Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of Provisional U.S. Patent Application No. 60/849,690 filed Oct. 5, 2006, which is incorporated by reference herein. This application is also related to U.S. patent application Ser. Nos. 11/829,897 filed Jul. 28, 2007; 11/771,188 filed Jun. 29, 2007, 11/764,304 filed Jun. 18, 2007; 11/161,731 filed Aug. 15, 2005; 11/053,630 filed Feb. 7, 2005; and 11/041,836 filed Jan. 24, 2005, the entire disclosures of which are incorporated by reference herein. 
     
     TECHNICAL FIELD 
       [0002]    This disclosure generally relates to automated machining processes and equipment, and deals more particularly with a system for controlling processes performed by an automated friction stir welding machine. 
       BACKGROUND 
       [0003]    Friction stir welding (FSW) produces welds using a combination of frictional heating of metal by a rotating tool, and mechanical deformation of the metal by the tool. The tool may include a weld tip comprising a rotating pin surrounded by annular shoulder. FSW tools can be used to perform various types of FSW welding, including fixed tool welding, retractable pin-tool welding and fixed stir spot welding. In order to practice these welding techniques, the pin is designed to retract relative to the shoulder, and both the pin and the shoulder may be independently rotated at the same or different speeds, in the same or opposite directions. The pin penetrates the workpiece and the shoulder rubs top surfaces of the heated metal to produce a weld joint. As the weld is completed, the tool shoulder and pin are withdrawn from the workpiece. 
         [0004]    In order to move a FSW weld tip along a desired weld path, the weld tip may be mounted on a weld head that forms part of a multi-axis motion platform similar to a CNC machining center. In the case of workpieces having more complicated, contoured surfaces, such as those sometimes used in aircraft subassemblies, the problem of coordinating the movements of the FSW weld tip along a highly contoured weld path is challenging. 
         [0005]    Further complicating the task of FSW process control is the need to provide auxiliary process capabilities such as milling, drilling and probing. For example, light milling of the workpiece is often required in order to remove flash or runoff tabs on the workpiece. Drilling may be required to produce through-holes in the workpiece at mounting locations. Probing may be required in order to locate workpiece features so that the exact position of the features is known in relation to the weld tip. 
         [0006]    As a result of the forgoing requirements, CNC-type FSW machines have been produced that are capable of performing multiple FSW operations, including milling, drilling and probing. These processes use different tools and require differing control processes and control parameters. Thus, separate, sometimes proprietary, control systems and software logic may be required to support the individual machine processes, resulting in a relatively complex control system that may lack needed flexibility, particularly when tools or processes must be changed or added to the system. 
         [0007]    Accordingly, there is a need for a process control system for FSW machines having a simplified, open architecture that is flexible and readily adaptable to accommodate new or different tools or processes. Embodiments of the disclosure are directed toward satisfying this need. 
       SUMMARY 
       [0008]    Embodiments of the disclosure provide a process control system for FSW machines capable of carrying out multiple FSW processes as well as auxiliary operations such as milling, drilling and probing. Friction stir welding of workpieces having complex contours may be performed using conventional, single-piece tool welding, or advanced FSW techniques employing separate control of pin and shoulder tools during the weld process. Advanced algorithms may be used to achieve tunable axial force control, weld path force control, adaptive weld force control and position movement limits in combination with the force control. Additionally, tapered thickness welding, two sided welding and friction stir spot welding are possible. 
         [0009]    The disclosed embodiments provide a systematic approach of defining process functionality, system parameters and limits to achieve process control for complex contour friction stir welding using a multi-axis motion platform. Process flow diagrams are used to define process functions in terms of individual steps that may be combined, as desired to produce process sequences for carrying out both simple and complex weld processes. A master set of expandable process parameters and limits are used to define, track and pass information from one level of programming to another. The master set of process parameters and limits provide a common nomenclature that may be used by programming and operating personnel to define processes and carryout machine sequences. The flow diagrams identify required system parameters, limit values and other system checks/values required to be incorporated into program logic. 
         [0010]    In accordance with one disclosed embodiment, a method is provided for controlling a friction stir welding machine, comprising the steps of: generating definitions for each of a plurality of processes that may be performed by the machine; generating a master set of parameters used in the processes; and, using the definitions and the parameters to control the processes. The method may further comprising the step of associating certain of the parameters in the master set of parameters with at least one of the processes for which a definition was generated. The definitions may be generated by generating a plurality of process flowcharts respectively defining the processes, wherein each of the process flowcharts lists the steps for carrying out one of the processes. The method may also include the steps of associating certain of the parameters in the master set with at least certain of the steps in the flowcharts. 
         [0011]    According to another disclosed embodiment, a method is provided for controlling multiple processes performed by a friction stir welding machine, comprising the steps of: generating a set of logic defining steps for carrying out each of the processes; generating a set of programmed instructions for controlling the machine based on the generated logic, including generating subroutines for controlling machine operations used in carrying out the processes; generating sets of process parameters respectively used in the subroutines to control the machine operations; and, using the programmed instructions and the parameters to control the machine. The logic may be generated by generating software flowcharts for each of the subroutines. The multiple processes may include one or more of the following: fixed tool welding, retractable pin-tool welding, fixed stir spot welding, milling, adaptive milling, drilling, and probing. The sets of generated process parameters may include one or more of the following: command parameters used in commanding the operation of the machine; measurement parameters reflecting the response of the machine to commanded operations; and process limit parameters defining selected limits on the processes performed by the machine. 
         [0012]    According to a further disclosed embodiment, a method of controlling a friction stir welding machine is provided, comprising the steps of: generating a set of programmed instructions for automatically controlling operations performed by the machine on a workpiece; selecting a set of parameters used by the programmed instructions for controlling the machine operations; programming a controller using the generated programmed instructions and the selected parameters; and, using the controller to operate the machine. Selection of the parameters may be performed by: selecting a first a set of parameters defining operating characteristics of at least one welding tool; selecting a second set of parameters defining operating characteristics of a clamping system for clamping the workpiece during a weld operation; and, selecting a third set of parameters defining operating characteristics of a motion system used to move the weld tool and the clamping system along a weld path on the workpiece 
         [0013]    Other features, benefits and advantages of the disclosed embodiments will become apparent from the following description of embodiments, when viewed in accordance with the attached drawings and appended claims. 
     
     
       BRIEF DESCRIPTION OF THE ILLUSTRATIONS 
         [0014]      FIG. 1  is a block diagram illustrating the relationship between process definitions, process parameters and subroutines used in a process control system. 
           [0015]      FIG. 2  is a side illustration of an FSW machine using the process control system according to the disclosed embodiments. 
           [0016]      FIG. 3  is a front illustration of the FSW machine shown in  FIG. 2 . 
           [0017]      FIG. 4  is an isometric illustration of a weld head forming part of the FSW machine illustrated in  FIGS. 2 and 3 . 
           [0018]      FIG. 5  is an isometric, cross-sectional illustration of a spindle forming part of the weld head illustrated in  FIG. 4 . 
           [0019]      FIG. 6  is a combined block and diagrammatic illustration of a system for controlling the FSW machine shown in  FIGS. 2 and 3 . 
           [0020]      FIG. 7  is a flow diagram illustrating the steps for generating sets of process parameters and process definitions used in the process control system. 
           [0021]      FIG. 8  is a flow diagram illustrating the logic steps for carrying out a sequence of find, measure, drill, weld and mill operations according to the process control system. 
           [0022]      FIG. 9  is a flow diagram illustrating further details of the steps for performing the find operation. 
           [0023]      FIG. 10  is a flow diagram illustrating further steps for performing the measure operation. 
           [0024]      FIG. 11  is a flow diagram illustrating further steps for performing the drill operation. 
           [0025]      FIG. 12  is a flow diagram illustrating further steps for performing a weld operation. 
           [0026]      FIG. 13  is a flow diagram illustrating further steps for performing a mill operation. 
           [0027]      FIGS. 14   a - 14   c , taken together, form a table of command parameters which identifies their use in each of the subroutines. 
           [0028]      FIGS. 15   a - 15   c , taken together, form a table of the primary measurement parameters, illustrating their use in each of the subroutines. 
           [0029]      FIGS. 16   a - 16   c , taken together, form a table illustrating the process limits and their use in each of the subroutines. 
