Advanced rotary friction controller
The advanced rotary friction controller is an innovative technological solution that LORTEK has developed in collaboration with BERKOA, a company specialising in friction welding solutions. This controller enables high quality, high strength joints between similar and dissimilar metallic materials using a controlled application of rotary motion and axial pressure. The controller is based on BLSC 4.0®, a software development that monitors and records process parameters such as speed, torque, force, storing them in a database system for further analysis and traceability that is adapted to the specific needs of each customer and application.
Target/Challenge
Offer a versatile and adaptable solution for joining metallic materials in industrial sectors that require high quality and reliable joints.
In the controller developments, the following challenges have been addressed:
- Selecting and implementing advanced sensor technology to capture the critical variables of the welding process. These sensors provide real-time information on temperature, pressure, torque, speed and position of the welding head.
- Monitoring and controlling welding processes, detecting any possible defects and optimising operating parameters. This provides the machine with the ability to extract useful knowledge from the rotary friction welding process in an automated, objective and intuitive way.
- Implementing EICT technologies, sensors, electric actuators and communications in a controlled way to allow the welding process to be adapted to the characteristics of the materials and parts to be joined.
The controller is adapted to the demand for increased productivity, variability and customisation, "High-Mix Low-Volume (HMLV)" in short series manufacturing of critical application parts, with the associated traceability requirement.
Result
The result of applying this solution is achieving high performance rotary friction welded joints, which have excellent structural integrity, minimal thermal damage and good compatibility between dissimilar materials.
The advanced rotary friction controller has been successfully tested in a test bench allowing Berkoa to offer third parties manufacturing services in product testing, prototyping and short series manufacturing.
- Automotive: Forging and steel connections.
- Tools: F114 and HSS joints.
- Terminals in power lines: Aluminium and copper joints.
An excellent production response has been demonstrated in the tool manufacturing sector, where it is used to join high speed steel parts with carbide inserts.
YouTube: https://www.youtube.com/watch?v=GUk6Y1gOaxc
Sectors
Energy storage
Automotive sector
Components and capital goods
Railway
Machine-Tool
