JP7415843B2 - Automatic joining system - Google Patents

Description

TECHNICAL FIELD The present invention relates to automatic joining systems.

For example, Patent Document 1 discloses a technique in which end portions of metal members are butted against each other to form an abutment portion, and a rotary tool is moved along the abutment portion to perform friction stir welding.

JP 2018-20345 Publication

If the arrangement position of the metal member is shifted or the ridgeline of the metal member is curved, there is a risk that the rotary tool will deviate from the preset movement route. In particular, if the height positions of the surfaces of metal parts differ, even a slight shift in the position of the rotating tool can cause problems such as a large number of burrs, rough joint surfaces, and undercuts at the joint. There is a risk.

From this viewpoint, an object of the present invention is to provide an automatic welding system that can suitably friction stir weld metal members having different surface height positions.

In order to solve the above problem, the present invention provides a first metal member and a second metal member arranged on a pedestal such that the surface of the second metal member is lower than the surface of the first metal member. a fixing device that butts the end faces together to form an abutment portion with a step, a friction stirrer that includes a rotary tool that performs friction stir welding of the abutment portion, and a friction stir device that performs friction stir welding of the abutment portion; a measuring unit that measures a ridgeline position of a member and at least one of a position of the rotary tool and a load applied to the rotary tool; and a control device that controls the fixing device and the friction stirrer; The rotary tool has a proximal pin and a distal pin formed continuously with the proximal pin, the proximal pin has a taper angle larger than the distal pin, and the proximal pin has a taper angle larger than the distal pin. A stepped pin stepped portion is formed on the outer circumferential surface of the proximal pin, and the control device controls the rotation when performing friction stir welding of the butt portion based on the ridge line position before performing friction stir welding. A movement route is set for the tool to move, and the friction stirrer applies friction along the movement route while maintaining a predetermined aiming angle of the rotary tool and pressing the plastic flow material with the bottom surface of the step of the pin step. Stir welding is performed, and the control device determines whether at least one of the position of the rotary tool during friction stir welding and the load during friction stir welding is within a predetermined numerical range. It is characterized by having the following.

According to such an automatic welding system, since the movement route of the rotary tool is set based on the ridgeline position of the first metal member measured before performing friction stir welding, it is possible to easily set an accurate movement route. In addition, by performing friction stir welding while holding down the plastic flow material at the bottom of the pin step of the proximal pin, it is possible to prevent the occurrence of burrs and undercuts and to make the joining surface clean. Furthermore, by providing a determination unit that determines whether at least one of the position of the rotary tool during friction stir welding and the load applied to the rotary tool is within a predetermined numerical range, the position of the rotary tool during friction stir welding and the load applied to the rotary tool can be It is possible to prevent problems caused by at least one of the loads applied to the.

Further, in the present invention, when it is determined that at least one of the position of the rotary tool during friction stir welding and the load during friction stir welding is outside the predetermined numerical range, the control device controls the position of the rotary tool during friction stir welding. It is preferable to calculate a corrected movement route in which the position of the rotary tool is reset according to the position of the rotary tool.

According to such an automatic joining system, joining accuracy can be further improved.

Further, when it is determined that at least one of the position of the rotary tool during friction stir welding and the load during friction stir welding is outside the predetermined numerical range, the control device controls the first metal member and the second metal member. It is preferable to determine that the metal member is outside the numerical value range.

According to such an automatic joining system, quality control can be easily performed.

The measurement unit measures the ridge line position and also measures the position of the rotary tool, and the control device determines the movement route and the movement route based on the ridge line position before performing friction stir welding. It is preferable that a permissible range is set, and the determination unit determines whether the position of the rotary tool during friction stir welding is within the permissible range.
The measurement unit may measure the ridgeline position and the load, and the determination unit may determine whether the load during friction stir welding is within a predetermined numerical range. preferable.

Further, the measuring unit measures the position of the ridge line and the position of the rotating tool and the load, and the determining unit measures the position of the rotating tool during friction stir welding and the load during friction stir welding. It is preferable to determine whether at least one of the values is within a predetermined numerical range.

Moreover, it is preferable that the position of the said rotary tool is a left-right position with respect to the advancing direction of the said rotary tool.

According to such an automatic welding system, it is possible to prevent problems caused by the left and right positions of the rotating tool during friction stir welding.

Moreover, it is preferable to further include an inspection section that measures at least one of the burr height and surface roughness of the joint after friction stir welding.

According to such an automatic joining system, quality control can be performed more easily.

The friction stir device also includes a load measuring section that measures an axial reaction load acting on the rotary tool, and the friction stir device measures the reaction load based on the result of the load measuring section. It is preferable that the load is controlled to be approximately constant.

According to such an automatic joining system, the reaction load of the rotary tool can be kept approximately constant, so joining accuracy can be improved.

Further, it is preferable that the front side of the pedestal is formed of an aluminum or aluminum alloy plate, and an anodized coating is applied to the surface.

According to such an automatic joining system, the wear resistance and corrosion resistance of the pedestal can be improved.

According to the automatic welding system according to the present invention, metal members having different surface height positions can be suitably friction stir welded.

FIG. 1 is a side view showing a rotary tool according to an embodiment of the present invention. FIG. 3 is an enlarged cross-sectional view of the rotary tool. It is a sectional view showing a first modification of a rotary tool. It is a sectional view showing a second modification of the rotary tool. It is a sectional view showing a third modification of a rotary tool. 1 is an overall perspective view of an automatic joining system according to a first embodiment of the present invention. FIG. 1 is a perspective view of essential parts of an automatic joining system according to a first embodiment. FIG. 1 is a block diagram of an automatic joining system according to a first embodiment. FIG. 3 is a schematic plan view for explaining the tolerance range according to the first embodiment. It is a schematic plan view for demonstrating the difference based on 1st embodiment. FIG. 2 is a schematic plan view for explaining the position of a rotating tool during friction stir welding according to the first embodiment. FIG. 3 is a cross-sectional view showing an inserted state of the rotary tool according to the first embodiment. It is a flowchart which shows an example of operation of the automatic joining system concerning a first embodiment. It is a schematic plan view for demonstrating the corrected movement route based on the 1st modification of 1st embodiment. It is a schematic plan view for demonstrating the difference based on the 1st modification of 1st embodiment. It is a schematic plan view which shows the measurement direction based on the 2nd modification of 1st embodiment. It is a schematic sectional view showing the measurement method concerning the second modification of the first embodiment. FIG. 7 is a schematic plan view for explaining a method of calculating a corrected movement route according to a second embodiment of the present invention. FIG. 7 is a schematic plan view for explaining a modified movement route according to another embodiment. FIG. 7 is a schematic plan view for explaining differences in other forms. FIG. 6 is a schematic diagram showing the step dimensions of the first metal member and the second metal member in Test 1 of the example. FIG. 3 is a schematic side view showing a state where the step size of the first metal member and the second metal member is large in Test 1 of the example. FIG. 3 is a schematic side view showing a state in which the step size of the first metal member and the second metal member is small in Test 1 of the example. FIG. 7 is a schematic side view showing another state in which the step size of the first metal member and the second metal member is small in Test 1 of the example. It is a graph showing the relationship between the step size and the burr height in Test 1 of the example. It is a graph showing the relationship between the traveling distance and the amount of gap before joining in Test 2 of the example. It is a graph showing the relationship between the gap amount on the start position side and the burr height on the start position side in Test 2 of the example. It is a graph showing the relationship between the gap amount on the end position side and the burr height on the end position side in Test 2 of the example. FIG. 3 is a schematic plan view showing an outline of Test 3 of the example. It is a graph showing the relationship between the joining distance and the Y direction position in Test 3 of the example. FIG. 3 is a cross-sectional view at a position where the bonding distance is 100 mm in Test 3 of the example. FIG. 3 is a cross-sectional view at a position where the bonding distance is 600 mm in Test 3 of the example. It is a sectional view of the position where the joining distance of Test 3 of Example is 800 mm. FIG. 3 is a cross-sectional view at a position where the bonding distance is 1000 mm in Test 3 of the example. FIG. 3 is a cross-sectional view at a position where the bonding distance is 1200 mm in Test 3 of the example. FIG. 3 is a cross-sectional view at a position where the bonding distance is 1800 mm in Test 3 of the example. FIG. 3 is a macro cross-sectional view of the butt portion at a position where the bonding distance is 100 mm in Test 3 of the example. FIG. 3 is a macro cross-sectional view of the abutting portion at a position where the bonding distance is 600 mm in Test 3 of the example. FIG. 3 is a macro cross-sectional view of the abutting portion at a position where the bonding distance is 800 mm in Test 3 of the example. FIG. 3 is a macro cross-sectional view of the abutting portion at a position where the bonding distance is 1000 mm in Test 3 of the example. It is a macroscopic cross-sectional view of the butt part at the position where the joining distance of Test 3 of Example is 1200 mm. FIG. 3 is a macro cross-sectional view of the abutting portion at a position where the joining distance is 1800 mm in Test 3 of the example. It is a graph showing the relationship between the position of the rotary tool, the burr height, and the oxide film height in Test 3 of the example. FIG. 7 is a schematic plan view showing the position of a rotating tool during friction stir welding in Test 3 of the example. It is a graph showing the relationship between bonding speed and cavity defect size in Test 3 of Example. 7 is a graph showing the running trajectory of the rotary tool in Test 5. It is a macrostructure diagram and a microstructure diagram of each position in Test 5. FIG. 7 is a schematic plan view for explaining a method of calculating a corrected movement route according to Test 6. FIG. 7 is a graph showing the travel locus of the rotary tool in Test 6. It is a macroscopic organization chart of each position in Test 6. It is a microstructure diagram of each position in Test 6. 12 is a graph showing the difference between the running trajectories of the rotary tool in Test 5 and Test 6. FIG. 7 is a cross-sectional view showing a joint in Test 7. It is a graph showing the relationship between the Y position of the rotary tool and the load in Test 7 (1). It is a macro organization chart of each position in Test 7 (1). It is a graph showing the relationship between the Yn value of the rotary tool and the load Fz in Test 7(1). The macro-organizational diagram and micro-organizational diagram of cases KA, KB, KC, and KD are shown in Test 7 (1). It is a graph showing the relationship between the Yn value of the rotary tool and the load Fz in Test 7 (2). It is a graph showing the relationship between the Yn value of the rotary tool and the load Fz in Test 7 (3).

Embodiments of the present invention will be described with reference to the drawings as appropriate. The present invention is not limited only to the following embodiments. Furthermore, some or all of the components in the embodiments can be combined as appropriate. First, the rotary tool used in the automatic joining system according to this embodiment will be explained.

[A. Rotate tool]
A rotary tool is a tool used for friction stir welding. As shown in FIG. 1, the rotary tool F is made of tool steel, for example, and mainly includes a base shaft portion F1, a proximal pin F2, and a distal pin F3. The base shaft portion F1 has a cylindrical shape and is a portion connected to the main shaft of the friction stirrer.

The proximal pin F2 is continuous with the base shaft portion F1 and tapers toward the distal end. The proximal pin F2 has a truncated cone shape. The taper angle A of the proximal pin F2 may be set as appropriate, and is, for example, 135 to 160°. When the taper angle A is less than 135° or more than 160°, the bonded surface roughness after friction stirring becomes large. The taper angle A is larger than the taper angle B of the tip end pin F3, which will be described later. As shown in FIG. 2, a step-like pin stepped portion F21 is formed on the outer circumferential surface of the proximal pin F2 over the entire height direction. The pin step portion F21 is spirally formed clockwise or counterclockwise. That is, the pin stepped portion F21 has a spiral shape when viewed from above, and has a stepped shape when viewed from the side. In this embodiment, in order to rotate the rotary tool F clockwise, the pin stepped portion F21 is set counterclockwise from the base end side to the distal end side.

In addition, when rotating the rotary tool F to the left, it is preferable to set the pin step part F21 clockwise from the base end side to the distal end side. As a result, the plastic flow material is guided to the tip side by the pin stepped portion F21, so it is possible to reduce metal overflowing to the outside of the metal members to be welded. The pin step portion F21 includes a step bottom surface F21a and a step side surface F21b. The distance X1 (horizontal distance) between the vertices F21c and F21c of the adjacent pin step portions F21 is appropriately set according to the step angle C and the height Y1 of the step side surface F21b, which will be described later.

The height Y1 of the stepped side surface F21b may be set as appropriate, and is set to, for example, 0.1 to 0.4 mm. When the height Y1 is less than 0.1 mm, the bonding surface roughness becomes large. On the other hand, if the height Y1 exceeds 0.4 mm, the bonding surface roughness tends to increase, and the number of effective step portions (the number of pin step portions F21 in contact with the metal member to be welded) also decreases.

The step angle C formed between the step bottom surface F21a and the step side surface F21b may be set as appropriate, but is set to 85 to 120 degrees, for example. In this embodiment, the step bottom surface F21a is parallel to the horizontal plane. The step bottom surface F21a may be inclined within a range of -5° to 15° with respect to the horizontal plane from the rotation axis of the tool toward the outer circumference (minus indicates downward with respect to the horizontal plane, positive indicates downward with respect to the horizontal plane). above). The distance X1, the height Y1 of the step side surface F21b, the step angle C, and the angle of the step bottom surface F21a with respect to the horizontal plane are such that when friction stirring is performed, the plastic fluid material does not stay inside the pin step portion F21 and adhere to the outside. It is appropriately set so that the joint surface roughness can be reduced by pressing the plastic flow material at the bottom surface F21a of the step.

As shown in FIG. 1, the distal pin F3 is formed continuously from the proximal pin F2. The tip side pin F3 has a truncated cone shape. The tip of the tip side pin F3 is a flat surface F4 perpendicular to the rotation axis. The taper angle B of the distal pin F3 is smaller than the taper angle A of the proximal pin F2. As shown in FIG. 2, a spiral groove F31 is carved on the outer circumferential surface of the tip end pin F3. The spiral groove F31 may be clockwise or counterclockwise, but in this embodiment, in order to rotate the rotary tool F clockwise, it is carved counterclockwise from the base end toward the distal end.

In addition, when rotating the rotary tool F counterclockwise, it is preferable to set the spiral groove F31 clockwise from the base end side to the distal end side. As a result, the plastic flow material is guided to the tip side by the spiral groove F31, so it is possible to reduce metal overflowing to the outside of the metal members to be welded. The spiral groove F31 includes a spiral bottom surface F31a and a spiral side surface F31b. The distance (horizontal distance) between the vertices F31c and F31c of adjacent spiral grooves F31 is defined as length X2. The height of the spiral side surface F31b is defined as a height Y2. The spiral angle DA formed by the spiral bottom surface F31a and the spiral side surface F31b is, for example, 45 to 90 degrees. The spiral groove F31 has the role of increasing frictional heat by contacting the metal member to be welded and guiding the plastic fluid material to the tip side.

The design of the rotary tool F can be changed as appropriate. FIG. 3 is a side view showing a first modification of the rotary tool of the present invention. As shown in FIG. 3, in the rotary tool FA according to the first modification, the step angle C between the step bottom surface F21a and the step side surface F21b of the pin step portion F21 is 85 degrees. The step bottom surface F21a is parallel to the horizontal surface. In this way, the step bottom surface F21a is parallel to the horizontal plane, and the step angle C may be an acute angle within a range where the plastic fluid material stays in the pin step portion F21 during friction stirring and escapes to the outside without sticking. .

FIG. 4 is a side view showing a second modification of the rotary tool of the present invention. As shown in FIG. 4, in the rotary tool FB according to the second modification, the step angle C of the pin step portion F21 is 115°. The step bottom surface F21a is parallel to the horizontal surface. In this way, the step bottom surface F21a may be parallel to the horizontal plane, and the step angle C may be an obtuse angle within the range that functions as the pin step portion F21.

FIG. 5 is a side view showing a third modification of the rotary tool of the present invention. As shown in FIG. 5, in the rotary tool FC according to the third modification, the step bottom surface F21a is inclined upward by 10 degrees with respect to the horizontal plane toward the outer circumferential direction from the rotation axis of the tool. The stepped side surface F21b is parallel to the vertical plane. In this way, the step bottom surface F21a may be formed to be inclined upward from the horizontal plane toward the outer circumferential direction from the rotation axis of the tool within a range that can suppress the plastic flow material during friction stirring.

[B. First embodiment]
[B-1. Automatic joining system]
Next, as shown in FIG. 6, an automatic joining system 1 according to a first embodiment of the present invention will be described. In the following description, the surface opposite to the "back surface" will be referred to as the "front surface."

As shown in FIGS. 6 and 7, the automatic joining system 1 includes a conveying device 2, a fixing device 3, a friction stir device 4, and a control device 5. The automatic joining system 1 is a system that automatically friction stir welds the ends of a first metal member 101 and a second metal member 102.