           [0030]      FIGS. 17   a - 17   b , taken together, form a table illustrating the functional parameters used in the process control system. 
           [0031]      FIG. 18  is a flow diagram illustrating the logic used to perform a milling operation using the FSW shoulder spindle. 
           [0032]      FIGS. 19   a  and  19   b , taken together, form a flow diagram illustrating the process logic for performing an adaptive milling operation using the FSW shoulder spindle. 
           [0033]      FIGS. 20   a - 20   e , taken together, form a flow diagram illustrating a subroutine for determining the correct plunge distance for a weld plunge operation. 
           [0034]      FIGS. 21   a - 21   e , taken together, form a flow diagram illustrating a subroutine for performing a position controlled weld plunge at an adaptive feed rate determined by axial force. 
           [0035]      FIGS. 22   a - 22   b , taken together, form a flow diagram illustrating a subroutine for performing adaptive drilling using clamp force provided by the shoulder tool. 
           [0036]      FIG. 23  is a flow diagram illustrating a subroutine for performing path welding with shoulder axial force control. 
           [0037]      FIGS. 24   a - 24   b , taken together, form a flow diagram illustrating a subroutine for performing position controlled weld plunge at an adaptive feed rate determined by axial force. 
           [0038]      FIG. 25  is a flow diagram illustrating a subroutine for terminating a welding process. 
           [0039]      FIGS. 26   a  and  26   b , taken together, form a flow diagram illustrating a subroutine for adaptive path welding using shoulder position control. 
           [0040]      FIGS. 27   a  and  27   b , taken together, form a flow diagram illustrating a subroutine for performing a position controlled weld plunge at a programmed feed rate. 
           [0041]      FIGS. 28   a  and  28   b , taken together, form a flow diagram illustrating a subroutine for performing path welding using shoulder axial force control. 
           [0042]      FIG. 29  is a flow diagram illustrating a subroutine for performing path welding under shoulder position control. 
           [0043]      FIG. 30  is a flow diagram of aircraft production and service methodology. 
           [0044]      FIG. 31  is a block diagram of an aircraft. 
       
    
    
     DETAILED DESCRIPTION 
       [0045]    Referring first to  FIG. 1 , a process control system for controlling the various operations performed by a FSW machine described below employ a master set of process parameters  158 . The master set of process parameters  158  is used in combination with a set of process definitions  160  and subroutines  162  to provide a flexible system for controlling operations performed by the FSW machine, including various FSW processes and auxiliary operations such as, without limitation, probing, drilling and milling. The master set of process parameters  158  include command parameters, measurement parameters, process limits, function parameters and other parameters as may be required by the particular application. One or more of the subroutines  162  may be employed in carrying out any of the defined processes  160 . Subroutines  162  comprise, for example, without limitation, Force Touch, Plunge Position, Plunge Adaptive, Position Adaptive, Force, Force Adaptive, Weld End, Drill Clamp, Drill Clamp Adaptive, Milling and Adaptive Milling. 
         [0046]    Attention is now directed to  FIGS. 2-6  which depict a CNC controlled FSW machine generally indicated by the numeral  100 , of the type that may be controlled using the process control system of  FIG. 1 . The FSW machine  100  broadly comprises a weld head  110  mounted on a motion platform  103  for movement along X, Y and Z axes. In the drawings, the X and Y axes extend into the page as viewed in  FIGS. 1 and 2 , respectively. The weld head  110  is mounted on a support arm  107  for movement along the Z (vertical) axis. Support arm  107  in turn, is mounted for sliding movement along the Y axis on a gantry bridge  102 . Gantry bridge  102  includes rollers  104  guided by tracks  106  which guide the movement of the gantry bridge  102 , and thus the weld head  110  along the X axis. 
         [0047]    The weld head  110  includes a weld tip  111  for performing FSW operations on a workpiece or part  187 . The weld head  110  is mounted on the support arm  107  for rotation about a “C” axis  118 , and includes a spindle housing  120  pivotally mounted on a yoke  116  for rotation about an “A” axis  122 . The spindle housing  120  is also mounted for linear sliding movement on a track  124 . 
         [0048]    As best seen in  FIG. 4 , the spindle housing  120  contains a pair of coaxial spindles that form corresponding quills  140  and  146  which are independently rotatable in the same or opposite directions by electric drive motors (not shown). Quill  140  may be linearly displaceable by a ball gear drive (not shown) which may be contained within or on the spindle housing  120 . The weld tip  111  comprises a pin tool  136  coaxially disposed within a shoulder tool  142 . The pin tool  136  is mounted on the end of quill  140  by a tool holder  138 . Similarly, the shoulder tool  142  is mounted on quill  146  by a second tool holder  144 . The previously mentioned ball gear drive (not shown) is used to extend or retract the pin tool  136  relative to the shoulder tool  142  by displacing the quill  140 . 
         [0049]    A clamping system generally indicated by the numeral  128  is used to apply clamping pressure to a workpiece (not shown) during a weld operation. The clamping assembly  128  includes a pair of clamping packs  130  each having extendable clamping rollers  134  that engage and roll along the surface of the workpiece  187 . The clamping packs  130  are removably secured to a collar  132  that is mounted on the spindle housing  120  for rotation around the “E” axis  126 . 
         [0050]    From the forgoing, it can be appreciated that the motion platform  103  provides for linear movement of the weld tip along the X, Y and Z axes, while features of the weld head  110  allow rotation of the weld tip  111  around the A, C and E axes,  122 ,  118  and  126 , respectively. 
         [0051]    The FSW machine  100  includes a CNC controller  114  which may be positioned adjacent the motion platform  103  on a base  108  or other factory floor. The CNC controller  114  may comprise a programmed computer that controls the operation of the weld head  110 , motion platform  103 , tool drives  152 , clamping system  128  and sensors/encoders  154 . The tool drives  152  may comprise, for example, the previously described electric motors on the spindle head  120  which rotate the quills  140 ,  146 , as well as the gear drive (not shown) that controls the linear displacement of the pin tool  136 . The sensors/encoders  154  may comprise sensing devices that sense the position of various movable components on the machine  100  such as, for example, and without limitation, the exact linear displacement position of the pin tool  136 . An electronic display  156  connected to the CNC controller  114  may be provided to display various data and visual information useful or required for an operator. 
         [0052]    The master set of process parameters  158  and the process definitions  160  shown in  FIG. 1  may be developed using a method described by the flow diagram illustrated in  FIG. 7 . Starting at  164 , the parameters of the particular machine are determined at step  166 , following which the process measurement parameters are defined at  168 . The machine parameters determined at  166  and the process measurement parameters determined at  168  form the basic set of process parameters at  160 , however as described below, additional process parameters may be added, depending upon the particular process control algorithms that are developed. At step  170 , a flow chart is developed describing the logic for FSW process control algorithms. A determination is made at  172  as to whether the required parameters have been fully defined. If these parameters have not been fully defined, then further process control parameters are developed at  174  and added to the preliminary master list of parameters at  160 . When the required process parameters have been defined at  172  the process parameter list and the process flow charts are reviewed at  176 , and a determination is made at  178  as to whether the definition data is acceptable. If, for any reason, the definition data is not acceptable, then the FSW process flow charts and/or the parameter list is revised at  180  and the master list of process parameters  158  and the process definitions  160  are updated as appropriate. When the definition data is found to be acceptable at  178 , the process is finished at  182 . 
         [0053]    Attention is now directed to  FIG. 8  which illustrates the basic steps of a complete FSW welding sequence which includes probing (finding), drilling, welding and milling a workpiece or part  187 . It should be understood that not all of these processes may be required for a particular welding sequence and that the operations illustrated in  FIG. 8  are merely intended to provide an overview of a complete sequence of possible welding operations. 
         [0054]    Beginning at  184 , all axes of the FSW machine  100  are moved to their home position and readied. The machine  100  is placed in a safe zone and no tools have been yet loaded into the weld head  110 . The appropriate tools to be used may be made available at a calibration stand (not shown), for example that may be located in proximity to the machine  100 . All subsystems of the machine  100  are aligned and readied. 
