, while in other variations the parameters are different during different stages.
In some variations of the present disclosure, torque is monitored (i.e., torque is a key FEW monitored parameter) and key FEW parameters such as RPM of the friction element 120 and/or insertion force applied to the friction element 120 are controlled and adjusted in real-time (i.e., RPM and insertion force are key FEW controlled parameters) during installing of the friction element 120. And in at least one variation, such key FEW controlled parameters are adjusted in real-time as a function of and in response to the torque exhibiting completion of a key FEW process characteristic has occurred.
Referring to
Referring to
Referring to
It should be understood that such variables during installation of friction elements 120 to form FEW joints 160 can result in variations in joint quality when process parameters are held constant during driving of the friction element 120 through the top panel 130 and welding the friction element 120 to the bottom panel 140. For example, traditional friction element welding systems typically control process parameters as a function of the height or depth (z direction) of the friction element 120 and/or the bit 112 during the FEW process. Accordingly, and given that thickness variations of the top panel 130, debris variations between the top panel 130 and the bottom panel 140, and/or coating variations of a coating on the bottom panel 140 can be present, monitoring and/or controlling installation friction elements 120 as a function of the friction element 120 and/or the bit 112 may not be desirable.
Referring to
Generally, to join a panel assembly 150 together, a plurality of friction elements 120 are installed. In addition, the FEW machine 100 is used to install a plurality of friction elements 120 into a plurality of panel assemblies 150 being manufactured in an assembly line manufacturing facility. Moreover, the deformation of the top panel 130 (and any intermediate panels), and welding of the friction element 120 to the bottom panel 140, depend on the material properties of the friction element 120 and the panels of the panel assembly 150, amount of debris 170 between panels of a panel assembly 150, and variations of coatings 172 included in panel assemblies 150. Therefore, the material properties of the friction element 120 and the panels of the panel assembly 150, the thicknesses of the panels of the panel assembly 150, the amount of debris 170 that is present, and a coating 172 that may be present affect the robustness and quality of the FEW joints of the joined assemblies.
The plurality of sensors 182, 184, 186 are disposed at the FEW machine 100 and/or proximal to the panel assembly 150 for sensing and monitoring the operating conditions of the FEW machine 100 and/or conditions of the panel assembly 150 prior to, during, and after installation of the friction element 120. The operating conditions of the FEW machine 100 include the key FEW controlled parameters and the key FEW monitored parameters mentioned above, among others. For example, the plurality of sensors 182, 184, 186 may include a temperature sensor, a height (z direction) sensor, an RPM sensor, a torque sensor, an electric current sensor, and a time sensor, among others. The temperature sensor may be used to measure an in-situ temperature at a position near or proximal to the FEW joint 50 as it is being formed. The height sensor is used to measure a height of the bit 112 and thus a height of the head 122 and/or distal end of the friction element 120. The RPM sensor is used to measure an in-situ RPM of the bit 112 and thus an in-situ RPM of the friction element 120, the torque sensor is used to measure an in-situ torque of the electric motor 103 and thus a torque being applied to the friction element 120, and the current sensor is used to measure an in-situ current being drawn by or supplied to the electric motor 103 and/or the servo-motor 104. The time sensor is used to measure time during installation of the friction element 120 during stages I-IV.
The plurality of sensors 182, 184, 186 send signals corresponding to the various measurements to the microprocessor 188. The microprocessor 188 is configured to store, receive, calculate and send key FEW controlled parameters and/or key FEW monitored parameters to the controller 102 prior to, during, and/or after installation of the friction element 120 into the panel assembly 150. In some variations the microprocessor 188 stores the key FEW controlled parameters and/or key FEW monitored parameters in a memory 190 or a remote database (not shown). The controller 102 may be provided with the key FEW controlled parameters and/or key FEW monitored parameters wirelessly from the memory 190 or the remote database.
In some variations, to obtain one or more initial key FEW controlled parameters and/or key FEW monitored parameters, one or more trial installation processes may be performed so that the plurality of sensors 182, 184, 186 may obtain measurements of certain parameters prior to, during, and after the trial installation process. For example, and with reference to
As shown in
It should be understood that such monitoring provides for determination of various aspects of the installation process such as whether or not a successful friction element installation has occurred, gradual changes in one or more operation parameters during installing a plurality of friction elements 120, among others. For example, in some variations the monitoring of a key FEW monitored parameter signals that at least one of the key FEW process characteristics (e.g., stage I, II, III, and/or IV) has not been completed or successfully executed. And in such variations the microprocessor 188 is configured to generate an alert in response to such a signal (or lack thereof). In the alternative, or in addition to, the monitoring of a key FEW monitored parameter signals that an undesired event has occurred during installation of a friction element 120 (e.g., overfilling of an underhead 123 of the friction element). And in such variations the microprocessor 188 is configured to generate an alert in response to such a signal.
