Experimental optimization of tab and slot plug welding method suitable for unique lightweight frame structures

Abstract

The tab and slot plug welding method applied to frame construction represents an interesting and low-cost construction system. Regarding the materials used, it is possible to create both unique lightweight aluminium frames, applied to service robots or effectors, as well as conventional steel frames for machines and peripherals. This article firstly summarizes the technologies and general aspects of the frame structure, and then it presents the characteristics of the tab and slot plug welding method, followed by a brief theoretical analysis. Furthermore, experimental and numerical simulations are performed based on the comparison of the given method with the common construction system of extruded profiles. The main focus is on optimizing the tab and slot system based on extensive laboratory experiments, where emphasis is placed on the dimensions of the joints in relation to used materials. This is followed by numerical simulation of the stress fields in joints. In the conclusion, recommendations are made for frames of different materials produced by the presented method; Work also includes selected real examples of structural applications of the given system.