Source:JASE-W Japanese Smart Energy Products & Technologies

https://www.jase-w.eccj.or.jp/technologies/index.html

F-26

Keywords

Y3

equipment or facility

Z4

E25

electricity

general-purpose
E26
generalmachinery
machinery

KAWASAKI HEAVY INDUSTRIES, LTD.

Friction Spot Joining SystemFeatures
u Friction Spot Joining (FSJ) is an entirely new joining method which is used on lap joints of aluminum,magnesium, and other light metals.
u The electric power consumption of the FSJ is 1/20 or smaller as compared to Aluminum Resistance SpotWelding (RSW).
u During the FSJ process the material does not actually melt, the heat deformation is minimal.
u The system mechanics are very simplistic with no need for auxiliary equipment as required by the RSW.
Neither cooling water nor compressed air is required, allowing for broad reductions in both equipment andrunning cost.
u The joining tool, used in the FSJ system, is susceptible to little wear and tear, keeping consumable costslow.
u With no dust or fumes to worry about and no need for a large electrical current, the FSJ process is clean
and does not generate any electromagnetic noise.

Basic Concept or Summary
There are 2 types of FSJ, i.e. “stationary system” and “robot system”.

[Stationary FSJ system]
The gun and backing are mounted on a special
trestle. The workpiece is secured by jigs. It canalso be held by a robot manipulator.

[FSJ Robot system]
The system is composed of a 6-axis articulated
robotic arm and an FSJ gun, and is moved tothe work to join. The gun is controlled by the
robot controller as an external drive.

The joining process is very simple, carried out in the following three stages:(1) Plunging: The joining tool, while rotating, is forced against the workpiece with a specified amount ofpressure. This pressure creates frictional heat between the workpiece and the pin on the tip of the tool ,softening the metal and allowing the pin to plunge into the workpiece.
(2) Joining: The pin becomes completely embedded in the workpiece and the press force on the tool ismaintained for a given interval even after the shoulder on the outer edge of the tool comes in contact
with the workpiece.
(3) Withdrawal: The tool and the pin are withdrawn after the joining is completed.
Rotation

Joining tool

ShoulderMaterial tobe joined

Stir zone

PinPlunging

Joining

Withdrawal
Pulling-outEffects or Remarks
The energy consumption can be 1/20 or smaller as compared to RSW, i.e. the energy conservation effectis 95% or more.
Besides, the system mechanics are very simplistic with no need for auxiliary equipment or air, allowing forbroad reductions in both equipment and running cost. This is a system product truly suited to the energy
conservation era.
Example comparison of resistance spot welding and friction spot joining systems structures
Welder power supply

Resistance Spot Welding

FSJ

Resistance spot welder
Timercontrol
deviceRobotpowerpanel

Robotpowerpanel

Joining gun

Welding gun

Robot

Current andvoltage
regulator
RobotTip dresser

The FSJ robot system is based on very simple
mechanics and operation.
For example, it has no need for various peripheraldevices required for resistance spot welding.

Cooling water piping
Robotcontroller

Robotcontroller

Air piping

If compared with other joining systems such as RSW or riveting, it is found that the FSJ is overwhelmingly
good at economic efficiency, as shown in the graph below.

Cost comparison (Our estimation)
Supplementarymaterials
Tip, tool

4.60

Cost per spot (JPY)

4.40

Air supply

1.20
1.00

Cooling water

0.80

Power supply

0.60
0.40
0.20
0.00

Self-piercing
riveting

Resistance spot
welding

Clinching

FSJ

We have a patent for this FSJ technology in Japan, U.S.A. and Europe.
The application of this technology is widening recently covering not only the joint of aluminum alloy but
also the joint of steel and aluminum alloy.
Installation in Practice or Schedule
Domestic A number of the FSJ systems have been shipped to many customers including automobile
manufacturers. However, we are not allowed to disclose the details.

Overseas

A number of the FSJ systems have been shipped to many customers including automobile
manufacturers. However, we are not allowed to disclose the details.

Contact:

Kawasaki Heavy Industries, Ltd., Robot Division
Tel: +81-3-3435-6908 Fax: +81-3-3437-9880
URL: http://global.kawasaki.com/F-26