         [0055]    Next, at  186 , a part  187  ( FIG. 2 ) and any associated fixturing (not shown) are loaded onto a support table (not shown), in readiness for a weld operation. An operator logs on to the CNC controller  114  at  188  and identifies the part at  190 . The operator may also log in the identification of the part  187 , as well as any other information, using any appropriate I/O devices such as, for example, a touch screen display, such as the screen  156  shown in  FIG. 6 . At  192 , the operator selects the “find” program, following which the find program is sent to the CNC controller  114 , as shown at step  194 . At  196  the operator then selects and runs the find program, resulting in a part location find operation being carried out by the machine  100  at step  198 . At this point, the machine  100  has located the part  187  within an operating envelope and therefore knows its precise location within the XYZ coordinate system used by the machine  100 . 
         [0056]    Next, at step  200 , the operator selects one or more measurement programs, resulting in the measurement program being sent to the CNC controller  114 , as shown at step  202 . At  204 , the operator selects and runs the particular measurement program, resulting in a part measurement operation being performed at step  206  to determine location of individual part substructure elements. In the illustrated example, the part  187  comprises a base part on which a skin is to be welded. Accordingly, as shown at step  208 , an operator places one or more skins on the part  187 . Then, at step  210 , the operator selects one or more clamp drill programs which are sent to the CNC controller  114  at step  212 . The operator selects and runs the drill at  214 , causing a drill operation to be performed at  216 . The drilling operation at  216  results in one or more holes being drilled in the part  187  as well as the skins (not shown). Drilling processes may be used later, to receive through-hole fasteners in the skins. At step  218  clamp fasteners may be installed which clamp the skin to the part  187 , as required. At step  220 , the operator selects one or more weld programs which are sent to the CNC controller  114  at step  222 . The operator then selects and runs the weld program  224 , resulting in a weld operation being carried out at step  226 . 
         [0057]    With a weld operation having been completed, the operator may then select one or more mill programs at  228  which are loaded in the CNC controller  114  at step  230 . The operator selects and runs the mill program at  232 , resulting in a mill operation being performed at  234 , which may be required for example, to mill away flash created by the weld operation at step  226  or to trim the skin outside edges. Finally, at  236 , the welded, finished part  187  and any associated fixtures are unloaded, and the process ends at  238 . 
         [0058]    Further details of the find, measure, drill, weld and mill programs are shown in.  FIGS. 9-13 , respectively. The find program illustrated in  FIG. 9  essentially comprises finding the part  187  and locating it within the XYZ coordinate system of the machine  100  so that the weld head  110  can be brought to a starting point whose coordinates are known in relation to various locations and/or features on the part  187 . Steps  400 - 422  used in the find program, load and identify a probe which is then calibrated and used to probe various features or locations on the part  187 . When it has been determined that it is safe to start at  422 , the operator may begin the find program at  424  which results in the probe being moved to the first part/fixture reference point at  426 . Depending on whether the reference point is a C-ball or a hole, at  428 , the reference point is probed at  430 ,  432 . The find program proceeds to move and locate second and third reference points as shown at steps  434 - 452 . 
         [0059]    With the part  187  having been located within the working envelope of the machine  100 , the measurement program illustrated in  FIG. 10  is used to measure features or distances on the part  187  using a probe (not shown) that has been previously loaded into the weld head  110 . A determination is made at  454  of whether or not a calibrated probe is present on the weld head  110 . If it is found that a probe is not present, then the operator proceeds through steps  456 - 472  in order to load and calibrate a probe. With a properly calibrated probe loaded in head  110 , the operator may complete steps  474 - 480  to start the measurement program. The probe is moved to a starting point at  482  and then is brought into contact with the part at step  484  to perform a measurement which is then saved at step  486 . Steps  482 - 486  are repeated until all points have been measured at  488 , following which the measurements are stored at step  490 . 
         [0060]    The drill program illustrated in  FIG. 11  is used to drill any holes that may be required in the part  187  prior to performing a weld operation. The drill program includes moving the weld head  110  to a tool changing location installing an appropriate drill tool, measuring tool parameters such as length and diameter, and verifying tool parameters, following which the weld head  110  is moved to one or more locations over the part  187  where holes are drilled. The drill program starts at  492 , with the machine in a safe zone and no drill bit having yet been loaded into the weld head  110 . The operator then selects and loads a drill at steps  494 - 498 , following which laser measurements are performed at steps  500 - 512  to verify that the drill has been properly loaded and positioned. One or more drilling operations are then performed at steps  514 - 518 . When all points have been drilled at  520 , the weld head  110  returns to its starting point, as indicated at  522 . 
         [0061]    The part  187  having been measured and drilled, the weld program shown in  FIG. 12  is then used to carryout the desired weld operation which, as previously discussed, may comprise fixed tool welding, retractable pin tool welding or fix stir spot welding. The weld program shown in  FIG. 12  includes selecting the particular type of welding operation to be performed and loading the corresponding pin and shoulder tools into the weld head  110 . The welding operation may include one or more subroutines which will be described later in more detail. These subroutines may include, for example, controlling the weld plunge process and the weld path process as well as the process that is used to retract the weld tools from the workpiece  187 . More particularly, the weld program begins at  524  with the machine  100  in a safe zone as indicated at  524 , with no tools present in the weld head  110 . 
         [0062]    A determination is made at  526  as to the type of weld tool that is to be used. The selected weld tool is loaded at steps  528 - 538 . The operator then continues to program at step  540 . The shoulder is installed at step  542  and is measured at steps  544 ,  546 . A force check function is performed at steps  548 - 552 , following which the weld head  110  is moved to a start position at  554 . A weld is performed using steps  556 - 566  which includes a force touch function  558 , weld plunge function  560 , weld path function  562 , programmed weld path motion  564 , and weld retract function  566 . When all weld paths have been completed at step  568 , the weld head  110  returns to its start position at  570 . 
         [0063]    The mill program illustrated in  FIG. 13  includes loading an appropriate milling tool on the weld head  110 , conducting cutter checks and moving the mill tool through a path over the workpiece  187  to mill away excess material. With the machine in a safe zone at  572 , a cutter is loaded at steps  574 ,  576  following which the operator continues the program at  578  to check the position of the cutter at  580 ,  582 . The cutter is then moved to a start position at  584 ,  586 , following which milling operations are performed at steps  588 ,  590  and  592 . When all of the milling paths have been completed at step  594 , the program terminates at  596 . 
         [0064]    Attention is now directed to  FIGS. 14   a - 14   c  which provide additional details of the command parameters that form part of the master set  158  ( FIG. 6 ) used to control machine operations. The command parameters are broadly divided into those controlling the shoulder element  134 , pin element  136 , clamping packs  130  and the weld head  110 . The particular command element is shown in column  240  in terms of a control axis. The specific command parameters are shown in column  242  and a description of these command parameters and their units of measure are shown in column  244 . Column  246  provides an explanation of the parameter, while columns  248  show the use of the parameter in each of the various subroutines which will be described below in more detail. As shown at  250 , command parameters relating to the shoulder tool  142  include parameters relating to a quill axis Ws and a spindle Ss. By way of example, the command parameter Wspr is the linear rate of displacement of the shoulder quill, while command parameter Ss indicates the rotational speed of the shoulder spindle in terms of revolutions per minute. 
         [0065]    The parameters indicated at  252  relate to the pin  136  which include those pertaining to the quill axis Wp and the spindle Sp. Parameters shown at  254  relating to the rollers  134  are given in terms of their relation to the rotary axis “E” and roller pressure Rp. Finally, parameters  256  relating to the weld head  110  are given in relation to a weld tool Wt and tool angle A. 
         [0066]    Depending on the application, additional parameters  260  relating to external command elements  258  may be provided. Thus, command parameters may be used that relate to temperature of the weld Tex or measurements of a tool performed, for example by a laser device (“Blum”) such as the length of the pin shown as Bpl. 
         [0067]    Referring now to  FIGS. 15   a - 15   c , measurement parameters are defined that relate to the shoulder  142 , pin  136 , roller  134 , weld head  110  and external elements  258 . Column  262  identifies the particular measurement element while column  264  gives the measurement parameter. A description of the measurement parameter is provided in column  266 , and column  268  provides an explanation of the parameter. Columns  248  show the use of the particular measurement parameter in each of the subroutines used to carryout the various processes. As shown at  270 , measurement parameters relating to the shoulder include those pertaining to the quill axis Ws, the spindle Ss, shoulder force Fs and shoulder torque Ts. Parameters relating to the pin  136  are given in terms of the quill axis Wp, the spindle Sp, pin force Fp and the pin torque Tp. Parameters relating to the roller  134  are given in terms of the rotary axis “E” and roller pressure Rp. Parameters relating to the weld head  110  include those relating to the weld tool Wt and the tool angle H. Parameters relating to external factors, may include, for example, those relating to temperature Tex and measurements of tool geometry B by the Blum laser tool measurement subsystem. 