As shown in FIG. 7, the first metal member 101 and the second metal member 102 are made of a friction stirable metal such as aluminum, aluminum alloy, titanium, titanium alloy, magnesium, magnesium alloy, copper, copper alloy, etc. It is a plate-like member. The plate thickness dimension of the second metal member 102 is smaller than the plate thickness dimension of the first metal member 101. In this embodiment, the first metal member 101 and the second metal member 102 are made of, for example, an aluminum alloy.

As shown in FIG. 7, the end surface 101a of the first metal member 101 and the end surface 102a of the second metal member 102 are butted against each other to form a butt portion J1. Since the back surface 101c of the first metal member 101 and the back surface 102c of the second metal member 102 are flush with each other, a step is formed between the surfaces 101b and 102b. That is, the end surfaces 101a and 102a are butted against each other such that the surface 102b of the second metal member 102 is lower in height than the surface 101b of the first metal member 101.

Note that the first metal member 101 and the second metal member 102 are sequentially conveyed in each friction stir welding process, and are taken out of the fixing device 3 after welding. For identification, serial numbers (hereinafter referred to as "work numbers") shall be given in the order of joining. Further, in this embodiment, although the first metal member 101 and the second metal member 102 have different plate thicknesses, the first metal member 101 and the second metal member 102 have the same plate thickness, and the surface 101b, 102b may be butted against each other with a difference in height.

[B-1-1. Conveyance device]
As shown in FIGS. 6 and 8, the transfer device 2 includes an arm robot 11, a base frame 12, and four suction sections 13. The arm robot 11 is electrically connected to the control device 5. The transport control unit 51 (see FIG. 8) of the control device 5 is a device that controls the transport operation of the arm robot 11. The arm robot 11 includes a multi-jointed arm 11a and an arm drive section (not shown), and is capable of three-dimensional movement based on a control signal transmitted from the transfer control section 51.

The base frame 12 is a frame-shaped member attached to the tip of the arm of the arm robot 11. The base frame 12 is attached perpendicularly to the axial direction of the arm 11a. The suction parts 13 are provided at the four corners of the base frame 12 perpendicularly to the plane of the base frame 12. The suction unit 13 can apply negative pressure or positive pressure to the suction pad 13a provided at the tip based on a control signal from the transport control unit 51. That is, by applying negative pressure to the suction pad 13a, the four corners of the first metal member 101 or the second metal member 102 can be suctioned, and by applying positive pressure to the first metal member 101 or the second metal member 102 can be removed. Thereby, the arm robot 11 can transport the first metal member 101 and the second metal member 102 to preset positions of the fixing device 3, respectively. For example, the first metal member 101 and the second metal member 102 before joining are placed in a material placement area (not shown) located within a range where the first metal member 101 and the second metal member 102 can be adsorbed by the conveyance device 2. ) can be stacked and arranged. The transport device 2 can transport the first metal member 101 and the second metal member 102 placed in the material placement area one by one to a predetermined position on the pedestal 21 .

Further, after friction stir welding, the arm robot 11 takes out the welded first metal member 101 and second metal member 102 (hereinafter also referred to as "metal members 103 to be welded") from the fixing device 3 and places them in a predetermined position. can be transported to the desired location. For example, the arm robot 11 transports the metal member 103 to be welded to the acceptable product placement area 15 (see FIG. 6) when the control device 5 determines that the product is an acceptable product, and transports the metal member 103 to be welded when the product is determined to be outside the numerical range. The bonded metal member 103 can be transported to the out-of-value range product placement area 16. Note that a product outside the numerical value range refers to a metal member 103 to be welded that is determined by the control device 5 to be not within a predetermined numerical value range (outside the numerical value range).

[B-1-2. Fixation device]
The fixing device 3 is a device that fixes the first metal member 101 and the second metal member 102 and serves as a pedestal for friction stir welding. As shown in FIGS. 6 and 8, the fixing device 3 includes a pedestal 21, a suction section 22, a temperature adjustment section 23, and a clamp section 24.

<Frame>
The pedestal 21 is a pedestal on which the first metal member 101 and the second metal member 102 are arranged on the upper surface, and has a rectangular parallelepiped outer shape. A reference position Y0 perpendicular to the longitudinal ridgeline 21a of the pedestal 21 is set at the center position on the upper surface of the pedestal 21. The reference position Y0 is a position that serves as a reference for positioning the first metal member 101 and the second metal member 102. The first metal member 101 and the second metal member 102 are arranged so as to form an abutting portion J1 at the reference position Y0. Here, the X direction, Y direction, and Z direction in the following description are based on the arrows shown in FIGS. 6 and 7. As shown in FIGS. 6 and 7, the X direction, Y direction, and Z direction are orthogonal to each other. The X direction is parallel to the reference position Y0 on the upper plane of the pedestal 21. The Y direction is perpendicular to the reference position Y0 on the upper plane of the pedestal 21. The Z direction is perpendicular to the upper plane of the pedestal 21.

A groove 25a is formed in the center of the front surface of the pedestal 21 along the reference position Y0. A mounting portion 25 is provided in the groove 25a at a position corresponding to the butt portion J1 along the reference position Y0. In this embodiment, the mounting portion 25 has a length that is approximately the same as the length of the pedestal 21 in the X direction, and has a width equal to the width of the plastic flow region formed by friction stir welding between the first metal member 101 and the second metal member 102. The width is the same as or larger than that. Moreover, the mounting portion 25 is formed of an aluminum or aluminum alloy plate. An anodic oxide film is applied to the surface side of the mounting portion 25. The mounting section 25 is arranged on the surface of the pedestal 21 and supports the first metal member 101 and the second metal member 102 placed thereon, and also supports the first metal member 101 and the second metal member 102. Functions as a backing plate for temperature adjustment.

<Suction part>
The suction unit 22 is a device that suctions the end of the second metal member 102 from the back surface 102c side. The suction section 22 includes a suction tube 26, a hose 28, and a suction device 29. The suction tube 26 is a hollow tube with a rectangular cross section. As shown in FIG. 7, the suction tube 26 is installed in a groove 25a provided on the surface side of the pedestal 21 in parallel to the X direction. In the groove 25a, the mounting portion 25 disposed on the first metal member 101 side and the suction pipe 26 disposed on the second metal member 102 side are installed adjacent to each other in the longitudinal direction. The surface of the suction tube 26 and the surface of the mounting portion 25 are flush with each other. In this embodiment, for example, the ridge line 26a on the first metal member 101 side in the surface longitudinal direction of the suction tube 26 is set to be located on the second metal member 102 side with respect to the reference position Y0.

A plurality of holes 27 are opened on the surface of the suction tube 26 at predetermined intervals. The suction pipe 26 is connected to a suction machine 29 via a hose 28. The suction machine 29 is a machine that generates negative pressure by suction, and is electrically connected to the suction control section 52 (see FIG. 8) of the control device 5. The suction control unit 52 of the control device 5 controls the suction operation of the suction machine 29. In other words, the suction device 29 can be turned on or off based on the control signal sent from the suction control unit 52. By generating negative pressure around the hole 27, the suction section 22 can suck the end of the second metal member 102 and prevent the end from rising.

In this embodiment, the second metal member 102 is sucked, but both the first metal member 101 and the second metal member 102 may be sucked. A plurality of suction tubes 26 may be provided.

<Temperature adjustment section>
As shown in FIGS. 6 and 8, the temperature adjustment unit 23 is provided inside the pedestal 21 of the fixing device 3, and is a device that measures the temperature of the pedestal 21 and adjusts the temperature of the surface of the pedestal 21. The temperature adjustment section 23 includes a heater (not shown) and a temperature sensor 23a (see FIG. 8). A mounting section 25, a temperature sensor 23a, and a heater are provided in this order from the front side of the pedestal 21. The heater is arranged so as to correspond to approximately the same position as the mounting portion 25 along the reference position Y0. The temperature sensor 23a measures the temperature of the mounting section 25, and the heater adjusts the temperature of the mounting section 25. The temperature adjustment section 23 is electrically connected to the temperature control section 53 of the control device 5. The temperature adjustment section 23 is configured to be able to control the operation of the heater based on a control signal transmitted from the temperature control section 53. For example, the configuration is such that the mounting section 25 can be heated by operating a heater, or the mounting section 25 can be cooled to around room temperature by stopping the heater. In this way, the temperature adjustment section 23 can measure the temperature of the mounting section 25 on the surface of the pedestal 21 using the temperature sensor 23a, and adjust the temperature of the mounting section 25 on the surface of the pedestal 21 using the heater. By adjusting the temperature of the mounting portion 25, the temperatures of the first metal member 101 and the second metal member 102 can be increased or decreased. Note that the temperature adjustment section 23 may further include a cooling device, and the mounting section 25 may be cooled by operating this cooling device.

Before performing each friction stir welding, the results measured by the temperature sensor 23a of the temperature adjustment section 23 are transmitted to the temperature control section 53 of the control device 5 in association with the workpiece number, and are also stored in the storage section 44. Ru. The result measured by the temperature sensor 23a may be displayed on the display section 43 of the control device 5 together with the work number.

<Clamp part>
As shown in FIGS. 7 and 8, the clamp section 24 is a device that is movably arranged around the pedestal 21 and fixes or releases the first metal member 101 and the second metal member 102 with respect to the pedestal 21. . The clamp unit 24 fixes or releases the first metal member 101 and the second metal member 102 based on a control signal transmitted from the clamp control unit 54 (see FIG. 8) of the control device 5. That is, after the first metal member 101 and the second metal member 102 are placed on the pedestal 21, the clamp part 24 approaches the first metal member 101 and the second metal member 102, and The two metal members 102 are immovably restrained on the pedestal 21. On the other hand, when the friction stir welding is completed, the clamp part 24 releases its restraint and retreats to a position where it does not interfere when the metal member 103 to be welded is taken out.

[B-1-3. Friction stirrer]
As shown in FIGS. 6 and 8, the friction stirrer 4 includes an arm robot 31, a rotation drive section 32, a load application section 33, a measurement section 34, and a load measurement section 35. . The friction stir device 4 is a device that performs friction stir welding of the first metal member 101 and the second metal member 102 by rotating and moving the rotary tool F.

The arm robot 31 is electrically connected to the control device 5. The friction stir control unit 55 (see FIG. 8) of the control device 5 is a device that controls the friction stir welding operation of the arm robot 31. The arm robot 31 includes a multi-joint arm 31a and an arm drive section (not shown), and is capable of three-dimensional movement based on a control signal transmitted from the friction stir control section 55.

The rotation drive section 32 is configured to include rotation drive means such as a motor that rotates the rotary tool F. The rotation drive unit 32, the load application unit 33, and the load measurement unit 35 are housed in a housing 39 (see FIG. 6). A chuck part to which the rotary tool F can be attached and detached is provided at the tip of the rotary drive part 32. The friction stir control section 55 (see FIG. 8) controls the rotation drive section 32 so that the rotation tool F has a predetermined rotation speed.

The load applying unit 33 (see FIG. 8) is configured to include a cylinder mechanism that is movable in the axial direction of the rotary tool F, and is configured to apply pressure to the first metal member 101 and the second metal member 102 during friction stir welding. This is a part that adjusts the pressing force of the rotary tool F.

The load measuring section 35 is a device that is interposed between the rotary tool F and a rotation drive means such as a motor, and measures the axial reaction force load that the rotary tool F receives during friction stir welding. The results measured by the load measurement section 35 are transmitted to the friction stir control section 55 of the control device 5 in association with the workpiece number, and are also stored in the storage section 44 .

The results measured by the load measuring section 35 may be displayed on the display section 43 of the control device 5 together with the workpiece number. The friction stir control unit 55 performs feedback control on the load applying unit 33 so that the reaction load of the rotary tool F approaches a preset set load.

In this embodiment, the pressing force (set load) of the rotary tool F is set to, for example, 2000 to 8000N. The pressing force of the rotary tool F is usually 2000N or more, preferably 2500N or more, and more preferably 3000N. Further, the pressing force of the rotary tool F is usually 8000N or less, preferably 6000N or less, more preferably 4000N or less, particularly preferably 3500N or less.

<Measurement part>
The measuring unit 34 is a measuring device attached to the outside of the rotation drive unit 32. The measurement unit 34 uses a line sensor in this embodiment. The measurement unit 34 is capable of acquiring irregularities, gaps, shapes, etc. around the abutting portion J1 (joint portion) using the reflected light of the irradiated line laser. The results measured by the measurement unit 34 are transmitted to the friction stir control unit 55 of the control device 5 in association with the workpiece number, and are also stored in the storage unit 44 . The results measured by the measurement unit 34 may be displayed on the display unit 43 of the control device 5 together with the work number.

More specifically, before friction stir welding is performed, the measuring unit 34 moves along the abutting part J1 by the arm robot 31, thereby measuring the step dimension h of the abutting part J1, the gap amount D, and the ridge line of the first metal member 101. The position Yp can be measured. The step dimension h is the height dimension from the surface 101b of the first metal member 101 to the surface 102b of the second metal member 102. The gap amount D is the distance from the end surface 101a of the first metal member 101 to the end surface 102a of the second metal member 102. As shown in FIG. 7, the ridgeline position Yp is the shape (position on the XY plane) of the ridgeline 101e on the upper surface side facing the abutting portion J1 of the first metal member 101.

Furthermore, the measuring unit 34 can measure the position Yn (position on the XY plane: see FIG. 11) of the rotary tool F during friction stir welding. Furthermore, the measuring unit 34 can measure the position Yb (initial position Yb0: see FIG. 9) of the rotary tool F before friction stir welding. This initial position Yb0 is the position of the rotary tool F immediately before it is inserted into the first metal member 101 and the second metal member 102 when performing friction stir welding.

Further, the measurement unit 34 can measure the burr height S (undercut) and surface roughness Ra of the joint by moving along the abutment J1 (joint) after friction stir welding. That is, the measurement section 34 can also function as an inspection section for checking the state of the joint and the quality of the joint after friction stir welding. Undercut refers to a state in which the surfaces 101b and 102b of the first metal member 101 and the second metal member 102 are depressed (shaved) compared to before joining. In this embodiment, the measurement unit 34 may measure at least one of the burr height S (undercut) and the surface roughness Ra of the joint. Further, although the measurement section (inspection section) 34 is attached to the outside of the casing 39 that houses the rotation drive section 32, it may be attached to another arm robot, for example. Further, the measurement section and the inspection section may be separate devices.

[B-1-4. Control device]
The control device 5 is a control device that controls the overall operation of the conveying device 2, the fixing device 3, and the friction stirring device 4, as shown in FIG. The control device 5 includes a calculation unit (CPU (Central Processing Unit): not shown), an input unit 42 such as a keyboard or touch panel, a display unit 43 such as a monitor or display, a RAM (Random Access Memory), and a ROM (Read only). memory) and the like.

The control device 5 also includes a main control section 41 , a conveyance control section 51 , a suction control section 52 , a temperature control section 53 , a clamp control section 54 , and a friction stirring control section 55 . The main control section 41 is a section that controls the conveyance control section 51, the suction control section 52, the temperature control section 53, the clamp control section 54, and the friction stirring control section 55. Further, after one friction stir welding is completed, the main control unit 41 reads out the determination result of the workpiece number from the storage unit 44, and reads out the determination result of the workpiece number from the storage unit 44, and ) is determined to be a product outside the numerical range.

The main control section 41, the conveyance control section 51, the suction control section 52, the temperature control section 53, the clamp control section 54, and the friction stir control section 55 are stored in the ROM as an automatic welding program. The calculation section reads the automatic joining program from the ROM, expands it to the RAM, and executes it, thereby controlling the main control section 41, the conveyance control section 51, the suction control section 52, the temperature control section 53, the clamp control section 54, and the friction stirring section. It is made to function as each part of the control section 55. The automatic joining program can be used to record media such as optical discs such as CD-ROM (Compact Disc Read only memory) and DVD-ROM (Digital Versatile Disc Read only memory); USB (Universal Serial Bus) memory, and flash memory such as SD memory. It may be recorded and distributed, or it may be distributed over a communications network such as the Internet, an intranet, or the like. The control device 5 can acquire and execute the automatic joining program by reading the automatic joining program from a recording medium or receiving the automatic joining program via a communication network.

Note that in this embodiment, each control unit is provided in the control device 5 at once, but a control unit may be provided for each device, or the control device 5 and each device may share the control unit. .

<Transport control unit>
The transport control unit 51 transmits a control signal to the transport device 2 to control transporting the first metal member 101 and the second metal member 102 to a predetermined position on the pedestal 21 . On the other hand, the conveyance control unit 51 performs control to take out the metal member 103 to be welded from the pedestal 21 after one friction stir welding is completed and the clamp unit 24 is retracted.

