Multi - Axis System FSW-DM5020 Industrial

Design

Dual-Station Friction Stir Welding (FSW) equipment is a highly efficient and intelligent welding system designed to meet modern manufacturing demands for high-precision and high-efficiency welding. Its design philosophy and core functionalities revolve around efficient production, reliability, and automated control, making it particularly suitable for welding lightweight materials such as aluminum alloys and magnesium alloys. It is widely used in aerospace, rail transit, new energy vehicles, and other advanced industries. By integrating dual-station coordination, intelligent control, and modular design, the SFST Dual-Station FSW equipment achieves breakthroughs in efficiency, quality, and cost-effectiveness, positioning it as a core solution in high-end manufacturing to replace traditional welding processes. Its technical advantages extend beyond welding performance alone; through flexible production capabilities and a green manufacturing philosophy, it drives the industrial sector toward greater efficiency and sustainability.

Features & Performance

Dual-Station Collaborative Operation

Parallel Mode: Two stations simultaneously weld different workpieces, doubling production capacity.

Alternate Mode: While one station welds, the other handles workpiece clamping or cooling, minimizing downtime.

High-Precision Welding Control

Utilizes servo motor-driven systems to achieve precise three-dimensional movement of the welding head (X/Y/Z-axis positioning accuracy of ±0.01mm).

Dynamic pressure control technology adapts to materials of varying thicknesses (e.g., 1mm–50mm aluminum alloys).

Versatile Welding Capabilities

Supports multiple joint types (butt, lap, corner, and multi-layer welds) and complex weld paths (curves, circumferential seams, 3D trajectories).

Optional rotary fixtures enable all-position welding for cylindrical components (e.g., rocket fuel tanks, battery casings).

Intelligent Monitoring & Data Management

Built-in welding process monitoring system (e.g., torque, temperature, vibration tracking) with automatic alarms for abnormal conditions.

Process parameter database management enables rapid parameter retrieval and traceability.

Optional Features
a) Dual-Mode Process Control: Integrated system supports CNC programming for both constant-pressure and constant-displacement FSW modes, ensuring consistent weld quality.
b) Follow-Up Pressure Roller: Eliminates workpiece misalignment during welding without interrupting the process. Post-weld flash grinding during retraction cleans excess material without damaging the base metal.
c) Laser Seam Tracking: Automated laser-guided system ensures precise weld seam positioning and tracking.
d) Dynamic In-Process Clamping: Real-time clamping adjustments during welding to control weld deformation.

Core Technical Advantages

1. Production Efficiency Multiplied

Dual-station design boosts overall efficiency by 30%–50%, ideal for batch production scenarios (e.g., welding battery trays for new energy vehicles).

2. Exceptional Welding Quality

Solid-state welding eliminates defects like porosity or cracks, with joint strength reaching 80%–100% of the base material.

Automated control ensures high weld consistency (aerospace-grade quality standards) by eliminating human errors.

3. Operational Cost Optimization

No consumables (welding wire, gas) required, resulting in significantly lower long-term costs compared to traditional fusion welding.

High equipment reliability (key component lifespan exceeding tens of thousands of operating hours) minimizes maintenance expenses.

4. Enhanced Adaptability

Highly scalable design supports integration with robots, AGVs, and other automated systems to build smart production lines.

Compatible with oversized workpieces (e.g., rail vehicle bodies exceeding 20m in length), meeting heavy-duty industrial demands.

5. Eco-Friendliness & Safety

Emissions-free operation (no fumes, arc radiation) ensures a worker-friendly environment, complying with ISO 14001 Environmental Management Standards.

Multi-layered safety protections (emergency stop, collision prevention, pressure overload protection) guarantee operational safety.

Applications

Aerospace: aircraft skins, rocket fuel tanks, satellite structural components.
Rail Transit: high-speed train bodies, subway underframes, aluminum alloy carriages.
New Energy Vehicles: battery trays, motor housings, lightweight vehicle bodies.
Marine & Nuclear Power: ship decks, nuclear reactor cooling pipes.

FAQ

Q1: How does the dual-station design improve efficiency?
A1: Time Optimization

Alternate Mode: While Station A welds, Station B performs workpiece clamping, positioning, or cooling, eliminating downtime.

Parallel Mode: Both stations weld different workpieces simultaneously, doubling production capacity (requires automated loading/unloading systems).

Case Study: In a new energy vehicle battery tray welding line, dual-station equipment increased daily output from 80 to 120 units, achieving a 50% efficiency boost.

Q2: What is the automation level of the equipment? Does it require manual intervention?
A2: Automation Features

Fully Automated Mode: Integrates robotic loading/unloading and vision positioning systems for unmanned production.

Semi-Automated Mode: Combines manual clamping with automated welding (ideal for small-batch flexible production).

Manual Intervention Scenarios:

Initial setup for complex workpieces (requires welding path and parameter configuration).

Maintenance and tool replacement (standard operation takes ~30 minutes).