Automated fusion bonding apparatus
First Claim
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1. A method of fusion bonding a rotatable workpiece to a stationary workpiece comprising the steps of:
- providing an integrated drive-pressure mechanism;
providing a passive fusion bonding mechanism comprising an external housing, said passive fusion bonding mechanism coupled to said drive-pressure mechanism;
providing a support assembly comprising a clamping mechanism;
securing said stationary workpiece to said clamping mechanism in a fixed, non-rotating relationship relative to said rotatable workpiece;
securing said rotatable workpiece to said passive fusion bonding mechanism;
placing said rotatable workpiece in a contacting pressure relationship relative to said stationary workpiece;
maintaining said rotatable workpiece and said stationary workpiece in a relative axial orientation;
providing a source of pressurized fluid energy to said drive-pressure mechanism;
rotating said rotatable workpiece relative to said stationary workpiece, thereby inducing a burn-off phase and an upset phase;
increasing the axial contacting force between said rotatable workpiece and said stationary workpiece to a maximum pressure permitted by a fluid supply source pressure;
completing the fusion bonding process, thereby terminating rotation of said rotatable workpiece relative to said stationary workpiece;
maintaining the axial contacting force between said rotatable workpiece and said stationary workpiece at a rotation termination pressure, until released either manually or automatically after a forging cool-down time sufficient to fuse said rotatable workpiece to said stationary workpiece; and
removing said drive-pressure mechanism from said passive fusion bonding mechanism, thereby permitting removal of said clamping mechanism.
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Abstract
A lightweight, portable automated fusion bonding apparatus consistently permits the accomplishment of fine grain, forged friction weld fusion bonding with the use of pressurized air sources commonly available at industrial facilities, automotive repair shops, and other manufacturing plants. The automated fusion bonding apparatus includes the following integrally coupled components: a drive-pressure mechanism, a passive fusion bonding mechanism, a stationary workpiece clamping mechanism, a rotatable workpiece and a stationary workpiece.
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Citations
47 Claims
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1. A method of fusion bonding a rotatable workpiece to a stationary workpiece comprising the steps of:
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providing an integrated drive-pressure mechanism; providing a passive fusion bonding mechanism comprising an external housing, said passive fusion bonding mechanism coupled to said drive-pressure mechanism; providing a support assembly comprising a clamping mechanism; securing said stationary workpiece to said clamping mechanism in a fixed, non-rotating relationship relative to said rotatable workpiece; securing said rotatable workpiece to said passive fusion bonding mechanism; placing said rotatable workpiece in a contacting pressure relationship relative to said stationary workpiece; maintaining said rotatable workpiece and said stationary workpiece in a relative axial orientation; providing a source of pressurized fluid energy to said drive-pressure mechanism; rotating said rotatable workpiece relative to said stationary workpiece, thereby inducing a burn-off phase and an upset phase; increasing the axial contacting force between said rotatable workpiece and said stationary workpiece to a maximum pressure permitted by a fluid supply source pressure; completing the fusion bonding process, thereby terminating rotation of said rotatable workpiece relative to said stationary workpiece; maintaining the axial contacting force between said rotatable workpiece and said stationary workpiece at a rotation termination pressure, until released either manually or automatically after a forging cool-down time sufficient to fuse said rotatable workpiece to said stationary workpiece; and removing said drive-pressure mechanism from said passive fusion bonding mechanism, thereby permitting removal of said clamping mechanism. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A programmable control system for controlling an automated fusion bonding apparatus, wherein said automated fusion bonding apparatus comprises a drive-pressure mechanism, a drive-pressure mechanism external housing and two or more forging piston chambers, said drive-pressure mechanism slidably engaged to a passive fusion bonding mechanism which holds a rotatable workpiece, said drive-pressure mechanism causing said passive fusion bonding mechanism to rotate and move forward in an axial direction toward a stationary workpiece, so as to induce burn-off, upset, forging and fusion phases to produce a fusion weld between said workpieces, said programmable control system comprising:
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a quick disconnect assembly through which plant air flows to said automated fusion bonding apparatus, said quick disconnect assembly releasably coupled to said drive-pressure mechanism external housing; a power source-control valve disposed within said drive-pressure mechanism external housing to turn on and shut off flow of said plant air; a plurality of pressure-flow passages disposed within said drive-pressure mechanism external housing through which said plant air flows to a rotatable drive means, said forging piston chambers, said drive-pressure mechanism external housing, and the atmosphere as exhaust; a start valve connected to said drive-pressure mechanism external housing which starts circulation of said plant air to said programmable system; a stop valve connected to said drive-pressure mechanism external housing which stops circulation of said plant air to said programmable system; a forging pressure relief valve disposed within said drive-pressure mechanism external housing; diagnostic ports disposed within said drive-pressure mechanism external housing which measure pressure throughout said programmable control system; a programmable regulator means disposed within said drive-pressure mechanism external housing which provides pressure to said piston chambers; a programmable fusion completion triggering means disposed within said drive-pressure mechanism external