Furthermore, if the main control unit 41 determines that the product is outside the numerical range even once, the conveyance control unit 51 takes out the metal member 103 to be welded from the pedestal 21 and places it in the outside numerical range placement area 16. Controls the conveyance to On the other hand, if the main control unit 41 determines that the product has never been determined to be a product outside the numerical range, the transport control unit 51 takes out the metal member 103 to be welded from the pedestal 21 and places it in the acceptable product placement area 15. Controls the conveyance to Note that control may be performed so that the metal members 103 to be welded are transported to the same position after friction stir welding, regardless of whether the product is outside the numerical value range or not.

<Suction control section>
After the clamp unit 24 fixes the first metal member 101 and the second metal member 102 to the pedestal 21, the suction control unit 52 transmits a control signal to the suction unit 22 to turn the suction device 29 on to suction. Control is performed to suck the end of the fixed second metal member 102. When the friction stir welding is completed, the suction control unit 52 performs control to turn off the suction.

<Temperature control section>
The temperature control unit 53 transmits a control signal to the temperature adjustment unit 23 and controls the heater to operate or stop so as to reach a set temperature. The predetermined numerical range of the temperature adjustment section 23 may be set as appropriate, but is set to, for example, 30 to 120°C, preferably 60 to 90°C.

Furthermore, the temperature control section 53 includes a determination section 66 . Immediately before one friction stir welding, the determination unit 66 determines whether the result (temperature T) transmitted from the temperature sensor 23a of the temperature control unit 53 is within a predetermined numerical range. Note that the temperature T represents the temperature of the surface of the pedestal 21, more specifically, the temperature of the mounting section 25.

When the determination unit 66 determines that the temperature T is outside the predetermined numerical value range, the determination unit 66 associates the first metal member 101 and the second metal member 102 with the workpiece number and determines that the first metal member 101 and the second metal member 102 are products outside the numerical value range. The determination section 66 transmits the determination result to the main control section 41 and stores it in the storage section 44 . The determination result may be displayed on the display unit 43, or may be notified by a notification means that outputs sound, light, etc. according to the determination result. Further, the determination unit 66 may be provided in the main control 41.

Note that when it is determined that the result transmitted from the temperature sensor 23a is outside the predetermined numerical range, the temperature control section 53 heats or cools the mounting section 25 by controlling the heater of the temperature adjustment section 23 to adjust the temperature. You may control so that the result transmitted from the sensor 23a falls within a predetermined numerical range.

<Clamp control section>
The clamp control unit 54 performs control to fix (set) the first metal member 101 and the second metal member 102 placed on the pedestal 21 by transmitting a control signal to the clamp unit 24 . Further, when the friction stir welding is completed, a control signal is sent to the clamp section 24 to control the fixation of the first metal member 101 and the second metal member 102 to be released.

Note that if it is determined that the fixed state (step dimension h, gap amount D, temperature T) before friction stir welding is outside the predetermined numerical range, the clamp portion 24 immediately closes the first metal member 101 and the second metal member 102. Control may also be performed to release the fixation. In this case, for example, the arm robot 11 of the transfer device 2 may slightly correct the positions of the first metal member 101 and the second metal member 102, or the first metal member 101 and the second metal member 102 may be Alternatively, the first metal member 101 and the second metal member 102 may be newly placed after being taken out from the pedestal 21.

<Friction stir control section>
The friction stir control unit 55 sends a control signal to the friction stir device 4 to control friction stir welding of the first metal member 101 and the second metal member 102. The friction stirring control section 55 includes a target movement route generation section 61 , an allowable range generation section 62 , a set movement route generation section 65 , a corrected movement route generation section 63 , and a determination section 64 .

The target movement route generation unit 61 is a part that generates a target movement route R1 for the rotary tool F, as shown in FIG. Here, FIG. 9 is a schematic diagram showing the relationship between a target movement route R1 along which the rotary tool F moves when performing friction stir welding and a corrected movement route R2 along which the rotary tool F moves in a no-load state. . The target movement route R1 is used to set a target locus along which the rotary tool F moves when performing friction stir welding of the butt portion J1. The target movement route generation unit 61 calculates the ridge line position Yp transmitted from the measurement unit 34 as the target movement route R1 before performing friction stir welding. Since the ridge line 101e of the first metal member 101 is not necessarily a straight line due to tolerances and the like, the ridge line position Yp is generally a jagged line. The target movement route R1 may be the same route as the ridgeline position Yp (a jagged route), or may be a straight line based on the method of least squares or the like.

The tolerance generation unit 62 sets a tolerance range M that allows movement of the rotary tool F in the Y direction during friction stir welding. As shown in FIG. 9, the allowable range M is calculated, for example, as a range surrounded by boundary lines Ma and Mb that are distances m and m in the width direction with the ridge line position Yp as the center. More specifically, the allowable range M is a range surrounded by the boundary lines Ma and Mb, the ridgelines 101f and 101g of the first metal member 101, and the ridgelines 102f and 102g of the second metal member 102. The size of the allowable range M may be appropriately set according to the accuracy required for friction stir welding, and for example, the distance m may be set at 0.3 to 0.6 mm. In particular, it is preferable to set the tolerance range M ₁ on the first metal member 101 side to be wider than the tolerance range M ₂ on the second metal member 102 side. Note that the boundary lines Ma and Mb of the allowable range M may be jagged lines depending on the ridgeline position Yp, or may be straight lines based on the least squares method or the like. Furthermore, although the boundary lines Ma and Mb are set at equal distances from the ridgeline position Yp in this embodiment, they may be set at different distances.

The set travel route generation unit 65 is a unit that generates a set travel route. The set movement route is a designated position (teaching position) for moving the rotary tool F. The set movement route specifies the locus that the rotation tool F passes by using coordinate positions. The set movement route can be specified, for example, by specifying the coordinate positions of a starting point and an ending point along which the rotating tool moves, and by specifying a trajectory along which the rotating tool moves on a line between the starting point and the ending point. The friction stirring control unit 55 controls the rotary tool F to move along the trajectory specified by the set movement route by transmitting a control signal to the arm robot 31 and causing it to operate based on the set movement route. When controlling the rotary tool F to move along the set movement route, depending on the situation at the time of welding, the trajectory may be displaced without the rotary tool F passing through the coordinate position specified on the set movement route. The set movement route is used to generate the corrected movement route R2 using the displacement of the locus of the rotary tool F.

The modified movement route generation unit 63 is a part that generates the corrected movement route R2. The corrected movement route R2 is a designated position for moving the rotation tool F, similar to the set movement route. In particular, the corrected movement route R2 indicates a trajectory along which the rotary tool F is controlled to move when performing friction stir welding of the butt portion J1. By controlling the rotary tool F to move along the corrected movement route R2, friction stir welding is performed so that the rotary tool F moves along the target movement route R1. Furthermore, as will be described later, the corrected movement route is set using the set movement route.

Here, FIG. 10 is a schematic diagram showing a test trajectory Q1 and a test trajectory Q2. As shown in FIG. 10, before performing friction stir welding, a test trial is performed to generate a modified movement route R2 using a pair of metal members 301 and 302. It is preferable that the metal members 301 and 302 have the same or similar material, thickness, etc., as the first metal member 101 and the second metal member 102 to which friction stir welding is actually performed. That is, similarly to the abutting part J1 formed by the first metal member 101 and the second metal member 102, the abutting part J30 is formed by abutting the metal members 301 and 302 against each other. That is, in this test trial, compared to the first metal member 101 and the second metal member 102, a plate-like member made of the same type of metal and having the same thickness dimension was It is preferable to use two metal members 301 and 302 having different surface height positions, which are butted against each other so as to form a .

The test trajectory Q1 indicates a travel trajectory in which the friction stirrer 4 was moved experimentally according to a preset movement route without inserting the rotary tool F into the metal members 301, 302. In other words, the test trajectory Q1 is a travel trajectory in which the arm robot 31 of the friction stirrer 4 is moved in a no-load state. At this time, as long as the rotary tool is moved without inserting it into the metal members 301, 302 and without a load, the rotary tool F may be moved without being attached. In addition, in this specification, a "travel trajectory" may be simply called a "trajectory."

On the other hand, the test trajectory Q2 is a trajectory in which the rotary tool F is inserted into the metal members 301, 302 and friction stirring is performed on a trial basis according to the same set movement route as the preset test trajectory Q1. Although the test trajectory Q1 and the test trajectory Q2 are both moved according to the same set movement route, a predetermined difference (difference YL) occurs when friction stirring is actually performed. The difference here is that the test trajectory Q2 is displaced approximately parallel to the test trajectory Q1 by a difference YL in a direction perpendicular to the welding direction.

This is because when the rotary tool F comes into contact with two metal members that are butted against each other so that their surface heights are different, the position of the rotary tool F changes from the test trajectory Q1 to the test trajectory Q2 due to the deflection that occurs in the arm robot 31. It is presumed that this is due to displacement. It is also inferred that it is influenced by the habits of the arm robot 31, the material resistance of the metal members, etc. Therefore, when it is desired to run the test trajectory Q2 in friction stir welding, it is necessary to set the set movement route in consideration of the difference YL. The difference YL was determined by a test trial in which friction stir welding was performed with the rotary tool F inserted into the metal member before friction stir welding of the first metal member 101 and the second metal member 102, and a test trial in which friction stir welding was performed in a state with no load. It can be calculated in advance based on test trials. More specifically, the difference YL is calculated by inserting the rotary tool F into a metal member in which a butt part is formed in the same manner as the butt part J1 between the first metal member 101 and the second metal member 102, and the rotary tool F is inserted while performing friction stir welding. Calculated from the difference in travel trajectory (average of differences) between the test trajectory Q2 when moving tool F and the test trajectory Q1 when moving tool F without inserting it into a metal member and with no load. be able to. Note that it is preferable that the travel route set for obtaining the test trajectory Q1 and the test trajectory Q2 is set such that the test trajectory Q2 passes through the abutting portion J30 of the abutted metal members. In particular, it is preferable to set the set movement route so as to pass through the abutment J30 near the start position of the test trajectory Q2 and move along the abutment J30 toward the metal member side of the thick plate. When performing a test trial, the rotary tool F may be inserted into at least one of the metal members 301 and 302 to obtain test trajectories Q1 and Q2.

The corrected movement route generation unit 63 calculates a corrected movement route R2 based on the target movement route R1 and the difference YL, as shown in FIG. In this embodiment, as shown in FIG. 10, the test trajectory Q2 in which friction stir welding was performed with the rotating tool F inserted is approximately a difference YL to the left (thin plate side) from the test trajectory Q1 in the no-load state. Since there is a tendency for displacement in parallel, the corrected movement route R2 is set at a position displaced by a difference YL to the right (toward the thick plate (first metal member 101) side) with respect to the target movement route R1. In other words, the corrected movement route generation unit 63 generates the length ( A corrected movement route R2 is set at a position where the target movement route R1 is displaced substantially parallel to the direction in which the test trajectory Q2 is displaced by the difference YL). In other words, the friction stirring control unit 55 controls the rotary tool F to move along the corrected movement route R2, so that the difference YL is absorbed and the rotary tool F moves on the target movement route R1, thereby causing friction stirring. Joining will now take place.

Note that if the difference YL between the test trajectory Q1 and the test trajectory Q2 is small or absent, the rotary tool F may be moved based on the target movement route R1 without setting a corrected movement route. Although it is not necessary to obtain (calculate) the difference YL for each friction stir welding, for example, when replacing the rotary tool F, the plate thickness dimension, material type, etc. of the first metal member 101 and the second metal member 102, It is preferable to obtain the information in accordance with the case where the height position of the surface, etc. is changed, and calculate the difference YL and the corrected movement route R2.

When the determination unit 64 determines that the position of the rotary tool F during friction stir welding is outside the allowable range M, the modified movement route generation unit 63 adjusts the position of the rotary tool F according to the position of the rotary tool F during friction stir welding. It is preferable to calculate a corrected movement route R2 in which the position is reset. Specifically, in a place where the position of the rotary tool F in the Y direction during friction stir welding was on the first metal member 101 side, the position of the rotary tool F at this place is on the second metal member 102 side. The corrected movement route R2 is reset. Similarly, in a location where the position of the rotary tool F in the Y direction during friction stir welding was on the second metal member 102 side, the position of the rotary tool F at this location is corrected so that it is on the first metal member 101 side. Reset travel route R2.

As shown in FIG. 8, the determining unit 64 is a part that determines whether the result transmitted from the measuring unit 34 is within a predetermined numerical range. That is, the determining unit 64 determines whether the step dimension h, the gap amount D, the temperature T, and the initial position Yb0 of the rotary tool F before friction stir welding are each within a predetermined numerical range. Further, the determination unit 64 determines whether the position Yn of the rotary tool F during friction stir welding is within a predetermined numerical range (tolerable range M). In particular, the determination unit 64 determines whether or not the left and right positions with respect to the advancing direction of the position Yn of the rotary tool F during friction stir welding are within a predetermined numerical range (tolerable range M). Further, the determination unit 64 determines whether both the burr height S and the surface roughness Ra of the welded portion after friction stir welding are within a predetermined numerical range. Further, the determination unit 64 determines whether the axial reaction force load acting on the rotary tool F is within a predetermined numerical range. The determination unit 64 may make a determination on any one of the above-mentioned determination items, or may make a determination on a combination of two or more of the above-mentioned determination items. For example, the determination unit 64 may determine whether at least one of the position Yn of the rotary tool F during friction stir welding and the load during friction stir welding is within a predetermined numerical range. . In this embodiment, the set state before friction stir welding (step dimension h, gap amount D, temperature T, initial position Yb0 of rotary tool F), position Yn of rotary tool F during friction stir welding, and after friction stir welding An example will be described in which the burr height S and surface roughness Ra of the joint are determined.

<Step dimension h>
The determining unit 64 moves the measuring unit 34 along the abutting portion J1 before performing friction stir welding, so that the result (step dimension h (mm)) sent from the measuring unit 34 is within a predetermined numerical range. Determine whether or not.

In this embodiment, the plate thickness of the first metal member 101 is 2.0 mm, and the plate thickness of the second metal member 102 is set to 1.2 mm, so the set step size is 0.8 mm. . The predetermined numerical range of the step size h may be set as appropriate, but for example, when the set step size h of the first metal member 101 and the second metal member 102 is 0.8 mm, 0.75≦h≦0. It can be set to 93. The step dimension h to be determined may be the total number obtained by the measurement unit 34, the average value of the step dimensions for the entire joint length, the maximum value, or the step size measured at predetermined intervals. A plurality of step dimensions may be extracted and determined individually.

When determining that the step dimension h is outside the predetermined numerical range, the determining unit 64 associates the first metal member 101 and the second metal member 102 with the workpiece number, and determines that they are out of the numerical range. The determination section 64 transmits the determination result to the main control section 41 and stores it in the storage section 44 . The determination result may be displayed on the display unit 43, or may be notified by a notification means that outputs sound, light, etc. according to the determination result.

<Gap amount D>
Furthermore, by moving the measuring unit 34 along the butt portion J1 before performing friction stir welding, the determining unit 64 determines whether the gap amount D (mm) transmitted from the measuring unit 34 is within a predetermined numerical range. Determine whether or not. The predetermined range of the gap amount D may be set as appropriate, and may be set as 0≦D≦0.4, for example. The gap amount D to be determined may be the total number obtained by the measurement unit 34, the average value of the gap amounts for the entire joint length, the maximum value, or a plurality of gap amounts at predetermined intervals. You may extract and judge each.

When the determination unit 64 determines that the gap amount D is outside the predetermined numerical range, the determination unit 64 associates the first metal member 101 and the second metal member 102 with the workpiece number, and determines that the first metal member 101 and the second metal member 102 are products outside the numerical value range. The determination section 64 transmits the determination result to the main control section 41 and stores it in the storage section 44 . The determination result may be displayed on the display unit 43, or may be notified by a notification means that outputs sound, light, etc. according to the determination result.

<Initial position>
In addition, the determining unit 64 determines that the initial position Yb0 of the rotary tool F is measured by the measuring unit 34 before performing friction stir welding, so that the initial position Yb0 transmitted from the measuring unit 34 is the start of the corrected movement route R2. It is determined whether the position is within a predetermined numerical range. The predetermined range of the initial position Yb0 may be set as appropriate, but may be set within a range of, for example, 0 mm or more and 0.3 mm or less, centered on the starting position of the corrected movement route R2. In particular, it can be set within a range of 0 mm or more and 0.3 mm or less in the Y direction centering on the starting position of the corrected movement route R2.

When the determination unit 64 determines that the initial position Yb0 is outside the predetermined numerical value range, the determination unit 64 associates the first metal member 101 and the second metal member 102 with the workpiece number and determines that the first metal member 101 and the second metal member 102 are out of the numerical value range. The determination section 64 transmits the determination result to the main control section 41 and stores it in the storage section 44 . The determination result may be displayed on the display unit 43, or may be notified by a notification means that outputs sound, light, etc. according to the determination result.