In some variations the measurements are sent to the microprocessor 188 for process and analysis in order to obtain an optimum installation result. Therefore, through the trial installation process, the controller 102 controls the FEW machine 100 to apply the friction element 120 with a predetermined RPM and insertion force suitable for the particular friction element 120 and the particular panel assembly 150, and monitors the torque for a signature of a successful installation result which is subsequently stored in the memory 190 and/or remote database. And in at least one variation, the trial installation process includes installation of a plurality of friction elements 120 using a plurality of RPMs and insertion forces with an analysis of which RPM and insertion force or which range of RPMs and/or range of insertion forces provide an optimum installation result. Also, the torques for successful installations and/or an average of the torques are subsequently stored in the memory 190 and/or remote database.
The controller 102 is in communication with the microprocessor 188 and FEW machine 100 for controlling the operation of the FEW machine 100 based on the key FEW controlled parameters and/or key FEW monitored parameters. The controller 102 then sets up the FEW machine 100 based on the parameters obtained during the trial processes (e.g., RPM and insertion force as a function of time or as a function of a given torque versus time signature) for an optimum FEW joint result. The controller 102 may adjust one or more key FEW controlled parameters of the FEW machine 100 based on one or more key FEW monitored parameters such that the friction element 120 is adaptively installed into the panel assembly 150.
During installation of the friction element 120, the various parameters are continuously obtained to provide a feedback to the controller 102, so that the controller 102 can control the FEW machine in a closed-loop manner, thereby achieving real time control of the process through sensed values. The feedback loop also monitors and tracks the installed friction element head height, thereby eliminating the need for a post-insertion checks. In addition, in some variations the microprocessor 188 and memory 190 include one or more algorithms configured to provide machine learning from the various parameters continuously obtained during operation of the FEW machine 100. Stated differently, the one or algorithms use the measurements from the trial installation process and/or subsequent successful installations of the friction elements 120 and build a model based on the measurements that make predictions and/or decisions related to present and future installations of the friction elements without being explicitly programmed to do so. Non-limiting examples of the one or more algorithms include supervised learning algorithms (e.g., nearest neighbor algorithm, Vaive Baye algorithm, decision trees algorithm, linear regression algorithm, support vector machine (SVM) algorithm, neural network algorithm) unsupervised learning algorithms (e.g., k-means clustering algorithm, association rules algorithm) semi-supervised algorithms, and reinforcement learning algorithms (e.g., Q-learning algorithm, temporal difference (TD) algorithm, deep adversarial network algorithm) among others.
The controller 102 may be a smart phone, a tablet, a laptop, and a personal computer. Alternatively, the controller 102 may integrated into the FEW machine 100 to assist in monitoring and storing signals from the various sensors 182, 184, 186. Optionally, the adaptive system 180 may include a graphical user interface (GUI) 52, which may be a separate component from the controller 102 and in communication with the controller 102, or which may reside within the controller 102.
Referring to
In one example, and with reference back to
Referring to
In some variations, the top panels 130 from the first lot T1 compared to the top panels 130 of the second lot T2 have variations such as different thicknesses, different surface oxides, different surface oxide thicknesses, and/or a different surface film/lubricants, among others. Similarly, the bottom panels 140 from the first lot B1 compared to the bottom panels 140 form the second lot B2 have variations such as different coatings (e.g., Al—Si based coating or Zn based coating) and different surface film/lubricants, among others. And the amount of debris between a given top panel 130 and a given bottom panel 140 can vary from individual panel assemblies 150.
It should be understood that top panels 130 within a given lot can also have variations such as different thicknesses, different surface oxides, different surface oxide thicknesses, and different surface film/lubricants, among others. That is, variation between top panels 130 and bottom panels 140 can be present within a given lot of panels and between separate lots of panels. However, and unlike traditional FEW machines and/or systems that monitor such differences upstream from the FEW machine 100, the system 30 accommodates for such variations in real-time.
In some variations, the FEW machine 100 with the adaptive system 180 measures at least one key FEW parameter during stage I, stage II, stage III, and/or stage IV of the installation of at least one friction element 120 in a given panel assembly 150. In addition, the adaptive system 180 monitors stage I, stage II, stage III, and/or stage IV via at least one measured key FEW parameter and adjusts at least one of stage I, stage II, stage III, and/or stage IV as a function of the at least one key FEW parameter being measured.
Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.
As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”
In this application, the term “controller” and/or “module” may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components (e.g., op amp circuit integrator as part of the heat flux data module) that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.
The term memory is a subset of the term computer-readable medium. The term computer-readable medium, as used herein, does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); the term computer-readable medium may therefore be considered tangible and non-transitory. Non-limiting examples of a non-transitory, tangible computer-readable medium are nonvolatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).
The apparatuses and methods described in this application may be partially or fully implemented by a special purpose computer created by configuring a general-purpose computer to execute one or more particular functions embodied in computer programs. The functional blocks, flowchart components, and other elements described above serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer.
The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.