housing which programs a desired position of said rotatable workpiece and measures said position in a fixed relationship with said stationary workpiece and stops circulation of said plant air to said drive-pressure mechanism when said position is reached; a programmable first timing means disposed within said drive-pressure mechanism external housing, said programmable first timing means releasing a forging pressure from said piston chambers after a preprogrammable time delay after said apparatus is shut down; a programmable second timing means disposed within said drive-pressure mechanism external housing, wherein said programmable second timing means overrides said programmable control system to shut down said apparatus after a preprogrammed time period; a programmable third timing means disposed within said drive-pressure mechanism external housing, wherein said programmable third timing means overrides said programmable control system to provide for a predetermined fusion operational period after said start valve has been depressed; a multiport valve disposed within said drive-pressure mechanism external housing which overrides said start valve and said programmable control system; a programmable governor means disposed within said drive-pressure mechanism which permits selection of a preprogrammable operation speed of said rotatable drive means; and a programmable time delay means disposed within said drive-pressure mechanism external housing which delays a forging pressure rate of increase in one of said forging piston chambers while permitting a more rapid increase in pressure flow in said other forging piston chamber. - View Dependent Claims (11, 12, 13)
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14. A portable welding apparatus for fusion bonding a rotatable workpiece to a stationary workpiece, wherein the fusion bonding process includes burn-off, upset, forging and fusion phases, said apparatus comprising:
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a programmable control system for controlling the operation of said apparatus comprising control flow passages and control elements; means for rotating said rotatable workpiece against said stationary workpiece; an integrated drive-pressure mechanism, in which said means for rotating is disposed, said drive-pressure mechanism imparting a variable axial pressure between said workpieces for an adjustable time period, thereby inducing said phases to create a fusion weld between said workpieces; a drive-pressure mechanism external housing, said control system disposed within said drive-pressure mechanism external housing; a drive-pressure mechanism internal piston housing disposed within the lower part of said drive-pressure mechanism external housing; a passive fusion bonding mechanism slidably coupled to said drive-pressure mechanism external housing and said drive-pressure mechanism internal piston housing, comprising a passive fusion bonding mechanism internal shaft bearing housing, a shaft for holding a rotatable fitting, said shaft disposed within said passive fusion bonding mechanism internal housing, and bearings attached to said shaft; a fluid supply system comprising a plurality of pressure-flow passages operably connected to said drive-pressure mechanism external housing, said fluid supply system conveying fluid to said drive-pressure mechanism to circulate pressurized fluid to and from said means for rotating, said drive-pressure mechanism and said control system; a power source-control piston valve in said drive-pressure mechanism external housing; an upper pressurization chamber connected to said control flow passages and said power source-control piston valve; a start valve connected to said drive-pressure mechanism external housing for selectively starting circulation of said pressurized fluid to said apparatus; a stop valve connected to said drive-pressure mechanism external housing for selectively stopping circulation of said pressurized fluid to said apparatus to stop rotatable motion; and a regulating device connected to said drive-pressure mechanism external housing for selectively regulating the circulation of said pressurized fluid. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 34)
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25. A portable friction welding apparatus for fusion bonding a rotatable workpiece to a stationary workpiece, wherein the fusion bonding process comprises burn-off, upset, forging and fusion phases, said apparatus comprising:
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an integrated drive-pressure mechanism, comprising a drive-pressure mechanism external housing, a drive-pressure mechanism internal piston housing, a rotatable drive means and a rotatable drive means shaft in said drive-pressure mechanism internal piston housing, said drive-pressure mechanism internal piston housing slidably and axially disposed within said drive-pressure mechanism external housing so that a selected axial force is produced; a passive fusion bonding mechanism slidably coupled to said integrated drive-pressure mechanism, said passive fusion bonding mechanism comprising a passive fusion bonding mechanism external housing, a passive fusion bonding mechanism internal shaft-bearing housing, and a passive fusion bonding mechanism shaft, said passive fusion bonding mechanism internal shaft bearing housing slidably disposed in said passive fusion bonding mechanism external housing, said passive fusion bonding mechanism shaft slidably coupled to said rotatable drive means shaft, wherein said passive fusion bonding mechanism shaft holds said rotatable workpiece within said passive fusion bonding mechanism external housing and said passive fusion bonding mechanism shaft rotates said rotatable workpiece in an axial direction toward said stationary workpiece, and further wherein said passive fusion bonding mechanism shaft concurrently translates rotational motion to said rotatable workpiece for said phases; an engagement mechanism coupled to said drive-pressure mechanism and said passive fusion bonding mechanism to translate rotatable motion and axial movement forces to said passive fusion bonding mechanism shaft, thereby rotating said rotatable workpiece toward said stationary workpiece for said phases; and a control system for controlling said fusion bonding process. - View Dependent Claims (26, 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47)
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Specification