<Tolerance range M>
Further, the determining unit 64 determines whether the position Yn of the rotary tool F transmitted from the measuring unit 34 during friction stir welding is within the allowable range (numerical range) M. FIG. 11 is a schematic diagram showing the position Yn (traveling trajectory) of the rotary tool F after performing friction stir welding. In FIG. 11, for convenience of explanation, the scales in the X direction and the Y direction are changed to make it easier to understand the movement in the Y direction. In FIG. 11, the rotary tool F is moved from the bottom to the top in the figure, and the position Yn of the rotary tool F is moved within the tolerance range M.

The range of the allowable range M may be set appropriately, but for example, 0.6 mm (m=0.6 ), it can be set as an area surrounded by a position of 0.3 mm (m=0.3) on the second metal member 102 side.

When the determination unit 64 determines that the position Yn of the rotary tool F during friction stir welding is outside the allowable range (numerical range) M, the determination unit 64 associates the first metal member 101 and the second metal member 102 with the workpiece number and determines the numerical value range. It is judged to be a foreign product. The determination section 64 transmits the determination result to the main control section 41 and stores it in the storage section 44 . The determination result may be displayed on the display unit 43, or may be notified by a notification means that outputs sound, light, etc. according to the determination result.

<Burr height S and surface roughness Ra>
In addition, after friction stir welding, the determination unit 64 determines the burr height S and the surface It is determined whether both roughnesses Ra are within a predetermined numerical range. The burr height S may be set as appropriate, and may be set to 0≦S≦0.1 mm, for example. Further, the surface roughness Ra may be set as appropriate, and may be set to, for example, 0≦Ra≦5.0 μm. The burr height S and surface roughness Ra to be determined may be the total number obtained by the measurement unit 34, the average value for the entire bond length, the maximum value, or a plurality of values at predetermined intervals. The burr height S and surface roughness Ra may be extracted and determined respectively.

FIG. 12 is a sectional view showing the inserted state of the rotary tool according to this embodiment. As shown in FIG. 12, during friction stir welding, the rotary tool F is moved while being inclined at a predetermined target angle θ toward the second metal member 102 with respect to the vertical line. A plasticized region W is formed in the traveling locus of the rotary tool F. The aiming angle θ may be set appropriately. In this embodiment, for example, the center F5 of the flat surface of the tip end pin F3 is set to overlap with the target movement route R1 when viewed from above.

The insertion depth in friction stir welding may be set appropriately, but in this embodiment, the outer peripheral surface of the proximal pin F2 is brought into contact with the surface 101b of the first metal member 101 and the surface 102b of the second metal member 102, respectively. At the same time, the tip end side pin F3 is set to such an extent that it does not come into contact with the pedestal 21.

In this embodiment, the rotating direction and advancing direction of the rotating tool F are set so that the rotating tool F is rotated clockwise and the first metal member 101 is located on the right side in the advancing direction. The rotational direction and traveling direction of the rotary tool F may be set appropriately, but in this embodiment, the second metal member 102 side is the shear side of the plasticized region W formed in the travel locus of the rotary tool F, and the first metal member 102 side is the shear side. The metal member 101 side is set to be the flow side.

In addition, the shear side (Advancing side) means that the relative speed of the outer circumference of the rotary tool to the part to be welded is the value obtained by adding the magnitude of the moving speed to the magnitude of the tangential velocity at the outer circumference of the rotary tool. means side. On the other hand, the flow side (Retreating side) refers to the side where the rotation tool rotates in the opposite direction to the moving direction of the rotation tool, so that the relative speed of the rotation tool with respect to the welded part becomes low.

In addition, in the automatic welding system 1 of this embodiment, when performing friction stir welding, for example, the inclination angle of the rotary tool F may be tilted forward or backward at a predetermined angle with respect to the traveling direction.

[B-2. Operation flow]
Next, an example of the operation flow of the automatic joining system 1 according to this embodiment will be described. FIG. 13 is a flowchart showing an example of the operation of the automatic joining system according to this embodiment. In the automatic welding system 1 according to this embodiment, friction stir welding is automatically performed based on control signals sent from the control device 5 to each device.

As shown in FIG. 13, in step ST1, the transport control unit 51 controls the transport device 2 to transport the first metal member 101 and the second metal member 102 to a predetermined position of the fixing device 3. The first metal member 101 and the second metal member 102 are fixed by the clamp part 24, and the end of the second metal member 102 is sucked by the suction part 22.

In step ST2, the friction stir control section 55 moves the measurement section 34 of the friction stir device 4 along the abutting section J1 to measure the fixed state (set state). That is, the measurement unit 34 measures the step dimension h, the gap amount D, and the ridgeline 101e of the first metal member 101. Further, the measuring unit 34 measures the initial position Yb0 of the rotary tool F. The measurement section 34 transmits the measurement results to the friction stir control section 55. Further, the temperature sensor 23a of the temperature adjustment section 23 transmits the measurement result to the temperature control section 53.

In step ST3, the determination unit 66 of the temperature control unit 53 and the determination unit 64 of the friction stir control unit 55 respectively determine whether the set states of the first metal member 101 and the second metal member 102 are within a predetermined numerical range. do. When the determination units 64 and 66 determine that the step dimension h, the gap amount D, the temperature T, and the initial position Yb0 of the rotary tool F are all within the numerical range (YES in step ST3), the process proceeds to step ST5. When it is determined that at least one of the step dimension h, the gap amount D, the temperature T, and the initial position Yb0 of the rotary tool F is outside the numerical range (NO in step ST3), the determination unit 64 or 66 associates it with the workpiece number. Then, the first metal member 101 and the second metal member 102 are determined to be out of the numerical value range (step ST4), and the process moves to step ST5.

In step ST5, the friction stir control unit 55 (corrected movement route generation unit 63) generates a corrected movement route R2 based on the ridgeline position Yp and the difference YL obtained in advance. Specifically, the ridgeline position Yp is calculated as the target movement route R1, and a corrected movement route R2 is set at a position displaced approximately parallel to the thick plate side by a difference YL with respect to the target movement route R1.

In step ST6, the friction stir control unit 55 controls the friction stir device 4 to insert and move the rotary tool F, which rotates at a predetermined rotational speed, into the first metal member 101 and the second metal member 102, thereby causing friction. Perform stirring welding. Specifically, the friction stir control unit 55 controls the rotary tool F to move along the corrected movement route R2. At this time, as the rotary tool F is inserted into the first metal member 101 and the second metal member 102, the position of the rotary tool F changes from the initial position Yb0 before insertion, which is near the start position of the corrected movement route R2, to the second position. A displacement of the difference YL occurs on the metal member 102 side, and the metal member 102 moves to the vicinity of the ridgeline position Yp. In this way, friction stir welding is performed with the rotary tool F moving along the target movement route R1.

In step ST7, the determination unit 64 of the friction stir control unit 55 determines whether the position Yn of the rotary tool F during friction stir welding is within the allowable range (numerical range) M. When the determination unit 64 determines that the position Yn of the rotary tool F is within the allowable range M (YES in step ST7), the process moves to step ST9. If it is determined that even a part of the position Yn of the rotary tool F during friction stir welding is outside the allowable range M (NO in step ST7), the determination unit 64 associates the first metal member 101 and the first metal member 101 with the workpiece number. The bimetallic member 102 is determined to be outside the numerical value range (step ST8), and the process moves to step ST9.

In step ST9, after the friction stir welding is completed, the friction stir control unit 55 moves the measurement unit 34 of the friction stir device 4 along the abutting portion J1 to measure the burr height S and surface roughness Ra.

In step ST10, the determination unit 64 of the friction stir control unit 55 determines whether both the burr height S and the surface roughness Ra after friction stir welding are within a predetermined numerical range. If it is determined that both the burr height S and the surface roughness Ra are within the predetermined numerical range (YES in step ST10), the process moves to step ST12. When it is determined that at least one of the burr height S and the surface roughness Ra is outside the predetermined numerical range (NO in step ST10), the determination unit 64 associates it with the workpiece number and classifies the metal member 103 to be welded as a product outside the numerical range. It is determined that (step ST11), and the process moves to step ST12.

In step ST12, the main control unit 41 determines whether the product has never been determined to be outside the numerical range during one friction stir welding process. When the main control unit 41 determines that the product has never been determined to be a product outside the numerical value range (YES in step ST12), the process moves to step ST13. If the main control unit 41 determines that the product has been determined to be outside the numerical value range even once (NO in step ST12), the process moves to step ST14.

In step ST13, the transport control unit 51 controls the transport device 2 to take out the metal member 103 to be welded, arranges the metal member 103 to be welded in the accepted product placement area 15 (see FIG. 6), and ends the process.

In step ST14, the transport control unit 51 controls the transport device 2 to take out the metal member 103 to be welded, and arranges the metal member 103 to be welded as a product outside the numerical value range in the product placement area 16 for the product outside the numerical value range, and ends the process.

Although an example of the operation flow of this embodiment has been described above, changes can be made as appropriate. For example, if there is a problem with the set state in step ST3, that is, if the step dimension h and the gap amount D are outside the predetermined numerical range, the clamp part 24 is released, and the arm robot 11, for example, The positions of the first metal member 101 and the second metal member 102 may be corrected, or the first metal member 101 and the second metal member 102 may be taken out from the fixing device 3 and replaced with new first metal members 101 and second metal members 102. may be placed. Further, in step ST3, if the initial position Yb0 of the rotary tool F is outside the predetermined numerical range, the position of the rotary tool F may be adjusted.

Further, in step ST3, the step size h, the gap amount D, the temperature T, and the initial position Yb0 of the rotary tool F are determined, but at least one of these may be determined. Further, if it is determined in step ST3 that the temperature T is outside the predetermined numerical range, the temperature adjustment section 23 heats or cools the temperature T until it falls within the predetermined numerical range before proceeding to step ST5. You can also do this. Note that the determination of the temperature T and the heating or cooling by the temperature adjustment section 23 may be performed during the friction stir welding process.

Further, if the determination is NO in step ST3 and step ST7, the automatic joining system 1 is stopped, the determination result is displayed on the display unit 43, and furthermore, sound, light, etc. are outputted according to the determination result. The notification may be made using a notification means.

Further, although omitted in the explanation of the operation flow with reference to the flowchart of FIG. 13, it is preferable to obtain the difference YL prior to the generation of the corrected movement route R2 by the corrected movement route generation unit 63 in step ST5. To obtain the difference YL, first, the target travel route generation section 61 sets the target travel route R1, and the set travel route generation section 65 generates the set travel route. Next, according to the generated set movement route, a test trajectory Q1 in which the rotating tool F is moved without inserting it into the metal members 301 and 302 and a test trajectory Q1 in which the rotating tool F is moved in an unloaded state without inserting the rotating tool F into the metal members 301 and 302 is created. A test locus Q2 of movement while performing friction stir welding is obtained. Then, a difference YL is obtained from the difference between the test trajectory Q1 and the test trajectory Q2. Although the difference YL may be obtained at a timing before step ST5, it is preferable to obtain the difference YL before step ST1 in which the first metal member 101 and the second metal member 102 are set.

[B-3. Effect】
Although it is preferable that the ridge line 101e (see FIG. 7) of the first metal member 101 is originally a straight line, it is not strictly a straight line due to tolerances and the like. Further, when the first metal member 101 and the second metal member 102 are transported and fixed to the pedestal 21 by the transport device 2, the fixing position (set position) may shift. Therefore, even if the rotary tool F is moved linearly so as to trace the reference position Y0 (see FIG. 6) set on the pedestal 21, the rotary tool F will deviate from the abutting portion J1 that is actually set, resulting in poor joining quality. may decrease. In particular, when the height positions of the surfaces 101b and 102b of the first metal member 101 and the second metal member 102 are different as in this embodiment, even a slight shift in the joining position tends to cause problems.

However, the inventors' studies have revealed that the locus of the position where the rotary tool F actually moves when performing friction stir welding of the butt portion J1 is different from the locus of the position where the movement of the rotary tool F is controlled. It was found that it was displaced substantially parallel toward the second metal member 102 side (thin plate side). It is thought that such a substantially parallel displacement occurs mainly due to the set state of two metal members that are butted against each other so that their surface height positions are different. That is, the first metal member 101, 301 and the second metal member 102, 302 are placed such that their end surfaces are butted together such that the surface of the first metal member 101, 301 is higher than the surface of the second metal member 102, 302. Abutting portions J1 and J30 with steps are formed. When performing friction stir welding with the rotary tool F inserted in this set state, the rotary tool F receives a reaction force from the first metal member 101, 301 on the thick plate side. The position of F moves toward the second metal member 102, 302 on the thin plate side over the entire joining length. In this way, it is believed that a substantially parallel displacement occurs.

According to the automatic welding system 1 according to the present embodiment, the target movement route R1 of the rotary tool F is set based on the ridgeline position Yp of the first metal member 101 measured before performing friction stir welding, and the target movement route A correction movement route R2 is set at a position displaced approximately parallel to the first metal member 101 side (thick plate side) with respect to R1. By controlling the rotary tool F to move along the corrected movement route R2, it became possible to perform friction stir welding using the rotary tool F along the target movement route R1. In this way, based on the ridge line position Yp of each set first metal member 101, the rotary tool F is controlled to be moved to a position that compensates for the displacement that occurs when performing friction stir welding of the abutting portion J1. Therefore, it is possible to easily set an accurate movement route that suppresses displacement of the rotary tool F. This makes it possible to improve bonding quality. In particular, in this embodiment, the target movement is determined based on the length of the difference YL between the test trajectory Q2, which is the trajectory with the tool inserted, and the test trajectory Q1, which is the trajectory with no load. A corrected movement route R2 is set at a position where the route R1 is displaced approximately parallel to the route R1. As a result, it is possible to set a movement route that suppresses the substantially parallel displacement of the traveling locus of the rotary tool F that occurs depending on the set state of the metal members 101 and 102, thereby improving the joining quality.

In addition, the arm robot 31 does not follow the corrected movement route R2 set by the control device 5 because there is mechanical deflection, quirks, etc., and there is also resistance that the rotary tool F receives from the first metal member 101 and the second metal member 102. On the other hand, the route along which the rotary tool F actually moves may deviate from the target movement route R1. In this regard, in the present embodiment, by setting the target movement route R1 based on the ridgeline position Yp and the corrected movement route R2 based on the pre-calculated difference YL, the actual movement route of the rotary tool F can be further improved. Can be set accurately. At this time, according to the target movement route R1 or the corrected movement route R2 of this embodiment, the rotary tool F can be moved to an appropriate position according to the first metal member 101 and the second metal member 102. This allows the bonding quality to be further improved.

Further, according to the automatic joining system 1 according to the present embodiment, the control device 5 sets the set movement route. Then, the control device 5 controls the inserted rotary tool F to move along the set movement route, and moves the rotary tool F along the set movement route. The target movement route R1 is corrected and moved to a position where the target movement route R1 is displaced approximately parallel to the first metal member 101 by the difference YL based on the difference from the travel trajectory that is controlled so as to move with no load. Calculate route R2. In this way, in order to obtain the difference YL by comparing the traveling locus moved while performing friction stir welding with the traveling locus when the friction stir welding device 4 is moved under no load, It is possible to compensate for the effects that occur when the device 4 is operated.

Further, friction stir welding is performed while tilting the rotary tool F toward the second metal member 102 side on the thin plate side at an aiming angle θ and pressing the plastic flow material with the step bottom surface F21a of the pin step portion F21 of the proximal pin F2. This prevents the occurrence of burrs and undercuts, and makes it possible to clean the bonding surface.

More specifically, by bringing the outer circumferential surface of the proximal pin F2 into contact with the surfaces 101b and 102b of the first metal member 101 and the second metal member 102 to press down the plastic flow material, it is possible to suppress the occurrence of burrs. . In addition, since the plastic flow material can be held down by the outer circumferential surface of the proximal pin F2, it is possible to eliminate or reduce the step grooves formed on the joining surfaces (surfaces 101b and 102b), and also to It is possible to eliminate or reduce the size of the bulge formed on the side of the bulge. Furthermore, since the step-like pin step portion F21 of the proximal pin F2 is shallow and has a wide outlet, the plastic fluid material can easily escape to the outside of the pin step portion F21 while being held down by the step bottom surface F21a. There is. Therefore, even if the plastic flow material is held down by the base pin F2, the plastic flow material is difficult to adhere to the outer circumferential surface of the base pin F2. Therefore, the surface roughness Ra can be reduced, and the bonding quality can be suitably stabilized.

Furthermore, if the step dimension h is outside the predetermined numerical range, the burr height S may decrease and an undercut may occur. Furthermore, if the gap amount D is outside the predetermined numerical range, the burr height S may decrease and an undercut may occur. In this regard, according to the present embodiment, if either the step dimension h or the gap amount D obtained by the measurement unit 34 before friction stir welding is outside the predetermined numerical range, for example, the first metal member 101 and By resetting the second metal member 102 in the fixing device 3, friction stir welding can be suitably performed with the second metal member 102 properly set. In addition, if the numerical value is outside the predetermined numerical range, quality control can be easily performed by determining, for example, the first metal member 101 and the second metal member 102 (metal member to be welded 103) as products outside the numerical value range. .