         [0068]      FIGS. 16   a - 16   c  describe in greater detail the parameters relating to process limits. Process limit parameters are provided for the shoulder  142 , pin  136 , weld head  110 , and external elements  258 . Column  280  describes the particular element while column  282  provides the parameters relating to the element. Column  284  provides a description of the parameter and its units of measure while column  286  provides an explanation of the parameter. Columns  288  show the application of the parameter in the various subroutines discussed below. 
         [0069]    As shown at  290 , limit parameters are provided which relate to the quill axis Ws, spindle Ss, shoulder force Fs and shoulder torque Ts. With respect to the pin tool  136 , limit parameters are provided for the quill axis Wp, spindle Sp, pin force Fp and pin torque Tp. As shown at  294 , limit parameters are provided which relate to the weld tool rate Wtr. Additional parameters can be provided for external elements shown at  296  which may include by way of example, without limitation, weld nugget temperature Tex and tool measurement. 
         [0070]    Attention is now directed to  FIGS. 17   a  and  17   b  which provide a list of function parameters  298  that are used in processes  302  carried out in the various operation modes  300  of the machine  100 . The machine modes include weld preparation  301 , weld plunge  303 , weld path  305 , weld termination  307 , drilling  309  and milling  311 . The processes  302  include Force Touch  313 , Position Plunge  315 , Position Plunge Adaptive  317 , Position Control  319 , Position Control Adaptive  321 , Force Control  323 , Force Adaptive  325 , Weld End  327 , Clamping  329 , Clamping Adaptive  331 , Milling  333  and Adaptive Milling  335 . A description of the various function parameters  298 , which are programmable, is given in column  304 , along with the corresponding units of measure. 
         [0071]      FIG. 18  illustrates a flow diagram for a milling subroutine in which the shoulder spindle  146  is used to drive a cutter to perform milling and routing. In the context of aerospace applications for example, the milling subroutine may be used to remove weld tabs in structural skins and to provide access door cutouts. Instrumentation (not shown) may be provided to measure both the milling radial force and torque. Shoulder spindle radial force and torque are compared to their respective programmed maximum levels and the mill process is aborted if a maximum level is exceeded. The mill function is modal and may remain in effect until explicitly canceled or superseded by another programmed modal function. 
         [0072]    The mill subroutine uses the parameters of radial shoulder force Fsr and shoulder tool torque Ts. The milling subroutine begins at steps  598  and  600  with setting preliminary parameters, following which the mill path is started at  602 . Function internals and outputs are initialized at  604 , following which shoulder and radial torque are checked at steps  610 ,  612 ,  616  and  618 . If the shoulder or radial forces exceed pre-selected limits, alarm messages are issued at  616  and  618 , and the program is halted at  620 . If it is determined at  614  that the process has not yet been cancelled, then the program continues to a loop point  606 , otherwise the end path position as well as peak force and torque values are recorded at  622  and the subroutine ends at  624 . 
         [0073]      FIGS. 19   a  and  19   b  illustrate a flow diagram for the mill adapt subroutine which uses the shoulder spindle  146  to perform milling and routing operations, in which the commanded milling path rate (tool tip velocity) is overridden to maintain a constant milling reactive force. The mill adapt subroutine provides an adaptive control based on the shoulder radial force. A preprogrammed, target milling force is compared with actual radial force levels to increase or decrease the milling rate within given tolerance limits. The shoulder spindle radial force and torque are compared to their respective programmed maximum levels and the milling process is terminated if a maximum level is exceeded. The mill adapt subroutine is modal, and remains in effect until explicitly cancelled or superseded by another programmed modal function. The mill adapt subroutine utilizes the parameters of: radial shoulder force Fsr, maximum radial shoulder force limit Fsrmax, shoulder tool torque Ts, maximum shoulder tool torque limit Tsmax, commanded milling rate Wtr, maximum milling rate limit Wtrmax and minimum milling rate limit Wtrmin. The mill adapt subroutine may use the following parameters: 
         [0074]    Fsr: Radial Shoulder Force 
         [0075]    Ts: Shoulder Tool Torque 
         [0076]    Wtr: Commanded Milling Rate 
         [0077]    Wtra: Actual Milling Rate 
         [0078]    The mill adapt program is readied at  626 ,  628  and started at  630 . Function internals and outputs are initialized at  632 . Path commands are issued at  636 , following which milling motion is checked at  638  and radial force is checked at  640  and  642 . The milling rate is checked to determine whether it is within minimum and maximum limits at step  644 ,  646  and alarms are issued at  648 ,  650  if the milling rate exceeds these limits. An adaptive algorithm is carried out at  652  and the mill rate command is changed, as appropriate at  654 . Next, the shoulder torque and radial force are checked at  656  and  660 , respectively, and alarms are issued at  658  and  662  if pre-selected limits are exceeded. If the limits are exceeded, the program is halted at  664 . Providing the process has not been cancelled at  666 , the program loops back to loop point  634  where the subroutine is repeated. If the process has been cancelled at  666  or if the program has been halted at  664 , then the end path position is recorded along with peak force and torque values at  668 , following which the subroutine terminates at  670 . 
         [0079]      FIGS. 20   a - 20   e  illustrate a flow diagram for the force touch flow subroutine which may be used before each weld plunge operation to ensure that the correct plunge distance is achieved and the force instrumentation is operational. The force touch subroutine may handle both fixed and retractable pin welding tools. The FSW tool is positioned a fixed distance above the work surface which may be referred to as the FAL point. The tool is then slowly moved until it touches the work surface (WL point) with a specified force level. The actual distance moved is recorded and compared to a calibrated value obtained during FSW tool setup. The difference between these two values may be used to adjust program plunge distance of the following weld plunge operation. The adjustment compensates for workpiece surface variations and FS tool and head thermal growth. The adjustment value is zeroed by a subsequent, successful weld plunge process. This subroutine may use the following parameters: Wsp, Wsap, Wpp, Wpap, Fsa, Fstmax, Fstmin, Fpa, Fptmax, Fptmin, Bmpl, Bplsafe, Bplmax, Bplmin. 
         [0080]    Additional details of the force touch subroutine are shown in  FIGS. 20   a - 20   e . Preliminary checks are made at step  672 ,  674 , following which the subroutine starts at  676 . Function internals and outputs are initialized at  678  and a start point is recorded at  680 . Checks are made on the touch distance and touch force to determine whether they are within limits, and if they are outside the limits alarms are issued at  684 ,  688  and an error is issued at  686 . A determination is made at  692  as to what type of weld tool is being used. If a fixed tool is being used, the current axial shoulder force is saved at  694  and the shoulder quill motion is started at  696 . If a retractable pin weld tool is being used, the pin is retracted at  698  and the current point force and axial shoulder force are saved at steps  700 ,  702 , respectively. The shoulder quill motion is then started at  704 . A check is made of the shoulder force at  706 . If the shoulder force is less than a pre-selected value, a determination is made of what tool type is being used at  708  and the pin force is measured at  710 . Also, at  714 , a determination is made as to whether the pin has reached a maximum distance. Alarms may be issued at  712 ,  716 , following which the pin is retracted at  718 . Depending upon the tool type determined at  720 , the pin is extended to the start position and the subroutine is terminated at  724 . 
         [0081]    If the check made at  706  indicates that the shoulder force exceeds the pre-selected value, the process continues through steps  726 - 732  in which parameters are calculated, recorded and saved. The subroutine is completed through steps  734 - 746  and the subroutine ends at  750 ,  752 . As shown at step  740 , however, if the weld tool is a retractable pin tool, then the pin is extended to the start position at  748  at steps  756 - 774  are completed. If the maximum distance has been reached at  764  the subroutine ends at  776  otherwise step  778 - 792  are completed and the process ends at  790 ,  794 . 
         [0082]      FIGS. 21   a - 21   e  illustrate a flow diagram for a weld step plunge operation. The weld step plunge operation provides a position-controlled weld plunge at an adaptive (override) feed rate determined by axial force. The plunge distance is the distance from the FAL (fast access level) to the WL (work surface level). If the force touch function is not executed immediately, the programmed plunge distance can be adjusted by the difference between the touched work surface and programmed work surface. The plunge rate is decreased if an axial force target value is exceeded. 
