The collaboration between Berkoa Machine Tools, the Lortek technology centre and the university spin-off Vors Control has resulted in an innovative solution in advanced welding, developing a digital twin that positions the SoldAvanza machine as a benchmark in the development of rotary friction welding machines at the national level.
SoldAvanza represents one of the most ambitious projects in the field of advanced welding developed in Spain. This rotary friction welding machine, manufactured by Berkoa Machine Tools in collaboration with Lortek, has positioned itself as the only one of its kind manufactured in Spain. Its uniqueness lies in its ability to achieve two working ranges: up to 20 tonnes of thrust at 3,000 rpm and up to 60 tonnes of thrust at 1,500 rpm. This versatility allows it to cover a wide range of applications, although it also poses significant technical challenges.
As a machine intended for the manufacture of short series and prototypes for customers, it faces a wide variety of shapes and materials of the parts to be welded, which poses a challenge when manufacturing parts at the limits of the machine’s capacity. Achieving good results at these limits requires an adjustment in the control of the thrust force; this is where model-based control comes into play.
A modelling project was proposed to serve as a tool for better understanding the dynamics of the process and optimising process control to ensure the level of quality required in sectors such as automotive, machine tools and power generation.
The foundation on which the project was developed was the BLSC 4.0 registered controller co-designed with Lortek. Thanks to its modular architecture and its traceability and parameter storage capabilities, the system has made it possible to streamline the creation of new experimentation processes. In addition, new variables are registered automatically, which facilitates the accurate identification of the model parameters.
Vors Control, a spin-off from the Public University of Navarra specialising in advanced control engineering, has contributed its experience in implementing control models in real environments such as power generation and industry.
This digital twin consists of a detailed modelling of the welding process, based on physics-based models, which allow the actual behaviour of the system to be simulated and predicted. This advanced modelling has facilitated the precise parameterisation of processes, adapting to the specific needs of each application.
The models have been rigorously validated using data obtained under real operating conditions, ensuring their reliability and predictive capacity in industrial environments. Adjustments have been made to the control systems, optimising the dynamic response of the process. Notable technical improvements include: a significant reduction in system signal noise, a decrease in overshoot in transient responses, the correction of flickering phenomena in the control system, and the readjustment of the force control loop parameters for greater stability and precision.
The joint work has made it possible to identify opportunities for improvement and propose a redesign of the system, aimed at further increasing the quality and reliability of the welding process.
The SoldAvanza machine has become a fundamental test bed for customers to experiment with new joining solutions and validate their designs before moving on to large-scale production. This allows companies to access advanced technology without the need for a significant initial investment.
The project is an exemplary case of how collaboration between industrial companies such as Berkoa Machine Tools, technology centres such as Lortek and university spin-offs such as Vors Control can generate highly innovative solutions that respond to specific market needs.
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