Here, even if the movement route of the rotary tool is set and the movement is controlled, when friction stir welding is actually performed, the traveling trajectory of the rotary tool changes and the rotary tool moves along the ridgeline position. It may not. For example, depending on the friction stirrer 4, especially the arm robot 31, the amount of displacement of the rotary tool F toward the target movement route R1 may change. Further, depending on the arm robot 31, the inclination of the moving direction of the rotary tool F with respect to the ridgeline position Yp may change, or the traveling locus of the rotary tool F may partially change. In addition, the traveling locus of the rotary tool F may change due to wear and tear on the rotary tool F or damage to the pedestal 21. Further, also when the first metal member 101 and the second metal member 102 and the butting conditions thereof change, the traveling locus of the rotary tool F may change.

According to the automatic welding system 1 according to the present embodiment, during friction stir welding, the determination unit 64 determines whether the position Yn of the rotating tool F that is actually moving is within the allowable range (predetermined numerical range) M. Therefore, the bonding quality can be further improved.

In addition, when it is determined that the position of the rotary tool F during friction stir welding is outside the allowable range M, the modified movement route generation unit 63 adjusts the position of the rotary tool F according to the position of the rotary tool F during friction stir welding. A corrected movement route R2 with the position reset is calculated. By feeding back information during friction stir welding based on the position Yn of the rotating tool F that is actually moving, the traveling trajectory of the rotating tool F can be corrected more accurately, further improving welding quality. can be done.

Furthermore, after friction stir welding, the inspection section (also used as the measurement section 34 in this embodiment) measures the burr height S and surface roughness Ra of the joint after friction stir welding, thereby improving the welding quality. can be increased.

That is, according to the automatic welding system 1 of this embodiment, it is possible to monitor all the parts to be subjected to friction stir welding, and to perform quality inspection on all parts, so that quality control can be easily performed. In addition, by including the set state before friction stir welding (step dimension h, gap amount D, temperature T, initial position Yb0 of rotary tool F) as a quality control judgment factor, welding quality (quality reliability) can be improved. It can be further improved.

Furthermore, even if a product is determined to be outside the numerical range during the process, friction stir welding can be performed until the end, making it easier to stop the system or reset the first metal member 101 and second metal member 102. You can increase work efficiency by comparison. In addition, even if a product is determined to be outside the numerical range during the process, by performing friction stir welding until the end, data on products outside the numerical range can be accumulated, which can contribute to setting more suitable welding conditions and numerical ranges. I can do it.

Further, in the automatic welding system 1 of the present embodiment, quality control can be performed in a well-balanced manner by incorporating factors before friction stir welding, during friction stir welding, and after friction stir welding into the quality control judgment factors.

In addition, in this embodiment, the load applying unit 33 and the load measuring unit 35 of the friction stirrer 4 feed back the reaction load and control the load so that the reaction load that the rotary tool F receives is approximately constant. Therefore, joining accuracy can be improved. That is, in this embodiment, since the tolerance range M is provided in the Y direction and the load is controlled in the Z direction, it is possible to further improve the joining accuracy.

Further, since the mounting portion 25 is provided on the surface side of the pedestal 21 and an anodic oxide coating is applied to the surface side of the mount portion 25, the abrasion resistance, corrosion resistance, etc. of the mount 21 can be improved.

Here, since the second metal member 102 has a small plate thickness, the end portion thereof tends to rise. Furthermore, as will be shown in Examples to be described later, if the end portion of the second metal member 102 rises and the step dimension h becomes too small, there is a tendency for poor bonding to occur. In this regard, according to the present embodiment, since the suction section 22 that sucks the end of the second metal member 102 from the back surface 102c side is provided, lifting of the end of the second metal member 102 can be suppressed. . Thereby, the accuracy of joining can be further improved.

Regarding the gap amount D, as shown in the examples described later, the burr height S tends to have a greater effect on the gap amount on the start position side than on the end position side. Therefore, regarding the determination target of the gap amount D, for example, the gap amount D at a predetermined distance (for example, 5 to 15 cm) from the starting position may be extracted and compared and determined with a predetermined numerical range.

Further, as shown in the examples below, when the temperature T is, for example, less than 30° C., cavity defects become large, and when the temperature T is 60 to 120° C., cavity defects tend to be small or not occur. As in this embodiment, by setting a predetermined numerical range for the temperature T and incorporating it into the quality control judgment factor, it is possible to further improve the bonding quality.

[C. First variation]
[C-1. Automatic joining system]
Next, a first modification of the first embodiment described above will be explained. In the first modification, the method of calculating the corrected movement route is different from the above-described embodiment. In the first modified example, the explanation will focus on parts that are different from the above-described embodiment. In the first embodiment described above, the corrected movement route R2 was set at a position moved approximately parallel to the target movement route R1 (see FIG. 9), but in the first modification, as shown in FIG. A corrected movement route R2a is set at a position obliquely displaced with respect to the target movement route R1a.

FIG. 15 is a schematic diagram showing a test trajectory Q1a and a test trajectory Q2a. As shown in FIG. 15, in the first modification, a test trial is performed to generate a modified movement route R2a using a pair of metal members 301 and 302 before performing friction stir welding. It is preferable that the metal members 301 and 302 have the same or similar material, thickness, etc., as the first metal member 101 and the second metal member 102 to which friction stir welding is actually performed. That is, similarly to the abutting part J1 formed by the first metal member 101 and the second metal member 102, the abutting part J30 is formed by abutting the metal members 301 and 302 against each other. That is, in this test trial, compared to the first metal member 101 and the second metal member 102, a plate-like member made of the same type of metal and having the same thickness dimension was It is preferable to use two metal members 301 and 302 having different surface height positions, which are butted against each other so as to form a .

The test trajectory Q1a shows a traveling trajectory in which the friction stirrer 4 was experimentally moved according to a preset moving route without inserting the rotary tool F into the metal members 301, 302. In other words, the test trajectory Q1a is a travel trajectory in which the arm robot 31 of the friction stirrer 4 is moved in a no-load state. At this time, as long as the rotary tool is moved without inserting it into the metal members 301, 302 and without a load, the rotary tool F may be moved without being attached.

On the other hand, the test trajectory Q2a is a trajectory obtained by inserting the rotary tool F into the metal members 301, 302 and performing friction stirring on a trial basis according to the same set movement route as the preset test trajectory Q1a. In both the test trajectory Q1a and the test trajectory Q2a, the rotary tool F was moved from the front side of the metal members 301, 302 toward the back side. Even though the test trajectory Q1a and the test trajectory Q2a are both moved according to the same set movement route, a predetermined angular difference σ1 occurs when friction stirring is actually performed. Although the test trajectory Q1a and the test trajectory Q2a match at the starting point of friction stirring, the test trajectory Q2a is angled to the left (toward the thin plate (second metal member 302) side) from the test trajectory Q1a in the no-load state. It is displaced diagonally with a difference of σ1. As a result, between the test trajectory Q1a and the test trajectory Q2a, the difference YLb on the far side is larger than the difference YLa on the side near the middle. In other words, the difference YL in the direction perpendicular to the welding direction gradually increases as the rotary tool F advances.

Such a deviation of the rotary tool F is caused by the position of the rotary tool F being tested due to the deflection that occurs in the arm robot 31 when the rotary tool F contacts two metal members that are butted against each other so that their surface heights are different. It is presumed that this is caused by the displacement from the trajectory Q1a to the test trajectory Q2a. It is also inferred that it is influenced by the habits of the arm robot 31, the material resistance of the metal members, etc.

Therefore, when it is desired to run the test trajectory Q2a in friction stir welding, it is necessary to set the set movement route in consideration of the difference σ1. The difference σ1 was determined between a test trial in which friction stir welding was performed with the rotary tool F inserted into the metal member before friction stir welding of the first metal member 101 and the second metal member 102, and a test trial in which friction stir welding was performed in a state with no load. It can be calculated in advance based on test trials. More specifically, the difference σ1 is calculated by inserting the rotary tool F into a metal member in which a butt part is formed in the same way as the butt part J1 between the first metal member 101 and the second metal member 102, and the rotary tool F is inserted while performing friction stir welding. It can be calculated from the difference σ1 in the angle of the running trajectory between the test trajectory Q2a when F is moved and the test trajectory Q1a when the rotary tool F is moved without inserting it into a metal member and without load. can.

Note that the travel route set for obtaining the test trajectory Q1a and the test trajectory Q2a is preferably set such that the test trajectory Q2a passes near the abutting portion J30 of the abutted metal members. In particular, it is preferable to set the set movement route so as to pass through the abutment J30 near the start position of the test trajectory Q2a and move along the abutment J30 toward the metal member side of the thick plate. In addition, when performing a test trial, the rotary tool F may be inserted into at least one of the metal members 301 and 302 to obtain the test trajectories Q1a and Q2a.

As shown in FIG. 14, the corrected movement route generation unit 63 calculates a corrected movement route R2a based on the target movement route R1a and the difference σ1. In this modification, as shown in FIG. 15, the test trajectory Q2a in which friction stir welding was performed with the rotating tool F inserted is diagonal by a difference σ1 to the left (thin plate side) from the test trajectory Q1a in the no-load state. Therefore, the corrected movement route R2a is set at a position that is obliquely displaced by a difference σ1 to the right side (thick plate (first metal member 101) side) with respect to the target movement route R1a. In other words, the corrected movement route generation unit 63 generates an angle σ1 by which the test trajectory Q2a, which is the traveling trajectory with the tool inserted, is obliquely displaced with respect to the test trajectory Q1a, which is the traveling trajectory with no load. The corrected movement route R2a is set at a position where the traveling direction (inclination) of the target movement route R1a is obliquely displaced by the direction opposite to the direction in which the test trajectory Q2a is displaced. That is, the corrected movement route R2a is set so as to gradually move away from the target movement route R1a as the rotating tool F moves toward the direction of movement. The friction stir control unit 55 controls the rotary tool F to move on the corrected movement route R2a, thereby absorbing the difference σ1, moving the rotary tool F on the target movement route R1a, and performing friction stir welding. will be carried out.

In the first modification, when the determination unit 64 determines that the position of the rotary tool F during friction stir welding is outside the allowable range M, the modified movement route generation unit 63 changes the position of the rotary tool F during friction stir welding to the position of the rotary tool F during friction stir welding. It is preferable to calculate a corrected movement route R2a in which the position of the rotary tool F is reset accordingly. Specifically, in a place where the position of the rotary tool F in the Y direction during friction stir welding was on the first metal member 101 side, the position of the rotary tool F at this place is on the second metal member 102 side. The corrected movement route R2a is reset. Similarly, in a location where the position of the rotary tool F in the Y direction during friction stir welding was on the second metal member 102 side, the position of the rotary tool F at this location is corrected so that it is on the first metal member 101 side. Reset the travel route R2a.

Further, when it is determined that the position of the rotary tool F during friction stir welding is outside the allowable range M, the determination unit 64 associates the first metal member 101 and the second metal member 102 with the workpiece number to produce a product that is outside the numerical range. It may be determined that

Note that if the difference σ1 between the test trajectory Q1a and the test trajectory Q2a is small or absent, the rotary tool F may be moved based on the target movement route R1a without setting the corrected movement route. Although it is not necessary to obtain (calculate) the difference σ1 for each friction stir welding, for example, when replacing the rotary tool F, the plate thickness dimension, material type, It is preferable to obtain the difference σ1 and the corrected movement route R2a according to the case where the height position of the surface, etc. is changed.

[C-2. Operation flow]
The automatic joining system 1 according to this modification can operate in the same manner as the operational flow of the automatic joining system according to the first embodiment described with reference to FIG. 13.

In the automatic joining system 1 according to this modification, in step ST5, the friction stir control unit 55 (corrected movement route generation unit 63) generates a corrected movement route R2a based on the ridgeline position Yp and the difference σ1 acquired in advance. Specifically, the ridgeline position Yp is calculated as the target movement route R1a, and the corrected movement route R2a is set at a position diagonally displaced by a difference σ1 with respect to the target movement route R1a.

It is preferable to obtain the difference σ1 before the modified travel route generation unit 63 generates the modified travel route R2a in step ST5. To obtain the difference σ1, first, the target movement route generation unit 61 sets the target movement route R1a, and the set movement route generation unit 65 generates the set movement route. Next, according to the generated set movement route, a test trajectory Q1a is obtained by moving the rotary tool F into the metal members 301 and 302 without inserting the rotary tool F in an unloaded state, and a test trajectory Q1a in which the rotary tool F is inserted into the metal members 301 and 302. A test trajectory Q2a is obtained by moving while performing friction stir welding. Then, a difference σ1 is obtained from the difference between the test trajectory Q1a and the test trajectory Q2a. Although the difference σ1 may be obtained at a timing before step ST5, it is preferable to obtain the difference σ1 before step ST1 in which the first metal member 101 and the second metal member 102 are set.

[C-3. Effect]
If the rotating tool F is inserted and controlled to move along a predetermined moving route while performing friction stir welding, the running trajectory of the rotating tool F will deviate from the moving route, causing route flow, etc. There is a risk that the bonding quality will deteriorate. For example, as shown in FIG. 6, the friction stir welding is performed by a friction stir device 4 equipped with an arm robot 31 passing through a movement route parallel to the abutting portion J1 of the first metal member 101 and the second metal member 102. In this case, the travel locus of the rotary tool F may be obliquely displaced from the abutting portion J1, and the deviation may become wider as the position of the rotary tool F advances in the traveling direction.

The inventors' studies have revealed that the travel locus that the rotary tool F actually moves when performing friction stir welding of the butt portion J1 is obliquely displaced with respect to the locus of the position where the movement of the rotary tool F is controlled. A case was found where this was the case. It is thought that such oblique displacement occurs mainly due to the posture of the arm robot 31 of the friction stirrer 4. That is, as the rotary tool F advances in the welding direction as the metal members 101 and 102 are joined on the abutting portion J1, the posture of the arm robot 31 having the rotary tool F attached to its tip changes. For example, when the arm robot 31 is equipped with a multi-joint arm 31a, there is a case where the multi-joint arm 31a is extended and spread to connect a position far from the main body of the friction stirrer 4, and a case where the multi-joint arm 31a is folded and contracted. The posture will be different when joining a position close to the main body of the friction stirrer 4. When the posture of the arm robot 31 changes depending on the traveling position, the direction in which the arm robot 31 receives force changes, and the spring constant of the arm robot 31 changes. Inserting the rotary tool F into the metal members 101 and 102 will cause the arm robot 31 to deflect, but since the spring constant of the arm robot 31 changes depending on the traveling position of the rotary tool F, the arm robot 31 will be deflected. The amount will change. When the rotary tool F is controlled and moved so that it moves along a predetermined movement route, the amount of deflection of the arm robot 31 increases as the rotary tool F moves, and the traveling trajectory of the rotary tool F is moved along a predetermined movement route. This means that they will deviate from their travel route. In this way, it is believed that a diagonal displacement occurs.

According to the automatic welding system 1 according to the present modification, the target movement route R1a of the rotary tool F is set based on the ridge line position Yp of the first metal member 101 measured before performing friction stir welding, and the target movement route A corrected movement route R2a is set at a position obliquely displaced with respect to R1a. By controlling the rotary tool F to move along the corrected movement route R2a, it became possible to perform friction stir welding using the rotary tool F along the target movement route R1a. In this way, based on the ridge line position Yp of each set first metal member 101, the rotary tool F is controlled to be moved to a position that compensates for the displacement that occurs when performing friction stir welding of the abutting portion J1. Therefore, it is possible to easily set an accurate movement route that suppresses displacement of the rotary tool F. This makes it possible to improve bonding quality. In particular, in this modification, the target movement route is determined based on the angle of the difference σ1 between the test trajectory Q2a, which is the trajectory with the tool inserted, and the test trajectory Q1a, which is the trajectory with no load. A corrected movement route R2a is set at a position where the traveling direction (inclination) of R1a is obliquely displaced. As a result, it is possible to set a movement route that suppresses the diagonal displacement of the running trajectory of the rotary tool F, which occurs depending on the posture of the arm robot 31 of the friction stir device 4 for joining the metal members 101 and 102, thereby improving the joining quality. can be increased.

[D. Second modification]
Next, a second modification of the first embodiment described above will be described. In the embodiment described above, the step dimension h was measured before performing friction stir welding, but instead of or in addition to the step dimension h, the first thickness dimension t11 and the second thickness dimension t12 (FIG. 12 ) may also be measured.

As shown in FIG. 12, the first thickness dimension t11 refers to the distance (height dimension) from the surface of the pedestal 21 to the surface 101b of the first metal member 101. The second thickness dimension t12 refers to the distance (height dimension) from the surface of the pedestal 21 to the surface 102b of the second metal member 102.