         [0083]    The weld step plunge process handles both the fixed and retractable pin welding tools. The shoulder tool is positioned at a programmed plunge point, some fixed distance above the work surface. The plunge function moves the tool the requested plunge distance at programmed steps. Plunge distance is compensated, if desired, from data from the force touch subroutine ( FIG. 20 ). The shoulder quill axis W 1  is used to obtain require plunge distance and rate. Torque and rate override are compared to their respective programmed limits, and the plunge is aborted in the event a limit is exceeded. After the plunge distance is reached, a programmed dwell time is maintained before the function is completed. Upon successful completion, the force touch developed offset data is cleared and marked invalid to prevent possible misuse at a future plunge point. For retractable pin tool welding, for example the weld step plunge subroutine may use the following parameters: 
         [0084]    Wsp &amp; Wsap: Shoulder Position (command &amp; actual) 
         [0085]    Wspr &amp; Wsapr: Shoulder Rate (command &amp; actual) 
         [0086]    Fsa: Axial Shoulder Force 
         [0087]    Fpa: Axial Pin Force 
         [0088]    Ts: Shoulder Tool Torque 
         [0089]    Tp: Pin Tool Torque 
         [0090]    Wspend: Retract to Shoulder position (W 1 ) 
         [0091]    Wsprend: Retract Rate for Shoulder 
         [0092]    Sssend: Retract Shoulder Speed (S 1 ) 
         [0093]    Ssdend: Retract Shoulder Direction 
         [0094]    Wppend: Move to Pin position (W 2 ) 
         [0095]    Wpprend: Move Rate for Pin 
         [0096]    Spsend: Move Pin Speed (S 2 ) 
         [0097]    Spdend: Move Pin Direction 
         [0098]    Referring particularly to  FIGS. 21   a - 21   e , the weld step plunge subroutine begins with initial checks at  796 ,  798 , following which the subroutine is started at  800 . Shoulder force and torque are checked at  802 - 806  and the tool type is checked at  808 - 812 . Additional checks are performed at  814 - 824  and an error is issued at  820  if the checks are not satisfactory. A start point is recorded at  828  following which the shoulder quill motion is started at  830 . Then, a series of checks are performed at  832 - 856 . If certain of these checks are not satisfactory, the weld procedure ends at  836 ,  838 . At  856 , if the plunge distance has been reached, the shoulder quill motion is started at  858  and again, a series of parameters are checked at  860 - 882 . If these checks are not satisfactory, the process ends at  864 ,  866 . The plunge distance is checked at  884 , and if the pre-selected plunge distance has been reached, the shoulder quill motion is started at  886 , and a series of checks are again performed at  888 - 910 . If these checks are not satisfactory, the process ends at  892 ,  894 . If the plunge distance has been reached at  912 ,  914 , a dwell timer is started at  916  and when the dwell time has been reached at  918 , an end point is recorded at  920 , following which the force touch offset is cleared at  922  and the process ends at  924 . 
         [0099]      FIGS. 22   a  and  22   b  illustrate a flow diagram for the drill clamp adaptive subroutine which may be used to perform an adaptive drill operation with clamping force provided via shoulder and axial force control. Drill feed and speed are adaptively controlled based on drill axial force (pin quill axis). An adaptive drill axial force level is programmed so that the pin (drill) axial forces in excess of this value reduce both drill feed and speed. Feed and speed reduction will in turn reduce the drill axial force. The clamping pressure applied by the shoulder reduces any gap between the skin and a substructure, and also accurately locates the skin surface for potential countersink or multi-diameter hole operations. 
         [0100]    The drill (pin) tool tip and clamp (shoulder) tool surfaces are set to be at the same position. The CNC controller  114  moves the positioner to the FAL (fast approach level) above the work surface. Certain of the programmed parameters are then verified, and if valid, the process continues. The shoulder quill W1 axis is used to provide a clamping force and a measurement of the work surface location. The pin spindle is started and the pin axial force measurement system is activated and zeroed. Pin quill motion and rate are commanded according to the programmed parameters. Pin axial force is monitored to determine if the programmed adaptive level is exceeded. If the drilling axial force exceeds the adaptive level, both drill (pin) feed and speed are reduced until drill force is less than the adaptive level. In the event that the drill feed and/or speed are reduced below the set minimum values, an alarm message is generated and the drill function is aborted. The drill clamp adaptive subroutine may use the following parameters: 
         [0101]    Wsp &amp; Wsap: Shoulder quill command &amp; actual position 
         [0102]    Wsf: Shoulder quill command force 
         [0103]    Wpp &amp; Wpap: Pin quill command and actual position 
         [0104]    Bplsafe: Additional Distance to retract pin 
         [0105]    Wppr &amp; Wpapr: Pin quill command and actual rate 
         [0106]    Spd &amp; Sps: Pin spindle rotation direction and speed 
         [0107]    Spsa: Actual Pin Spindle Speed 
         [0108]    Fpa: Axial Pin Force 
         [0109]    Additional details of the drill clamp adaptive subroutine are shown in  FIGS. 22   a  and  22   b . After preliminary checks are performed at  926 ,  928 , the drill clamp adaptive subroutine is started at  930 . After function internals and outputs are initialized at  932 , checks are made on the clamp distance and clamp force relative to pre-selected limits at steps  934 ,  936 . If these parameters are not within the proper ranges, alarms are issued at  940 ,  946  and the program is halted at  942  following which the subroutine is exited at  944 . Assuming the parameters are within limits, a check is made at  938  to determine whether the proper drill clamp has been installed. If the proper drill clamp has not been installed, an alarm is issued at  948  and the program is halted at  942 . Assuming the checks performed at  934 ,  936  and  938  are satisfactory, steps  950 - 968  are carried out which result in extension of the drill to the start position  966  and starting of the drill motion at  968 . 
         [0110]    A check is made at  972  to determine whether the drill operation has been completed. If the drill operation is not complete, a check on drill force is made at  974  and if the drill force is not greater than a pre-selected value, the subroutine loops back to point  970 , otherwise the process continues to steps  976 ,  978  where the feed rate and spindle speed are checked relative to minimum values. If the feed rate and spindle speed are less than the pre-selected values, alarms are issued at  984 ,  986  and steps  998 - 1010  are carried out before the process ends at  1012 . Returning to step  972 , if the drill operation is determined to be complete, then the drill is retracted to the start position at  988 , the drill spindle is stopped at  990  and steps  992 - 996  are completed before the subroutine exits at  997 . 
         [0111]    Reference is now made to  FIG. 23  which illustrates a flow diagram for a weld path axial force subroutine used for path welding with shoulder axial force control. Shoulder axial force is held constant over the programmed weld path and weld rate. The weld path axial force subroutine handles both fixed (FIX) and retractable pin (RPT) welding tools. The FSW tool shoulder (W1-axis) has been positioned at the work surface W 1 , by a preceding weld plunge or path process. 
         [0112]    The commanded FSW shoulder axial force is held constant during the path welding action specified via following positional control statements in the program. The shoulder quill (W1) length is varied so that the axial force level is held at the desired value. This length variation is checked against programmed limits and if the workpiece limits WFspmin or WFspmax are exceeded, the condition is alarmed. For the minimum limit case, the current W1 axis length is fixed at the minimum limit until the axial reaction force increases beyond the target value. In those situations where the shoulder axial force exceeds the target value, control reverts to force permitting the W1 length to be decreased, thus moving the shoulder out of the workpiece  187 . Head torque, path forces and pin axial force are compared to their respective programmed process limit levels, and if a limit is exceeded, the weld is aborted in a defined way by the Weld End function. For retractable pin tool welding, for example, the weld path axial force subroutine may use the following parameters: 
         [0113]    Wsf: Commanded Axial Shoulder Force 
         [0114]    Fsa: Axial Shoulder Force 
         [0115]    Wsp: Commanded Shoulder Position 
         [0116]    Wsap: Shoulder Actual Position 
         [0117]    Fpa: Axial Pin Force 
         [0118]    Ts: Shoulder Tool Torque 
         [0119]    Tp: Pin Tool Torque 
         [0120]    Fsp: Radial Path Shoulder Force 
         [0121]    Fsn: Radial Normal Shoulder Force 
         [0122]    Wspend: Retract to Shoulder position (W 1 ) 
         [0123]    Wsprend: Retract Rate for Shoulder 
         [0124]    Sssend: Retract Shoulder Speed (S 1 ) 
         [0125]    Ssdend: Retract Shoulder Direction 
         [0126]    Wppend: Move to Pin position (W 2 ) 
         [0127]    Wpprend: Move Rate for Pin 
         [0128]    Spsend: Move Pin Speed (S 2 ) 
         [0129]    Spdend: Move Pin Direction 
         [0130]    As shown in  FIG. 23 , the weld path axial force subroutine begins with preliminary checks  1014 ,  1016  and is started at  1018 . Function internals and outputs are initialized at  1020  and the value of the shoulder force is set at  1022 . NC program path commands are issued at  1026  resulting in value checks of the shoulder position, and shoulder force at  1028 ,  1034  and  1038 . These values are either fixed or alarms are issued at  1030 ,  1032 ,  1036 , and  1040  as appropriate. Checks are carried out of the shoulder torque, path force and normal force at  1042 ,  1046 , and  1050 , respectively. If these values exceed preset values, then alarms are issued at  1044 ,  1048  and  1052  resulting in the subroutine being halted at  1070  which in turn causes the process to end at  1072 ,  1074 . 
         [0131]    A determination is made at  1054  of the type of tool. If an RPT tool is being used, a determination is made as to whether the pin force exceeds a pre-selected value at  1056 . If the pin force exceeds pre-selected value, an alarm is issued at  1058 . If the pin force pre-selected value is not exceeded, then a determination is made of whether the pin torque exceeds another pre-selected value at  1060 . If the pin torque exceeds the pre-selected value, an alarm is issued at  1062 , and the program is halted at  1070 . Assuming the checks made at  1042 ,  1046 ,  1050  and  1054  are satisfactory, and the tool type is a fixed tool, a determination is made at  1064  of whether the process terminated. If the process has been terminated, end path position, peak shoulder position, peak forces and torque values are recorded at  1066  and the subroutine ends at  1068 . If, however, the process has not been terminated as determined at step  1064 , then the subroutine returns to the loop point  1024 . 
         [0132]      FIGS. 24   a  and  24   b  illustrate a flow diagram for a weld plunge adaptive subroutine which functions to provide a position controlled weld plunge at an adaptive (override) feed rate determined by axial force. The plunge distance is the distance from FAL (fast access level) to WL (work surface level). If the force touch function is executed immediately before this subroutine process, the programmed plunge distance can be adjusted by the difference between the touched work surface and programmed work surface. In this subroutine process, the plunge rate is decreased if an axial force target value is exceeded. The weld plunge adaptive process handles both fixed and retractable pin welding tools. The FSW tool shoulder is positioned at a programmed plunge point, some fixed distance above the work surface, the FAL point. The plunge function moves the tool of requested plunge distance at an adaptive feed rate based on axial force. Plunge distance is compensated, if desired, by data from the force touch function. The shoulder quill axis W 1  is used to attain the required plunge distance and rate. Torque and rate override are compared to their respective programmed limits and the plunge is aborted in the event that a limit is exceeded. To abort the non-modal weld plunge process, a Weld End function is called to retract the weld tool. For retractable pin tool welding, for example the weld plunge adaptive subroutine may use the following parameters: 
         [0133]    Wsp &amp; Wsap: Shoulder Position (command &amp; actual) 
         [0134]    Wspr &amp; Wsapr: Shoulder Rate (command &amp; actual) 
         [0135]    Fsa: Axial Shoulder Force 
         [0136]    Fpa: Axial Pin Force 
         [0137]    Ts: Shoulder Tool Torque 
         [0138]    Tp: Pin Tool Torque 
         [0139]    Wspend: Retract to Shoulder position (W 1 ) 
         [0140]    Wsprend: Retract Rate for Shoulder 
         [0141]    Sssend: Retract Shoulder Speed (S 1 ) 
         [0142]    Ssdend: Retract Shoulder Direction 
         [0143]    Wppend: Move to Pin position (W 2 ) 
         [0144]    Wpprend: Move Rate for Pin 
         [0145]    Spsend: Move Pin Speed (S 2 ) 
         [0146]    Spdend: Move Pin Direction 
         [0147]    As shown in  FIGS. 24   a  and  24   b , the weld plunge adaptive subroutine begins with preliminary checks at  1076 ,  1078  and starts at  1080 . Function internals and outputs are initialized at  1082  following which the active and tare shoulder force are measured at  1084 . The active and tare shoulder torque are measured at  1086  and a determination is made of the tool type at  1088 . If the tool type is RPT, additional measurements are performed at  1090 ,  1092 . If the tool type is a fixed tool the determination is made at  1094  of whether the force touch offset is being used. If the force touch offset is being used, a determination is made at  1096  of whether the force touch data is available. If this data is not available, an alarm is issued at  1100  and an error is issued at  1108 . If the force touch data is available, then the plunge depth is adjusted and recorded at  1098  following which a depth check is performed at  1102 . If this depth check results in the value that is greater than a pre-selected limit, then an alarm is issued at  1104  and the subroutine ends at  1108 . If, however, the depth check at  1102  is satisfactory, then a start point is recorded at  1106  and shoulder quill motion is started at  1110 . 
         [0148]    A check is made on shoulder force level at  1114  and if the tool type determined at  1116  is RPT, then a determination is made at  1118  of whether the pin force exceeds a limit value. If the pin force exceeds a limit value, the process continues to step  1130  where a determination is made of whether the minimum plunge rate has been achieved. If the minimum plunge rate has not been achieved, an alarm is issued at  1132  and the process ends at  1138 ,  1140 . If the tool type determined at  1116  is a fixed tool, then a check is made of shoulder torque at  1120 . 
         [0149]    If the shoulder torque is greater than a preset limit, an alarm is issued at  1134  and the process ends at  1138 ,  1140 . If the tool type determined at  1122  is RPT, then a determination is made at  1124  of whether the pin torque is greater than a pre-selected value, and if the pre-selected value is exceeded, an alarm is issued at  1136  and the process ends at  1138 ,  1140 . If the tool type is a fixed tool then a determination is made of whether the plunge distance has been reached at  1142 . If the plunge distance has not been reached, then the subroutine returns to a loop point  1112 . However, if the plunge distance has been reached, then a dwell timer is started at  1144  and when the dwell time has been reached as determined at  1146 , final values, including the end point are recorded at  1148 . Then, the force touch offset and mark invalid are cleared at  1150 , following which the subroutine ends at  1152 . 
         [0150]      FIG. 25  illustrates a flow diagram for a weld end subroutine which functions to terminate a welding process and retract the welding tool as well as the pressure rollers. The weld end subroutine is initiated as a result of an abort condition from the weld path and weld plunge subroutines. The weld end subroutine generates a weld end event, cancels the modal weld process, retracts the FSW tool and lifts the rollers from the workpiece  187 . For retractable pin tool welding, for example, the weld end subroutine may use the following parameters: 
         [0151]    Wsp &amp; Wsap: Shoulder Position (command &amp; actual) 
         [0152]    Wspr &amp; Wsapr: Shoulder Rate (command &amp; actual) 
         [0153]    Fsa: Axial Shoulder Force 
         [0154]    Fpa: Axial Pin Force 
         [0155]    Ts: Shoulder Tool Torque 
         [0156]    Tp: Pin Tool Torque 
         [0157]    Wspend: Retract to Shoulder position (W 1 ) 
         [0158]    Wsprend: Retract Rate for Shoulder 
         [0159]    Sssend: Retract Shoulder Speed (S 1 ) 
         [0160]    Ssdend: Retract Shoulder Direction 
         [0161]    Wppend: Move to Pin position (W 2 ) 
         [0162]    Wpprend: Move Rate for Pin 
         [0163]    Spsend: Move Pin Speed (S 2 ) 
         [0164]    Spdend: Move Pin Direction 
         [0165]    As shown in  FIG. 25 , the weld end subroutine begins with preliminary checks  1154 ,  1156  and the subroutine starts at  1158 . Function internals and outputs are initialized at  1160  and a series of values are recorded at  1162 . Weld plunge/path modes are cancelled at  1164  and force commands are cleared at  1166 . The current quill positions are held at  1168  and a dwell timer is started at  1170 . When the dwell time is reached at  1172 , the shoulder quill is retracted at  1174  and a determination is made at  1176  of whether the shoulder spindle direction should be changed. If the shoulder spindle direction should be changed, the shoulder spindle is stopped at  1178 , following which the shoulder spindle speed and direction are reset at  1180 . If the tool type, as determined at  1182  is an RPT/FIX then the pin quill is moved at  1184  and a determination is made at  1186  of whether the pin spindle direction should be changed. If the pin spindle direction should be changed, the pin spindle is stopped at  1188  and the spindle speed and direction are reset at  1190 . Finally, the clamping rollers are lifted at  1192  and the subroutine ends at  1194 . 