The first thickness dimension t11 and the second thickness dimension t12 can be measured by the measurement unit 34, for example. That is, before friction stir welding is performed, the first thickness dimension t11 and the second thickness dimension t12 can be obtained by moving the measuring section 34 along the abutting section J1. At this time, in addition to the abutting part J1, by moving the measurement part 34 so that the height position of the surface of the pedestal 21 can be measured, the surface 101b of the first metal member 101 and the second The distance to the surface 102b of the metal member 102 can be measured.

In the second modification, the determination unit 64 determines whether the results (first thickness dimension t11 and second thickness dimension t12) transmitted from the measurement unit 34 before or during friction stir welding are within a predetermined value. Determine whether the value is within the numerical range. When the determination unit 64 determines that the first thickness dimension t11 and the second thickness dimension t12 are outside the predetermined numerical range, the determination unit 64 associates the first metal member 101 and the second metal member 102 with the workpiece number and determines that the first thickness dimension t11 and the second thickness dimension t12 are outside the numerical range. It is determined that the product is of good quality. The determination section 64 transmits the determination result to the main control section 41 and stores it in the storage section 44 . The determination result may be displayed on the display unit 43, or may be notified by a notification means that outputs sound, light, etc. according to the determination result.

Further, if it is determined that the first thickness dimension t11 and the second thickness dimension t12 are outside the predetermined numerical range before or during friction stir welding, the clamp part 24 immediately Control may also be performed to release the fixation of the second metal member 102. In this case, for example, the arm robot 11 of the transfer device 2 may slightly correct (reset) the positions of the first metal member 101 and the second metal member 102, or the first metal member 101 and the second metal member 102 may be The metal member 102 may be taken out from the pedestal 21 and a new first metal member 101 and second metal member 102 may be placed.

Here, during friction stir welding, the plate thicknesses of the first metal member 101 and the second metal member 102 have a large effect on the welding quality. Depending on the combination of the plate thicknesses of the first metal member 101 and the second metal member 102, poor joining may occur no matter how the rotary tool F is controlled. Further, for example, when parts are procured overseas, variations in the thickness of the first metal member 101 and the second metal member 102 tend to increase.

In this respect, as in the second modification, the first thickness dimension t11 and the second thickness dimension t12 are measured before or during friction stir welding, and these measurement results are within a predetermined numerical range. By determining whether this is the case, the accuracy of quality control can be further improved.

In addition, when the control device 5 of the second modification determines that the first thickness dimension t11 and the second thickness dimension t12 are outside the predetermined numerical range, the control device 5 controls the aim angle, advance angle, insertion amount, and rotation of the rotary tool F. Control may be performed to change at least one position of the tool F from a preset condition. Regarding the aiming angle, advance angle, insertion amount, and position of the rotary tool F with respect to the first thickness dimension t11 and the second thickness dimension t12, the first metal member 101 and the second metal member 102 having different thicknesses Optimal or near-optimal conditions can be prepared from tests conducted in advance by preparing multiple conditions. According to such a second modification, friction stir welding can be performed under optimal or near-optimal conditions depending on the first thickness dimension t11 and the second thickness dimension t12, so stable welding quality can be maintained. can do.

Note that the forward angle refers to the angle of the rotation center axis U of the rotary tool F with respect to the vertical axis when the rotary tool F is viewed from the side with respect to the advancing direction. The insertion amount refers to the distance from the surface 101b of the first metal member 101 to the center F5 (see FIG. 12) of the flat surface of the tip end pin F3.

Here, the first thickness dimension t11 and the second thickness dimension t12 may be measured separately from the measurement of the step dimension h and the like before performing friction stir welding. For example, a line sensor (laser displacement meter) can be used as the measurement unit. As shown in FIG. 17, when a first metal member 101 with a large plate thickness and a second metal member 102 with a small plate thickness are butted against each other to form a butt portion J1, the measurement portion is connected to the root E1, the root E2, and the root The first thickness dimension t11 and the second thickness dimension t12 before friction stir welding can be measured by changing the position with E3 and moving it multiple times (here, three times).

As shown in FIG. 16, the route E1 moves the measuring section obliquely with respect to the abutting portion J1 from a point e1 on the surface 102b of the second metal member 102 to a point e2 on the surface 101b of the first metal member 101. That is, the measuring section passes through the surface 102b of the second metal member 102, the abutting portion J1, and the surface 101b of the first metal member 101. Thereby, as shown in the upper part of FIG. 17, the step dimension h can be measured.

In addition, the route E2 moves the measuring section obliquely with respect to the abutting section J1 from the point e3 on the surface 102b of the second metal member 102 to the point e4 on the surface of the pedestal 21. Route E2 and route E1 are parallel. In other words, the measuring section passes through the surface 102b of the second metal member 102, the abutting portion J1, the surface 101b of the first metal member 101, and the pedestal 21. Thereby, as shown in the middle part of FIG. 17, the step dimension h and the distance from the surface of the pedestal 21 to the surface 101b of the first metal member 101 (first thickness dimension t11) can be measured.

In addition, the route E3 moves the measuring section obliquely with respect to the abutting section J1 from the point e5 on the surface 102b of the second metal member 102 to the point e6 on the surface of the pedestal 21. Route E3 and route E2 are parallel. That is, the measuring section passes through the surface 102b of the second metal member 102 and the pedestal 21. Thereby, as shown in the lower part of FIG. 17, the distance (second thickness dimension t12) from the surface of the pedestal 21 to the surface 102b of the second metal member 102 can be measured.

The first thickness dimension t11 and the second thickness dimension t12 may be measured as described above. Moreover, the first thickness dimension t11 and the second thickness dimension t12 may be measured by other methods or other instruments.

[E. Second embodiment]
Next, a second embodiment of the present invention will be described. The second embodiment is different from the first embodiment described above in the method of calculating the corrected movement route. The second embodiment will be mainly described with respect to parts that are different from the first embodiment. In the first embodiment described above, the target movement route R1 is displaced based on the difference between the travel trajectory traveled with the rotary tool F inserted and the travel trajectory traveled with the rotary tool F moved with no load. A corrected movement route R2 was set at the position. In the second embodiment, a corrected movement route R2b is set at a position to which the set movement route P1b is displaced based on the difference between the travel trajectory moved with the rotary tool F inserted and the target movement route. In the second embodiment, the method of setting the corrected moving route R2b at a position where the set moving route P1b is displaced approximately parallel to the set moving route P1b is the same as the setting of the corrected moving route R2 based on the difference YL described in the first embodiment. can be done. In addition, in the second embodiment, the method of setting the corrected movement route R2b at a position where the set movement route P1b is obliquely displaced is based on the corrected movement route R2b based on the difference σ1 explained in the first modification of the first embodiment above. This can be done in the same way as setting route R2a.

FIG. 18 is a schematic plan view for explaining a method of calculating a corrected movement route according to the second embodiment. FIG. 18 shows a target movement route R1b, a set movement route P1b, a test trajectory Q2b, and a modified movement route R2b. In the method for calculating a corrected movement route according to the second embodiment, a test trial is performed using a pair of metal members 301 and 302 to generate a corrected movement route R2b. It is preferable that the metal members 301 and 302 have the same or similar material, thickness, etc., as the first metal member 101 and the second metal member 102 to which friction stir welding is actually performed. That is, similarly to the abutting part J1 formed by the first metal member 101 and the second metal member 102, the abutting part J30 is formed by abutting the metal members 301 and 302 against each other. That is, in this test trial, compared to the first metal member 101 and the second metal member 102, a plate-like member made of the same type of metal and having the same thickness dimension was It is preferable to use two metal members 301 and 302 having different surface height positions, which are butted against each other so as to form a .

Similar to the target movement route R1 described in the first embodiment, the target movement route R1b is used to set a target trajectory along which the rotary tool F moves when performing friction stir welding of the butt portion J1.

The set movement route P1b is a designated position for moving the rotary tool F, similar to the set movement route generation unit 65 described in the first embodiment. The set movement route P1b is used to generate a modified movement route R2b using the displacement of the locus of the rotary tool F.

The test trajectory Q2b is a travel trajectory in which the rotary tool F is inserted into the metal members 301 and 302, and is moved while performing friction stir welding by controlling the rotary tool F to move along the set movement route P1b. .

The corrected movement route R2b is a designated position for moving the rotary tool F, similar to the corrected movement route R2 described in the first embodiment. In particular, the corrected movement route R2b indicates a trajectory along which the rotary tool F is controlled to move when performing friction stir welding of the butt portion J1. By controlling the rotary tool F to move along the corrected movement route R2b, friction stir welding is performed so that the rotary tool F moves along the target movement route R1b. Furthermore, as will be described later, the corrected movement route R2b is set using the test trajectory Q2b and the target movement route R1b.

In the method for calculating a corrected movement route according to the second embodiment, first, the target movement route generation unit 61 sets a target movement route R1b. The target movement route R1b is a route along which the rotary tool F is actually desired to be moved. In this modification, the target movement route R1b is set on the surface of the first metal member 301 in parallel with the abutting portion J30.

Next, the set movement route generation unit 65 sets the set movement route P1b at a position displaced in parallel from the target movement route R1b. The set movement route P1b is a virtual movement route determined by inputting it into the friction stirrer 4. The set movement route P1b is set on the opposite side of the target movement route R1b from the abutting portion J30.

Next, the rotary tool F is moved along the set movement route P1b to obtain a test trajectory (traveling trajectory) Q2b. The test trajectory Q2b can be obtained as an approximate straight line based on measurement data. Here, the rotary tool F is inserted into the surface of the first metal member 301, and the rotary tool F is moved along the set movement route P1b. At this time, as described above, when the rotary tool F is moved along the abutting portion J30, the first metal member 301 and the second metal member 302 come into contact with the rotary tool F, thereby changing the posture of the arm robot 31. Correspondingly, the traveling locus of the rotary tool F is displaced obliquely. Further, since the thickness of the metal member 302 is thinner than that of the metal member 301, the traveling locus of the rotary tool F is displaced approximately parallel to the thin plate side (metal member 302). As a result, as the rotary tool F advances, a difference occurs between the test trajectory Q2b and the target movement route R1b in terms of inclination and distance.

Therefore, the corrected movement route generation unit 63 sets a corrected movement route R2b based on the difference between the test trajectory Q2b and the target movement route R1b. Specifically, the corrected movement route generation unit 63 determines that the test trajectory Q2b is displaced by the angle at which the test trajectory Q2b, which is the travel trajectory with the tool inserted, is obliquely displaced with respect to the target movement route R1b. The traveling direction (inclination) of the set movement route P1b is obliquely displaced in the opposite direction, and the test trajectory Q2b, which is the travel trajectory with the tool inserted, is approximately parallel to the target movement route R1b. A corrected movement route R2b is set at a position where the set movement route P1b is displaced substantially parallel to the direction in which the test trajectory Q2b is displaced by the length of the displacement.

By moving the rotation tool F along the corrected movement route R2b, the rotation tool F is moved on the target movement route R1b.

In this way, in the second embodiment, the modified movement route R2b can be set. The friction stir control unit 55 controls the rotary tool F to move along the corrected movement route R2b, so that the difference is absorbed, the rotary tool F moves on the target movement route R1b, and friction stir welding is performed. Becomes exposed. That is, in this embodiment, the traveling direction (inclination) of the set movement route P1b is changed diagonally based on the angle of the difference between the test trajectory Q2b, which is the travel trajectory with the rotary tool F inserted, and the target movement route R1b. A corrected movement route R2b is set at the position displaced to . As a result, similarly to the first modification of the first embodiment, the diagonal movement of the running trajectory of the rotary tool F, which occurs depending on the posture of the arm robot 31 of the friction stir device 4 for joining the metal members 101 and 102, can be avoided. By setting a movement route that suppresses displacement, it is possible to improve bonding quality. In addition, in this embodiment, the set movement route P1b is displaced approximately in parallel to a position based on the length of the difference YL between the test trajectory Q2b, which is the travel trajectory with the tool inserted, and the target movement route R1b. A modified movement route R2b is set. As a result, similarly to the first embodiment, it is possible to set a movement route that suppresses the substantially parallel displacement of the traveling locus of the rotary tool F that occurs depending on the set state of the metal members 101 and 102, thereby improving the joining quality. I can do it. Therefore, by displacing the traveling direction of the set movement route P1b obliquely and setting the corrected movement route R2b at a position displaced approximately in parallel, it is possible to reduce the influence of the friction stirrer that performs welding and the effect of the metal members that perform welding. By performing friction stirring while mitigating both the effects, it is possible to further improve the bonding quality.

In addition, in the second embodiment, based on the difference between the test trajectory Q2b, which is the travel trajectory with the tool inserted, and the target movement route R1b, the corrected movement route R2b is set at a position where the set movement route P1b is displaced. Set. As a result, in this embodiment, there is no need to move the rotary tool F in a no-load state as explained in the first embodiment, so that the running trajectory during welding can be adjusted without performing a test run in a no-load state. By comparing the corrected movement route R2b with the target movement route, it is possible to easily set the corrected movement route R2b.

Note that in the second embodiment described above, the case where a test trial for generating the corrected movement route R2b is performed using the pair of metal members 301 and 302 has been described as an example; The modified movement route R2b may be generated using the joining result obtained using the two-metal member 102. In other words, when friction stir welding is performed multiple times in a row under approximately the same conditions for the abutting portion J1 of the first metal member 101 and the second metal member 102, the target movement route for a certain time of welding is A corrected movement route R2b may be set according to R1b, the set movement route P1b, and the test trajectory Q2b, and this corrected movement route R2b may be used as the set movement route P1b in subsequent joins.

[F. others]
Each embodiment and each modification example mentioned above can be combined as appropriate.
For example, the automatic joining system 1 sets a corrected movement route by combining the setting of the corrected movement route explained in the first embodiment and the setting of the corrected movement route explained in the first modification of the first embodiment. You can do it like this.

In this case, as shown in FIGS. 19 and 20, the control device 5 sets the target movement route R1c based on the ridgeline position Yp, and displaces the target movement route R1c obliquely toward the first metal member 101. At the same time, a corrected movement route R2c is calculated at a position displaced substantially parallel to the first metal member 101 side with respect to the target movement route R1c.

More specifically, as shown in FIG. 20, the control device 5 moves the rotary tool F along a predetermined set movement route with the rotary tool F inserted into at least one of the pair of metal members 301 and 302. A test trajectory Q2c is obtained in which the test trajectory Q2c is controlled to move while performing friction stir welding. Further, the control device 5 causes the rotary tool F to move along the set movement route equivalent to that when acquiring the test trajectory Q2c without inserting the rotary tool F into the metal members 301 and 302 and in an unloaded state. A test trajectory Q1c that is controlled and moved is acquired. The test trajectory Q2c is displaced approximately parallel to the left side (thin plate (second metal member 302) side) by a difference YL from the test trajectory Q1c in the no-load state (see imaginary line r), and is displaced to the left side (thin plate (second metal member 302) It is obliquely displaced toward the member 302) side with a difference of an angle σ2. As shown in FIG. 19, the corrected movement route generation unit 63 changes the direction of movement of the target movement route R1c toward the direction of movement of the rotary tool F based on the difference YL and the difference σ2 between the test trajectory Q2c and the test trajectory Q1c. While diagonally displacing the difference σ2 toward the thick plate (first metal member 101) (see imaginary line r in FIG. 19), the displaced target movement route R1c (imaginary line r) is moved toward the thick plate (first metal member 101). A corrected movement route R2c is calculated in which the indicated position of the rotary tool F is set at a position displaced substantially parallel to the member 101) by the difference YL.

Thereby, the corrected movement route generation unit 63 can set a movement route that suppresses the substantially parallel displacement of the running trajectory of the rotary tool F that occurs depending on the set state of the metal members 101 and 102. In addition, the modified movement route generation unit 63 generates a movement route that suppresses diagonal displacement of the travel trajectory of the rotary tool F that occurs depending on the posture of the arm robot 31 of the friction stirrer 4 for joining the metal members 101 and 102. can be set. Therefore, by performing friction stirring, it is possible to further improve the joining quality by mitigating both the influence of the metal members performing the joining and the influence of the friction stirring device performing the joining.

<Test 1: Relationship between step dimension h and burr height S>
Next, examples of the present invention will be described. First, Test 1 was conducted to confirm the relationship between the step dimension h and the burr height S. In Test 1, as shown in FIG. 21A, a first metal member 101 and a second metal member 102 were prepared. The step dimension h refers to the dimension from the surface 101b of the first metal member 101 to the surface 102b of the second metal member 102. The burr height S was determined by measuring the distance from the surface 102b of the second metal member 102 to the tip of the burr using the measuring unit 34.

Both the first metal member 101 and the second metal member 102 are made of aluminum alloy. The first metal member 101 has a thickness of 2.0 mm, and the second metal member 102 has a thickness of 1.2 mm. Therefore, as shown in FIG. 21A, when the entire back surfaces 101c and 102c of the first metal member 101 and the second metal member 102 come into surface contact with the pedestal 21, the step dimension h becomes 0.8 mm.

FIG. 21B is a schematic side view showing a state in which the step size of the first metal member and the second metal member is large in Test 1 of the example. As shown in FIG. 21B, if the end of the first metal member 101 is warped upward when the two members are butted together, the step dimension h may become large (excessive). Foreign matter such as dust may enter between the first metal member 101 and the pedestal 21, causing the first metal member 101 and the pedestal 21 to warp.

On the other hand, FIG. 21C is a schematic side view showing a state in which the step size of the first metal member and the second metal member is small in Test 1 of the example. As shown in FIG. 21C, if the end of the second metal member 102 is warped upward when the two members are butted together, the step dimension h may become smaller (too small). Foreign matter such as dust may enter between the second metal member 102 and the pedestal 21, causing the second metal member 102 and the pedestal 21 to warp.

Moreover, FIG. 21D is a schematic side view showing another state in which the step size of the first metal member and the second metal member is small in Test 1 of the example. As shown in FIG. 21D, if the end of the second metal member 102 is curved when the two members are butted together, the step dimension h may become smaller (too small). In particular, since the second metal member 102 has a small plate thickness, its ends are likely to warp or curve.

In Test 1, a plurality of test specimens were prepared as a set of the first metal member 101 and the second metal member 102, and the step dimension h was measured for each specimen by moving the measurement unit 34 over the entire length of the butt portion J1. Afterwards, friction stir welding was performed under the same conditions. After bonding, the burr height S of each specimen was measured by moving the measurement unit 34 over the entire length of the abutting portion J1.

FIG. 22 is a graph showing the relationship between the step size and the burr height in Test 1 of the example. In FIG. 22, two specimens were extracted from a plurality of specimens, and two points were extracted from each specimen to confirm the step dimension h and the burr height S. The result G1 in FIG. 22 extracts a position where the step size h is small in one of the test specimens, the step size h=0.73 mm, and the burr height S=-0.185 mm. When the burr height S is negative, it means that there is an undercut.

The result G2 in FIG. 22 extracts the position where the step dimension h is approximately the median value in one test specimen, the step dimension h=0.75 mm, and the burr height S=0.067 mm.

The result V1 in FIG. 22 extracts the position where the step dimension h is approximately the median value in the other test specimen, the step dimension is 0.78 mm, and the burr height S is 0.065 mm. The result V2 extracts a position where the step size is large in the other test piece, and the step size h=0.093 mm and the burr height S=0 mm.

From the results shown in FIG. 22, it can be seen that the step size h influences the burr height S. If the result is G1, an undercut has occurred, so the step dimension h is too small. Further, as shown in result V2, when the step dimension h=0.93 mm is exceeded, there is a tendency for undercutting to occur. Therefore, it is preferable that the predetermined numerical range of the step size h be set to, for example, 0.75≦h≦0.93.

According to Test 1, when the step dimension h gradually increases from around the median value (0.8 mm), the position Yn of the rotary tool F shifts toward the second metal member 102, which has a smaller plate thickness, and the burr height S increases. There was a tendency for it to become smaller. On the other hand, if the step dimension h becomes too small (approximately 0.73 mm), the influence on the position Yn of the rotary tool F is small; It is presumed that the end of 102 was scraped off, causing an undercut.

Further, the slope of the graph on the smaller side of the step size h is larger than the slope of the graph on the larger side. In other words, it is considered that the amount of decrease in the burr height S greatly affects the lifting of the second metal member 102.

<Test 2: Relationship between gap amount D and burr height S>
Next, Test 2 was conducted to confirm the relationship between the gap amount D and the burr height S. In Test 2, a set of six test specimens each (test specimens TP11, TP12, TP13, TP14, TP15, TP16) was prepared using the first metal member 101 and the second metal member 102, and friction stir welding was performed. . Before performing friction stir welding, the measuring section 34 was moved along the abutting section J1 to measure the gap amount D, respectively. The gap amount D is the gap size between each member before friction stir welding. Both the first metal member 101 and the second metal member 102 are made of aluminum alloy. The step dimension h between the first metal member 101 and the second metal member 102 is 0.8 mm. The joining length is 1800 mm.

FIG. 23 is a graph showing the relationship between the running distance and the amount of gap before joining in Test 2 of the example. As shown in FIG. 23, test specimens TP11, TP12, and TP13 are the results of measuring the gap amount from the starting position (traveling distance 0 mm) to 1000 mm. Test specimens TP14, TP15, and TP16 are the results of measuring the amount of gap from the end position (position at a travel distance of 1800 mm) to 1000 mm. As shown in FIG. 23, the gap amount D before friction stir welding becomes gradually smaller on the start position side as the distance from the start position increases. On the other hand, the gap amount D before friction stir welding gradually increases from near the middle of the travel distance to the end position. The end faces 101a and 102a of the first metal member 101 and the second metal member 102 are usually formed into substantially straight lines. Therefore, when the first metal member 101 and the second metal member 102 are butted against each other, the first metal member 101 and the second metal member 102 are arranged so that one of the start position and the end position is close to each other, and a gap is left in the other. It is considered that because the two metal members 102 are arranged in a state where they are slightly apart from each other rather than being parallel, the gap amount D becomes larger as the starting position or the ending position is approached.

FIG. 24 is a graph showing the relationship between the gap amount on the start position side and the burr height on the start position side in Test 2 of the example. FIG. 24 is a graph showing the relationship between the gap amount on the end position side and the burr height on the end position side in Test 2 of the example.

In FIG. 24, a result Ds1 was extracted from the test specimen TP11 in FIG. 23, a result Ds2 was extracted from the test specimen TP12 in FIG. 23, and a result Ds3 was extracted from the test specimen TP13 in FIG.
In the result Ds1, the gap amount D=0.6 mm and the burr height S=-0.01 mm.
In the result Ds2, the gap amount D=0.4 mm and the burr height S=0 mm.
In the result Ds3, the gap amount D=0 mm and the burr height S=0.029 mm.

In FIG. 25, a result De1 was extracted from the test body TP14 in FIG. 23, a result De2 was extracted from the test body TP15, and a result De3 was extracted from the test body TP16.
In the result De1, the gap amount D=0.95 mm and the burr height S=0.06 mm.
In the result De2, the gap amount D=0.70 mm and the burr height S=0.05 mm.
In the result De3, the gap amount D=0.30 mm and the burr height S=0.06 mm.

As shown in FIGS. 24 and 25, as the gap amount D on the starting position side became larger, the burr height S on the starting position side became smaller. However, the result Ds1 is undercut. It is considered that when the gap amount D increases, the rotary tool is inserted deeply even with the same set load (pushing load), and the rotary tool F is displaced toward the second metal member 102 having a smaller plate thickness.

As shown in FIG. 25, on the end position side, the burr height S on the end position side was almost constant regardless of the gap amount D on the end position side. This is presumed to be due to the fact that the gap gradually becomes smaller as the abutting portion J1 is joined and the friction stir welding progresses toward the end position. It is also presumed that this is due to the fact that the first metal member 101 and the second metal member 102 expand due to frictional heat and the gap becomes smaller. In view of the results shown in FIGS. 24 and 25, it was found that the gap amount D on the start position side has a greater influence on the burr height S than on the end position side. In other words, when comparing the gap amount D with a predetermined numerical range, the gap amount over the entire length of the butt portion J1 may be considered, but for example, the gap amount at a predetermined distance (for example, 50 to 100 mm) from the starting position may be compared. It is preferable to extract and compare.

<Test 3: Relationship between the position of rotating tool F and burr height and oxide film during friction stir welding>
Next, Test 3 was conducted to confirm the relationship between the position of the rotary tool F during friction stir welding, the burr height, and the oxide film. As shown in FIG. 26, in Test 3, after abutting the first metal member 101 and the second metal member 102 to form an abutment part J1, the rotary tool F was not moved along the abutment part J1; The rotary tool F was moved diagonally so as to gradually move away from the abutting portion J1, and the relationship between the position Yn of the rotary tool F, the burr height S, and the oxide film K was confirmed. In FIGS. 26 and 27, for convenience of explanation, the scales in the X direction and the Y direction are changed to make it easier to understand the movement in the Y direction. In FIG. 26, the rotation tool F is moved from the front side to the back side of the drawing.

In FIG. 26, a set movement route Rt that is controlled when moving the rotary tool F in a no-load state and a movement route Rn that is actually passed when the rotary tool F is inserted into a metal member and subjected to friction stirring are shown. It shows a relationship. As shown in FIG. 26, in this example, the movement route Rn of the rotary tool F is set to pass from point α to point β. Point α is on the abutting portion J1 and is located at a joining distance of 100 mm. Point β is a position where the joining distance is 1800 mm and is 1.0 mm from the abutting portion J1 toward the first metal member 101 side.

FIG. 27 is a graph showing the relationship between the joining distance and the position in the Y direction in this example. The set travel route Rt in FIG. 27 is a travel route set for a test trial. The position Yt indicates the locus that the rotation center axis of the rotation drive means of the friction stirrer 4 actually passes when the rotation tool F is moved along the set movement route Rt without being inserted. The trajectory can be measured by the measurement unit 34 (line sensor). The minus side in FIG. 27 is the first metal member 101 side with the butt portion J1 in between, and the plus side is the second metal member 102 side. As shown at position Yt, when the rotary tool F is moved without being attached and under no load, the set movement route Rt and the actual locus of the rotation center axis generally overlap.

On the other hand, as shown in FIG. 27, when the rotary tool F is attached and friction stir welding is actually performed along the set movement route Rt, the rotary tool F passes along a trajectory represented by the position Yn of the rotary tool F. In other words, since the machine (arm robot 31) has deflections, quirks, etc., and there is also resistance that the rotary tool F receives from the first metal member 101 and the second metal member 102, the rotary tool F is moved along the set movement route Rt at the starting position. Even if F is inserted, in this embodiment, the rotary tool F is immediately displaced to the vicinity of Y=0, and thereafter moves to a position deviated from the set movement route Rt, almost parallel to the set movement route Rt. As shown by the (Yn-Yt) value in FIG. 27, in this example, a deviation (difference) of approximately 1.5 mm occurs between the set movement route Rt and the trajectory represented by the position Yn. Therefore, in friction stir welding, it is preferable to set a movement route (corrected movement route) in consideration of this difference in trajectory.

FIG. 28A is a cross-sectional view at a position where the bonding distance is 100 mm in Test 3 of the example. FIG. 28B is a cross-sectional view at a position where the bonding distance is 600 mm in Test 3 of the example. FIG. 28C is a cross-sectional view at a position where the bonding distance is 800 mm in Test 3 of the example. FIG. 29A is a cross-sectional view at a position where the bonding distance is 1000 mm in Test 3 of the example. FIG. 29B is a cross-sectional view at a position where the bonding distance is 1200 mm in Test 3 of the example. FIG. 29C is a cross-sectional view at a position where the bonding distance is 1800 mm in Test 3 of the example.

28A to 28C and FIGS. 29A to 29C show a state in which the position Yn of the rotary tool F during friction stir welding from the abutting portion J1 moves away from the abutting portion J1 as the welding distance progresses. The dotted line in the figure indicates the range of the plasticizing region W of the rotary tool F. The burr height S measures the height of the second metal member 102 from the surface 102b.

As shown in FIG. 28A, the abutting portion J1 at a position where the welding distance is 100 mm and the position Yn of the rotary tool F coincide. The burr height S (S10) is 0.034 mm.
As shown in FIG. 28B, the distance Lj from the abutting portion J1 at a position where the joining distance is 600 mm to the position Yn of the rotary tool F is 554 μm. The burr height S (S11) is 0.095 mm.

As shown in FIG. 28C, the distance Lj at the position where the bonding distance is 800 mm is 686 μm. The burr height S (S12) is 0.105 mm.

As shown in FIG. 29A, the distance Lj at a position where the bonding distance is 1000 mm is 743 μm. The burr height S (S13) is 0.092 mm.
As shown in FIG. 29B, the distance Lj at the position where the bonding distance is 1200 mm is 840 μm. The burr height S (S14) is 0.113 mm.

As shown in FIG. 29C, the distance Lj of the bonding distance of 1800 mm is 1085 μm. The burr height S (S15) is 0.123 mm.

As shown in FIGS. 28A to 28C and 29A to 29C, as the position Yn of the rotary tool F moves away from the abutting portion J1, the burr height S (the burr height on the second metal member 102 side) gradually increases. You can see that In other words, it can be seen that as the position Yn of the rotary tool F approaches the second metal member 102 side, the burr height S becomes smaller.

FIG. 30A is a macro cross-sectional view of the butt portion at a position where the joining distance is 100 mm in Test 3 of the example. FIG. 30B is a macro cross-sectional view of the butt portion at a position where the joining distance is 600 mm in Test 3 of the example. FIG. 30C is a macro cross-sectional view of the butt portion at a position where the joining distance is 800 mm in Test 3 of the example. FIG. 31A is a macro cross-sectional view of the butt portion at a position where the joining distance is 1000 mm in Test 3 of the example. FIG. 31B is a macro cross-sectional view of the abutting portion at a position where the joining distance is 1200 mm in Test 3 of the example. FIG. 32 is a macro cross-sectional view of the butt portion at a position where the joining distance is 1800 mm in Test 3 of the example. That is, FIGS. 30A to 30C, FIGS. 31A, 31B, and 32 are macro cross-sectional views around the abutting portion J1 at each position, showing the size and shape of the oxide film K.

As shown in FIG. 30A, there is no oxide film (K0) at a position where the bonding distance is 100 mm (position Yn=0 of rotary tool F).
As shown in FIG. 30B, the oxide film K (K1) at a position where the bonding distance is 600 mm (position Yn of rotary tool F = 554 μm) is 33 μm.

As shown in FIG. 30C, the oxide film K (K2) at the position where the bonding distance is 800 mm (position Yn of rotary tool F = 686 μm) is 59 μm.
As shown in FIG. 31A, the oxide film K (K3) at the position where the bonding distance is 1000 mm (position Yn of rotary tool F = 743 μm) is 72 μm.

As shown in FIG. 31B, the oxide film K (K4) at the position where the bonding distance is 1200 mm (position Yn of rotary tool F = 840 μm) is 115 μm.
As shown in FIG. 32, the oxide film K (K5) at a position where the bonding distance is 1800 mm (position Yn of rotary tool F = 1085 μm) is 235 μm.

FIG. 33 is a graph showing the relationship between the position of the rotary tool, the burr height, and the oxide film height in Test 3 of the example. As shown in FIG. 33, the burr height S gradually increases as the position Yn of the rotary tool F during friction stir welding moves away from the abutting portion J1. Further, the oxide film K gradually becomes larger as the position Yn of the rotary tool F during friction stir welding moves away from the butt portion J1. In other words, when the position Yn of the rotary tool F during friction stir welding approaches the butt portion J1, both the burr height S and the oxide film K become smaller.

According to the results in FIG. 33, for example, when the threshold values for the burr height S and the oxide film K height are set to 0.10 mm, the position Yn of the rotary tool F is from the abutting portion J1 to the second metal member 102 side. It is preferable to set the distance within 0.6 mm (600 μm).

Therefore, as shown in FIG. 34, when the measuring part 34 is moved along the abutting part J1 and the ridge line of the first metal member 101 is measured to measure the ridge line Yp, the first metal member It is preferable to set the allowable range M to be 0.6 mm (m=0.6 mm) on the 101 side and 0.3 mm (m=0.3) on the second metal member 102 side. Note that the range of the permissible range M is merely an example, and may be appropriately set based on the required joining accuracy and the like.

<Test 4: Relationship between temperature and cavity defect size>
Next, Test 4 was conducted to confirm the relationship between temperature and cavity defect size. In test 4, four first metal members 101 and second metal members 102 (test specimens TP41, TP42, TP43, TP44) were prepared, the temperature was set before joining, and friction stir welding was performed on each specimen. Ta.

For test specimen TP41, friction stir welding was performed without a heater (room temperature: 20° C.), and the welding speed was increased from 500 mm/min to 1250 mm/min. In the test specimen TP42, friction stir welding was performed with the temperature adjustment unit 23 set at 30° C., and the welding speed was increased from 600 mm/min to 1000 mm/min.

Further, in the test specimen TP43, the temperature adjustment unit 23 was set at 60° C., and the joining speed was increased from 600 mm/min to 1000 mm/min. In addition, in the test specimen TP44, the joining speed, which was set at 90° C. in the temperature adjustment section 23, was increased from 600 mm/min to 1000 min/min.

As shown in FIG. 35, in the test specimen TP41, the temperature of the temperature adjustment section 23 was 20° C., and the size of the cavity defect was extremely large. When the bonding speed was increased, the cavity defect size increased as the speed increased. In the test specimen TP42, the temperature of the temperature adjustment section 23 was 30° C., and the cavity defect size was about 50 μm 2 . When the temperature of the temperature adjustment section 23 was set at 60 to 90° C., almost no cavity defects were observed. In this case, no cavity defects were observed even when the bonding speed was increased.