         [0166]      FIGS. 26   a  and  26   b  illustrate a flow diagram for a weld path position adaptive subroutine which is used to provide adaptive path welding with shoulder position control. Shoulder position is held constant over a programmed weld path and weld rate. The commanded weld path rate is overridden to maintain a constant weld path reactive force. 
         [0167]    The weld position adaptive subroutine handles both fixed and retractable pin welding tools. The FSW tool shoulder (W1-axis) has been positioned at the work surface by a preceding weld plunge or path function. The shoulder quill position is held constant during the path welding action specified. This subroutine provides an adaptive control based on the shoulder weld path force. A preprogrammed, target weld path force is compared with actual path force levels to increase or decrease, the weld path rate within given tolerance limits. Weld variables (forces, torques, etc.) are compared to their respective programmed limits and the weld is aborted in the event that a tolerance level is exceeded. For retractable pin tool welding, for example, the weld path position adaptive subroutine may use the following parameters: 
         [0168]    Fsp: Path Reactive Shoulder Force 
         [0169]    Wtr: Commanded Weld Path Rate 
         [0170]    Wtra: Actual Weld Path Rate 
         [0171]    Fsa: Axial Shoulder Force 
         [0172]    Fpa: Axial Pin Force 
         [0173]    Ts: Shoulder Tool Torque 
         [0174]    Tp: Pin Tool Torque 
         [0175]    Fsn: Reactive Normal Shoulder Force 
         [0176]    Wspend: Retract to Shoulder position (W 1 ) 
         [0177]    Wsprend: Retract Rate for Shoulder 
         [0178]    Sssend: Retract Shoulder Speed (S 1 ) 
         [0179]    Ssdend: Retract Shoulder Direction 
         [0180]    Wppend: Move to Pin position (W 2 ) 
         [0181]    Wpprend: Move Rate for Pin 
         [0182]    Spsend: Move Pin Speed (S 2 ) 
         [0183]    Spdend: Move Pin Direction 
         [0184]    The weld path position adaptive subroutine begins, as shown in  FIGS. 26   a  and  26   b  with preliminary checks at  1196 ,  1198 . The weld path position adaptive subroutine starts at  1200 . Function internals and outputs are initialized at  1202  and NC program path commands are then issued at  1206 . Values are checked at  1202 ,  1210  and  1212  relating to tool motion and path force. If the weld rate is less then the minimum value at  1214 , an alarm is issued at  1216 . Similarly, if the weld rate exceeds maximum value at  1218 , an alarm is issued at  1220 . Assuming the values checked at  1214 ,  1218  are within acceptable ranges, an adaptive algorithm is carried out at  1222  and changes are made in the weld rate command at  1224 . 
         [0185]    Next, shoulder force, shoulder torque, path force and normal force are compared with preset values at steps  1226 ,  1228 ,  1230 ,  1232  respectively. If these values are not within the proper ranges, then corresponding alarms are issued at  1236 ,  1238 ,  1240 ,  1242  and the program is halted at  1258 . Assuming the checks made at  1226   1232  are satisfactory and the tool type determined at  1234  is RPT, then the pin force is checked at  1244  and if it is not within range, an alarm is issued at  1246 . If the pin force is within range, then the pin torque is checked at  1248 . If the pin torque is not satisfactory an alarm is issued at  1250 , otherwise a determination is then made at  1252  of whether the process should be cancelled. If the process has been cancelled, then values are recorded at  1254  and the subroutine ends at  1256 . However, if it has been determined that the process has not been canceled at  1252 , then the subroutine returns to the loop point  1204 . 
         [0186]      FIGS. 27   a  and  27   b  illustrate a flow diagram for a weld plunge subroutine used to provide a position controlled weld plunge at a programmed feed rate. The weld plunge distance is the distance from FAL to WL. If the force touch function is executed immediately before this subroutine, the programmed plunge distance can be adjusted by the difference between touched work surface and programmed work surface. This subroutine handles both fixed and retractable pin welding tools. The FSW tool shoulder is positioned at the programmed plunge point a fixed distance above the work surface. The plunge subroutine moves the tool to a requested plunge distance at a constant feed rate. The shoulder quill axis (W 1 ) is used to obtain required plunge distance and rate. Force and torque are compared to their respective programmed maximum levels, and the plunge is aborted in the event that a maximum level is exceeded. After the plunge distance is reached, a programmed dwell time is maintained before this function is completed. For retractable pin tool welding, for example, the weld plunge position subroutine may use the following parameters: 
         [0187]    Wsp &amp; Wsap: Shoulder quill command and actual position 
         [0188]    Wspr: Shoulder quill command rate 
         [0189]    Fsa: Axial Shoulder Force 
         [0190]    Fpa: Axial Pin Force 
         [0191]    Ts: Shoulder Tool Torque 
         [0192]    Tp: Pin Tool Torque 
         [0193]    Wspend: Retract to Shoulder position (W 1 ) 
         [0194]    Wsprend: Retract Rate for Shoulder 
         [0195]    Sssend: Retract Shoulder Speed (S 1 ) 
         [0196]    Ssdend: Retract Shoulder Direction 
         [0197]    Wppend: Move to Pin position (W 2 ) 
         [0198]    Wpprend: Move Rate for Pin 
         [0199]    Spsend: Move Pin Speed (S 2 ) 
         [0200]    Spdend: Move Pin Direction 
         [0201]    As shown in  FIGS. 27   a  and  27   b , the weld plunge subroutine begins with preliminary checks  1264 ,  1266  and the weld plunge subroutine starts at  1268 . Function internals and outputs are initialized at  1270  following which measurements are made of active and tare shoulder force and shoulder torque at  1272 ,  1274  respectively. If the tool type is RPT as determined at  1276 , then measurements are made of active and tare pin force and torque at  1278 ,  1280  respectively. Next, a determination is made at  1282  of whether a force touch offset is to be used. If the offset is to be used, then a determination is made as to whether force touch data is available at  1284 . If this data is not available, an alarm is issued at  1286  and the subroutine ends at  1288 . However, assuming the force touch data is available, then the plunge depth is adjusted and recorded at  1290 . Then, a depth check is performed at  1292  and if the depth is not within range, an alarm is issued at  1294  and the subroutine ends at  1288 . 
         [0202]    At  1296 , a start point is recorded and shoulder quill motion is commenced at  1298 . Shoulder force and shoulder torque are checked at  1300 ,  1360 , respectively and alarms are issued at  1302 ,  1304  if these values are not within appropriate ranges. If the tool type as determined at  1316  is RPT, then the pin force and pin torque are checked at  1318  and  1320 , and alarms are issued at  1306 ,  1308  as appropriate. Next, a determination is made at  1302  of whether the plunge distance has been reached, and when the plunge distance as been reached, a dwell timer is started at  1324 . When the dwell time has been reached at  1326 , values, including an end point, are recorded at  1328  following which the force touch offset and marked invalid are cleared at  1330  and the subroutine ends at  1332 . 
         [0203]      FIGS. 28   a  and  28   b  illustrate a flow diagram for a weld path axial force adaptive subroutine. This subroutine provides path welding with shoulder axial force control and an adaptive control on the weld path rate. Shoulder axial force is held constant over the programmed weld path and weld rate. The commanded weld path rate is overridden to maintain constant weld path reactive force. This subroutine handles both fixed and retractable pin welding tools. The FSW tool shoulder has been positioned at the work surface by a preceding weld plunge or path process. The commanded FSW shoulder axial force is held constant during the path welding actions specified in the program. 
         [0204]    The shoulder quill access (W1) length is varied so that the axial force level is held at the desired value. This length variation is checked against programmed limits and if the workpiece limit (WFspmin) is exceeded, control is switched to position. In other words, the current W1 axis length is fixed at the minimum limit until the axial reaction force increases beyond the target value where control of the process reverts to adaptive force control. The process provides an adaptive control based on the shoulder (radial) weld path force. A preprogrammed, target weld path force is compared with the actual path force levels to increase or decrease, the weld path rate within given tolerance limits. Weld variables (forces, torques, etc.) are compared to their respective programmed maximum levels, and the weld is aborted in the event a tolerance level is exceeded. For retractable pin tool welding, for example, this subroutine may use the following parameters: 
         [0205]    Wsf: Commanded Axial Shoulder Force 
         [0206]    Fsa: Axial Shoulder Force 
         [0207]    Wsp: Commanded Shoulder Position 
         [0208]    Wsap: Shoulder Actual Position 
         [0209]    Fsp: Path Reactive Shoulder Force 
         [0210]    Wtr: Commanded Weld Path Rate 
         [0211]    Wtra: Actual Weld Path Rate 
         [0212]    Fpa: Axial Pin Force 
         [0213]    Ts: Shoulder Tool Torque 
         [0214]    Tp: Pin Tool Torque 
         [0215]    Fsn: Normal Reactive Shoulder Force 
         [0216]    Wsprend: Retract Rate for Shoulder 
         [0217]    Sssend: Retract Shoulder Speed (S 1 ) 
         [0218]    Ssdend: Retract Shoulder Direction 
         [0219]    Wppend: Move to Pin position (W 2 ) 
         [0220]    Wpprend: Move Rate for Pin 
         [0221]    Spsend: Move Pin Speed (S 2 ) 
         [0222]    Spdend: Move Pin Direction 
         [0223]    As shown in  FIGS. 28   a  and  28   b , the weld path axial force adaptive subroutine begins with preliminary checks at  1334 ,  1336  and the subroutine is then started at  1338 . Function internals and outputs are initialized at  1340  and the shoulder force is set at  1342 . NC program path commands are then issued at  1346  resulting in shoulder position checks and force checks at  1348 ,  1354  and  1358  respectively. If the shoulder position value is less then a minimum value, then the shoulder position is held to the minimum value at  1350  and an alarm is issued at  1352 . If the shoulder position exceeds the pre-selected amount, as determined at  1354 , then an alarm is issued at  1356 . If the shoulder force is greater than a pre-selected value, as determined at  1358 , then the shoulder force is set at  1360 . A determination is made at  1362  of whether welding has commenced, and if welding has commenced then checks are made on the path force at  1364 ,  1366 . 
         [0224]    Minimum and maximum weld checks are performed at  1368  and  1372 , and alarms are issued at  1370 ,  1374  depending on the results of these checks. Assuming the preceding checks prove satisfactory, an adaptive algorithm is performed at  1376  and the weld rate command is then changed at  1378 , as appropriate. Next, shoulder torque, path force and normal force are checked at  1380 ,  1392 ,  1394  respectively and alarms are issued at  1382 ,  1384   1386 , as appropriate. If the tool type as determined at  1396  is RPT, then the pin force and pin torque are checked at  1398 ,  1400 , and alarms are issued, as appropriate at  1388 ,  1390 . Any of the alarms issued at  1382 - 1390  result in the subroutine being halted at  1408  and the subroutine ends at  1410 ,  1412 . A determination is made at  1402  of whether the process has been terminated. If the process has been terminated, then the end path position along with other values are recorded at  1404  and the subroutine ends at  1406 . If the process has not been terminated as determined at  1402 , then the subroutine returns to the loop point  1344  where the steps described above are repeated. 
         [0225]    Attention is directed to  FIG. 29  which illustrates a flow diagram for a weld path position subroutine used to perform a path weld under shoulder position control. Shoulder position is held constant over the programmed weld path and weld rate. This subroutine handles both fixed and retractable welding tools. The FSW tool shoulder has been positioned at the work surface, by proceeding a weld plunge or path function. The shoulder quill position is held constant during the path welding actions specified in the program. Force and torque are compared to their respective programmed maximum levels, and the weld is aborted in the event that a maximum level is exceeded. For retractable pin tool welding, for example, the weld path position subroutine may use the following parameters: 
         [0226]    Fsa: Axial Shoulder Force 
         [0227]    Fpa: Axial Pin Force 
         [0228]    Ts: Shoulder Tool Torque 
         [0229]    Tp: Pin Tool Torque 
         [0230]    Fsp: Radial Path Shoulder Force 
         [0231]    Fsn: Radial Normal Shoulder Force 
         [0232]    Wspend: Retract to Shoulder position (W 1 ) 
         [0233]    Wsprend: Retract Rate for Shoulder 
         [0234]    Sssend: Retract Shoulder Speed (S 1 ) 
         [0235]    Ssdend: Retract Shoulder Direction 
         [0236]    Wppend: Move to Pin position (W 2 ) 
         [0237]    Wpprend: Move Rate for Pin 
         [0238]    Spsend: Move Pin Speed (S 2 ) 
         [0239]    Spdend: Move Pin Direction 
         [0240]    As shown in  FIG. 29 , the weld path position subroutine commences with preliminary checks at  1414 ,  1416  and the subroutine then starts at  1418 . Function internals and outputs are initialized at  1420  and the NC program path commands are issued at  1424 . Next, shoulder force, shoulder torque, path force and normal force are checked at  1426 ,  1446 ,  1448  and  1450 , respectively. If these values are not satisfactory, corresponding alarms are issued at  1428 - 1434 , resulting in the subroutine being halted at  1440 , following which the subroutine ends at  1442 ,  1444 . If the tool type is RPT as determined at  1452 , pin force and pin torque are checked at  1454 ,  1456  and corresponding alarms are issued, as appropriate at  1436 ,  1438 . If the tool type is fixed, a determination is then made of whether the process has been canceled at  1458 . If the process has been canceled, then the end path position along with other values are recorded at  1460  and the subroutines ends at  1462 . If the process has not been cancelled, the subroutine returns to loop point  1422  where the above steps are repeated until the process has reached termination. 
         [0241]    Embodiments of the disclosure may find use in a variety of potential applications, particularly in the transportation industry, including for example, aerospace and automotive applications. Thus, referring now to FIGS.  30  and  31 , embodiments of the disclosure may be used in the context of an aircraft manufacturing and service method  1464  as shown in  FIG. 30  and an aircraft  1466  as shown in  FIG. 31 . Aircraft applications of the disclosed embodiments may include, for example, without limitation, composite stiffened members such as fuselage skins, wing skins, control surfaces, hatches, floor panels, door panels, access panels and empennages, to name a few. During pre-production, exemplary method  1464  may include specification and design  1468  of the aircraft  1466  and material procurement  1470 . During production, component and subassembly manufacturing  1472  and system integration  1474  of the aircraft  1466  takes place. Thereafter, the aircraft  308  may go through certification and delivery  1476  in order to be placed in service  1478 . While in service by a customer, the aircraft  1466  is scheduled for routine maintenance and service  1480  (which may also include modification, reconfiguration, refurbishment, and so on). 
         [0242]    Each of the processes of method  1464  may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of venders, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on. 
         [0243]    As shown in  FIG. 31 , the aircraft  1466  produced by exemplary method  1464  may include an airframe  1482  with a plurality of systems  1484  and an interior  1486 . Examples of high-level systems  1484  include one or more of a propulsion system  1494 , an electrical system  1488 , a hydraulic system  1490 , and an environmental system  1492 . Any number of other systems may be included. Although an aerospace example is shown, the principles of the disclosure may be applied to other industries, such as the automotive industry. 
         [0244]    Apparatus and methods embodied herein may be employed during any one or more of the stages of the production and service method  1464 . For example, components or subassemblies corresponding to production process  1472  may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft  1466  is in service. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the production stages  1472  and  1474 , for example, by substantially expediting assembly of or reducing the cost of an aircraft  1466 . Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft  1466  is in service, for example and without limitation, to maintenance and service  1480 . 
         [0245]    Although the embodiments of this disclosure have been described with respect to certain exemplary embodiments, it is to be understood that the specific embodiments are for purposes of illustration and not limitation, as other variations will occur to those of skill in the art.

Technology Category: 7