From the above, it is preferable to set the predetermined numerical range of the temperature T of the temperature adjustment section 23 as 60≦T≦90. In this case, even if the bonding speed is increased, cavity defects are less likely to occur, so the bonding time can be shortened while suppressing the occurrence of cavity defects.

<Test 5: Checking the running trajectory of rotary tool F>
Next, a test (Test 5) was conducted to confirm the difference between the set movement route of the rotary tool F and the trajectory of the rotary tool F during actual friction stir welding. In Test 5, a first metal member 101 and a second metal member 102 having a thinner plate thickness than the first metal member 101 are butted together to form an abutment portion J1, and a rotary tool F is used to friction stir weld the abutment portion J1. did. The length of the abutting portion J1 is 1300 mm.

FIG. 36 is a graph showing the running trajectory of the rotary tool in Test 5. The horizontal axis indicates the X direction (the direction of movement of the rotary tool F), and the vertical axis indicates the Y direction (the left-right direction of the direction of movement of the rotary tool F). The butt portion J1 is set to zero, and the side from the butt portion J1 to the first metal member 101 is set to be negative. As shown in FIG. 36, the set movement route (first movement route) Q1b in Test 5 was set parallel to the abutting portion J1 (Yn=0) at a position of Yn=-3.8 mm. The set movement route P1b is set on the first metal member 101.

The traveling trajectory N1 of Test 5 is the trajectory along which the rotary tool F actually moved when friction stir welding was performed along the set movement route P1b. As shown in the travel trajectory N1, the rotary tool F moves on the abutting portion J1 side (on the second metal member 102 side) rather than the set movement route P1b. Further, the rotary tool F is gradually displaced in the direction of movement so as to approach the abutting portion J1. In other words, even though the set movement route P1b is set parallel to the butt portion J1, when friction stir welding is actually performed, the rotating tool F shifts toward the thin plate side (second metal member 102) as it progresses. do. In Test 5, it was found that the rotary tool F moved approximately within the range of Yn=-1.3 to -0.5.

FIG. 37 is a macrostructure diagram and a microstructure diagram of each position in Test 5. The macro organization chart is a longitudinal cross-sectional view of the rotating tool F in the direction of movement. The microstructure diagram is an enlarged view of a portion of the plasticized region at each location. Here, the bonding conditions at sampling positions X=115, 675, and 1205 mm were confirmed. As shown in FIG. 37, a root flow (joint defect) of 0.16 mm occurred at the sampling position X=115. On the other hand, at the sampling position X=675, 1205 mm, almost no root flow occurs. In other words, it has been found that the further away from the abutting portion J1, the higher the possibility that root flow will occur. Furthermore, it has been found that when a corrected movement route is set by moving parallel to the target movement route by the difference, there is a possibility that the target movement route and the travel trajectory of the rotary tool F that performs friction stir welding may deviate from each other.

<Test 6: Setting the corrected movement route diagonally>
Therefore, the second modified example described above was performed under the conditions of Test 5 to calculate the corrected moving route (second moving route) R2b, and the welding accuracy when performing friction stir welding along the corrected moving route R2b was calculated. A test (Test 6) was conducted to confirm this. FIG. 38 is a schematic plan view for explaining a method of calculating a corrected movement route according to Test 6. As shown in FIG. 38, the target movement route R1b was set at a position of Yn=-0.9 mm. The target movement route R1b is parallel to the abutting portion J1 (Yn=0). The target movement route R1b is a route on which the rotary tool F is desired to travel when performing friction stir welding.

The set movement route (first movement route) Q1b was set parallel to the abutting portion J1 (Yn=0) at a position of Yn=-3.8 mm, as in Test 5. The test trajectory (traveling trajectory) Q2b is an approximate straight line obtained from the driving trajectory N1 of Test 5.

First, a corrected movement route R2b is calculated based on the target movement route R1b, the set movement route P1b, and the test trajectory Q2b. The corrected movement route R2b is made by reversing the inclination of the test trajectory Q2b so that it is line symmetrical with respect to the target movement route R1b, and moving it in parallel in a direction away from the abutting portion J1 at a predetermined distance from the target movement route R1b. Calculate. The predetermined distance refers to the shortest distance Db from the set travel route P1b to the test trajectory Q2b.

Next, the rotary tool F is moved along the corrected movement route R2b to actually perform friction stir welding on the butt portion J1. FIG. 39 is a graph showing the running trajectory of the rotary tool in Test 6. As shown in FIG. 39, the running trajectory N2 of Test 6 is the trajectory that the rotary tool F actually moved when friction stir welding was performed along the modified movement route R2b. Linear line Q3a is an approximate straight line of traveling trajectory N2. When linear Q3a is expressed as a linear function indicated by the X-axis and the Y-axis, y=0.0001x-0.955.

On the other hand, when the test trajectory Q2b, which is an approximate straight line of the traveling trajectory N1 performed in Test 5, is expressed as a linear function indicated by the X axis and the Y axis, y=0.0007x-1.332. In this way, the linear line Q3a obtained by moving the rotary tool F along the corrected moving route R2b has a slope smaller than that of the test trajectory Q2b, and the intercept of the linear line Q3a is the same as the target moving route R1b (Yn=-0 .9 mm (see Figure 38).

FIG. 40 is a macro-organizational diagram of each position in Test 6. The macro organization chart is a longitudinal cross-sectional view of the rotating tool F in the direction of movement. FIG. 41 is a microstructure diagram of each position in Test 6. The microstructure diagram is an enlarged view of a portion of the plasticized region at each location. Here, the bonding conditions at sampling positions X=115, 450, 675, and 1205 mm were confirmed. The Yn value is the distance from the butt portion J1 at each position. FzN is a reaction load acting in the axial direction of the rotary tool F at each position. As shown in FIG. 40, when friction stir welding was performed along the modified movement route R2b, the welding state was good at each sampling position. As shown in FIG. 41, when friction stir welding was performed along the modified movement route R2b, burrs (steps) could be reduced at each sampling position. In addition, root flow did not occur at any of the sampling locations.

From the above, compared to moving the rotary tool F along the set movement route P1b, moving the rotary tool F along the modified movement route R2b allows friction stir welding to be performed at a position closer to the target movement route R1b. I found out that it can be done. Further, when the rotary tool F was moved along the corrected movement route R2b, the welding condition of the joint portion was good.

FIG. 42 is a graph showing the difference between the running trajectories of the rotary tool in Test 5 and Test 6. Linear line N1a represents the difference between travel trajectory N1 of test 5 and set travel route P1b. Linear line N2a is the difference between travel trajectory N2 of test 6 and corrected travel route R2b. As shown in FIG. 42, the linear N1a and the linear N2a have approximately the same value. This is thought to be because the direction in which the arm 31a receives force changes as the rotary tool F advances and the posture of the arm robot 31 changes, causing the second moment of area to change and the amount of deflection to change as well. In other words, it is inferred that the amount of deflection (difference) is determined by the attitude of the arm robot 31 (the attitude in the traveling position X direction).

<Test 7: Left and right position of the rotating tool and reaction load acting on the rotating tool>
FIG. 43 is a cross-sectional view showing the joint in Test 7. In test 7, a first metal member 101 and a second metal member 102 having a thinner plate thickness than the first metal member 101 are butted together to form an abutment portion J1, and a rotary tool F is used to friction stir weld the abutment portion J1. did. As shown in Fig. 43, when friction stir welding is performed, the Y position (left and right position with respect to the direction of movement of the rotary tool F) and Z position are measured, and the influence of these on the joint part is confirmed. A test (Test 7) was conducted to Three types of Test 7 were conducted under different conditions (Test 7 (1), Test 7 (2), and Test 7 (3)).

As shown in FIG. 43, the Y position refers to the distance from the abutting portion J1 to the center F5 of the flat surface of the tip end pin F3. The Z position refers to the depth from the surface of the first metal member 101 on the thick plate side to the center F5 of the flat surface of the tip side pin F3, and measures the load (reaction force load) Fz received in the axial direction of the rotary tool F. You can understand it by doing this. FIG. 44 is a graph showing the relationship between the Y position of the rotary tool and the load in Test 7(1).

In test 7 (1), an arbitrary set movement route is set, and the rotary tool F is moved along the set movement route to perform friction stir welding. The joining length of the butt portion J1 is 1300 mm. As shown in FIG. 44, a line H1 indicates a travel locus of the rotary tool F. According to the line H1, the rotary tool F is moving the plate side (first metal member 101) that is thicker than the abutting portion J1 substantially parallel to the abutting portion J1. Linear H2 indicates the load Fz that was applied in the axial direction of the rotary tool F when Test 7(1) was performed. Although the load Fz increases and decreases to some extent, it is generally a constant value.

FIG. 45 is a macro organizational chart of each position in Test 7(1). The macro organization chart is a longitudinal cross-sectional view of the rotating tool F in the direction of movement. Here, the bonding conditions at the sampling positions Xα (front part), Xβ (center part), and Xγ (back part) were confirmed. As shown in FIG. 45, the bonding conditions were good at each of the sampling positions Xα, Xβ, and Xγ.

FIG. 46 is a graph showing the relationship between the Yn value of the rotary tool and the load Fz in Test 7(1). In this graph, the position Yn of the rotary tool is shown such that as the negative value increases, it moves toward the thick plate, and as the positive value increases, it moves toward the thin plate. Linear line N10 of the graph represents the trajectory of the position Yn of the rotary tool F and the load Fz in Test 7(1). It can be seen that the line N10 falls within a certain range.

FIG. 47 shows the macro-organizational diagram and micro-organizational diagram of cases KA, KB, KC, and KD in Test 7(1). The macro organization chart is a longitudinal sectional view in the direction of progress. The microstructure diagram is an enlarged view of a part of the plasticized region in each case. As shown in the microstructure of FIG. 47, root flow occurs in cases KA and KC. Furthermore, as shown in the macrostructure, in case KB, the plate thickness at the joint portion is greatly reduced. On the other hand, in case KD, there was no occurrence of root flow or reduction in plate thickness at the joint. In other words, it has been found that if the position Yn of the rotary tool F and the load Fz are out of the allowable range (predetermined numerical range), there is a possibility that a bonding defect may occur.

FIG. 48 is a graph showing the correlation between the Yn value of the rotary tool and the load Fz in Test 7(2). A line N11 in FIG. 48 represents the locus of the position Yn of the rotary tool F and the load Fz in Test 7(2). In test 7(2), friction stir welding was performed with the Y position and load changed from test 7(1).

Under the conditions of plot N12 (marked with a circle), the observation results of the microstructure were good. Under the conditions of plot N13 (triangle mark), the observation results of the microstructure were generally good, but a small root flow occurred. Under the conditions of plot N14 (x mark), the observation results of the microstructure were poor.

FIG. 49 is a graph showing the relationship between the Yn value of the rotary tool and the load Fz in Test 7(3). A line N15 in FIG. 49 represents the locus of the position Yn of the rotary tool F and the load Fz in test (3). In Test 7 (3), 13 types of friction stir welding were performed by changing the Y position and load conditions, and the results are displayed in an overlapping manner. Under the conditions of plot N16 (marked with a circle), the observation results of the microstructure were good. Under the conditions of plot N17 (x mark), the observation results of the microstructure were poor.

Furthermore, according to Tests 7 (1) to (3), the larger the position Yn of the rotary tool F becomes (as the rotary tool F moves away from the abutting portion J1 and toward the thin plate side), the thinner the plate thickness of the joint becomes. It turns out that there is a trend. It was also found that the smaller the position Yn of the rotary tool F (as the rotary tool F gets farther away from the butt portion J1 and toward the thick plate side), the more the root flow tends to increase. It was also found that the smaller the load, the more the root flow tends to increase. It is considered that when the load becomes excessive, the plate thickness at the joint portion tends to become smaller.

In this way, at least one of the position Yn of the rotary tool F during friction stir welding of the rotary tool F and the load (reaction load) Fz acting in the axial direction of the rotary tool F is measured, and at least one of these measurement results is measured. It may be determined whether one of the two is within the allowable range. The corrected movement route generation unit 63 determines that at least one of the left-right position of the rotary tool F during friction stir welding and the reaction force acting in the axial direction of the rotary tool F during friction stir welding is outside the allowable range, that is, If it is determined that the value is outside a predetermined numerical range, it is preferable to calculate a corrected movement route in which the position of the rotary tool F is reset according to the position of the rotary tool F during friction stir welding. Further, it is preferable to perform load control so that the reaction load that the rotary tool F receives is approximately constant by feeding back the reaction load. Thereby, joining accuracy can be further improved.

Furthermore, when it is determined that at least one of the left and right positions and the load Fz of the rotary tool F during friction stir welding is outside the allowable range, the determination unit 64 assigns the first metal member 101 and the second metal member 102 as work numbers. It may be determined that the product is outside the numerical value range by associating it with the product. Thereby, quality control can be easily performed. Note that among the lateral position and load Fz of the rotary tool F during friction stir welding, only the lateral position of the rotary tool F may be measured, and it may be determined whether or not it is within an allowable range based on the measurement result. Alternatively, of the lateral position and load Fz of the rotary tool F during friction stir welding, only the load Fz may be measured, and based on the measurement result, it may be determined whether or not it is within an allowable range. Further, each allowable range may be appropriately set in advance.

1 Automatic joining system 2 Conveying device 3 Fixing device 4 Friction stirring device 5 Control device 22 Suction unit F Rotating tool F2 Proximal pin F3 Distal pin R1 Target movement route R2 Correct movement route θ Aiming angle h Step dimension D Gap amount T temperature

Claims (10)

A first metal member and a second metal member placed on a pedestal are butted with a step by abutting their end surfaces such that the surface of the second metal member is lower than the surface of the first metal member. a fixing device for fixing the part in the formed state;
a friction stir device that includes a rotating tool that performs friction stir and performs friction stir welding of the abutting portion;
a measuring unit that measures the ridgeline position of the first metal member and also measures at least one of the position of the rotary tool and the load applied to the rotary tool;
a control device that controls the fixing device and the friction stir device;
The rotary tool has a proximal pin and a distal pin formed continuously with the proximal pin, and the proximal pin has a taper angle larger than the distal pin; A stepped pin step portion is formed on the outer peripheral surface of the proximal pin,
The control device sets a movement route along which the rotary tool moves when performing friction stir welding of the abutting portion, based on the ridgeline position before performing friction stir welding,
The friction stir device performs friction stir welding along the movement route while holding down the plastic flow material with the bottom surface of the step of the pin step while maintaining a predetermined target angle of the rotary tool,
The control device includes a determination unit that determines whether at least one of the position of the rotary tool during friction stir welding and the load during friction stir welding is within a predetermined numerical range. An automatic joining system featuring: When it is determined that at least one of the position of the rotary tool during friction stir welding and the load during friction stir welding is outside the predetermined numerical range, the control device adjusts the position of the rotary tool during friction stir welding to the position of the rotary tool during friction stir welding. The automatic joining system according to claim 1, further comprising calculating a corrected movement route in which the position of the rotary tool is reset accordingly. When it is determined that at least one of the position of the rotary tool during friction stir welding and the load during friction stir welding is outside the predetermined numerical range, the control device controls the first metal member and the second metal member. The automatic joining system according to claim 1 or claim 2, wherein the automatic joining system determines that a product falls outside the numerical value range. The measuring unit measures the ridgeline position and the position of the rotating tool,
The control device sets the movement route and an allowable range of the movement route based on the ridgeline position before performing friction stir welding,
The automatic method according to any one of claims 1 to 3, wherein the determination unit determines whether the position of the rotary tool during friction stir welding is within the allowable range. joining system. The measurement unit measures the ridgeline position and the load,
The automatic welding system according to any one of claims 1 to 3, wherein the determination unit determines whether the load during friction stir welding is within a predetermined numerical range. . The measuring unit measures the ridgeline position, and also measures the position of the rotary tool and the load,
The determination unit determines whether at least one of the position of the rotary tool during friction stir welding and the load during friction stir welding is within a predetermined numerical range. 4. An automatic joining system according to claim 3. The automatic joining system according to any one of claims 1 to 6, wherein the position of the rotary tool is a left-right position with respect to a traveling direction of the rotary tool. The automatic welding system according to any one of claims 1 to 7, further comprising an inspection section that measures at least one of burr height and surface roughness of the joint after friction stir welding. The friction stir device includes a load measuring section that measures an axial reaction force load acting on the rotating tool,
According to any one of claims 1 to 8, the friction stirrer is load-controlled so that the reaction load is approximately constant based on the result of the load measurement unit. automatic joining system. 10. The automatic joining system according to claim 1, wherein the front side of the pedestal is formed of an aluminum or aluminum alloy plate, and an anodized coating is applied to the surface.

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