Method for removing a weld bead

Abstract

The present invention relates to a method for removing a welding bead of a weld, comprising: (a) a process of preparing a skimmer having a melting point higher than a melting point of a base material and a melting point of an electrode; (b) a process of generating a molten pool in which the base material and the electrode are fused by heating the base material and the electrode at a temperature lower than the melting point of the skimmer; (c) a process of moving the skimmer with respect to a raised portion of the welding bead raised from a surface of the base material during melting of the molten pool, and separating at least a part of the raised portion from the base material using the skimmer; and (d) a process of discharging the at least a part toward a rear direction opposite to a front direction of a moving direction of the skimmer in the process (c) by moving the at least a part along a second surface opposite to a first surface of the skimmer facing the base material.

Description

Technical Field

[0001] This disclosure relates to a method for removing weld beads from welding. Background Technology

[0002] As a technique for removing weld beads produced by welding, there are known methods based on cutting tools, such as those described in Japanese Patent Application Publication No. 2020-124782. The removal method in Japanese Patent Application Publication No. 2020-124782 involves using a cutting tool to remove unwanted weld beads in the solidified state after welding.

[0003] Solder bead removal is typically performed using rotary cutting tools. Specifically, an end mill is used as the cutting tool. During solder bead removal, sometimes the removed solder beads may fuse to the cutting tool while removing the solidified solder beads. Summary of the Invention

[0004] Rotary cutting tools require a drive device to rotate them. Furthermore, as these tools rotate and chip away at solder beads, chips are scattered around. To recycle and reuse the material, these scattered chips need to be collected. Therefore, the chip dispersion complicates the removal process, including the collection of solder beads.

[0005] Furthermore, the aforementioned techniques require waiting for the weld beads to solidify, resulting in a long production cycle. Additionally, the lower the temperature, the more easily weld beads, primarily composed of aluminum or soft iron, are fused to the cutting tool during removal. Therefore, during weld bead removal, coolant is applied to the cutting tool, necessitating measures to prevent fusion.

[0006] Therefore, a technique has been sought that can remove molten weld beads in a manner that does not prolong the cycle and does not require prevention of fusion. Moreover, in this removal technique, it is desirable to use a cutting tool that does not require a drive device and does not cause chips to fly.

[0007] This disclosure can be implemented in the following ways.

[0008] (1) According to one aspect of this disclosure, a method for removing weld beads is provided. The removal method includes:

[0009] (a) The process of preparing a scraper made of raw materials having a melting point higher than that of the base material to be welded and the welding rod;

[0010] (b) A process of generating a molten pool by heating the base material and the welding electrode at a temperature lower than the melting point of the scraper;

[0011] (c) A process in which, during the melting of the molten pool, the scraper is moved relative to a raised portion of the weld bead that protrudes from the surface of the molten pool above the base material, thereby using the scraper to remove at least a portion of the material constituting the raised portion from the base material; and

[0012] (d) A process in which at least a portion of the material is discharged toward the rear, opposite to the forward direction of movement of the scraper in step (c), by moving the material along the second side opposite to the first side of the scraper that is opposite to the first side of the base material.

[0013] By designing the process in this way, the cycle time can be shortened compared to methods that remove the raised portion after the solder ball has cooled. Furthermore, the raised portion can be removed from the base material without rotating the cutting tool. Therefore, the raised portion leaving the base material can be removed without scattering. Moreover, the raised portion leaving the base material is discharged towards the rear of the scraper. Thus, the recovery of the raised portion becomes easier compared to situations where the raised portion leaving the base material scatters around.

[0014] (2) In the removal method described above, the scraper may further include a third surface disposed on the side opposite to the first surface. The rear edge of the second surface may be disposed above and behind the front edge of the third surface in the moving posture of the scraper. The step (d) may include: a step of solidifying at least a portion of the material flowing on the scraper in the region behind the rear edge of the second surface and above the third surface by the movement of the scraper.

[0015] By designing the process in this way, the molten raised portion can be solidified on the scraper. That is, solder beads removed at a lower temperature than the molten raised portion can be recovered. Therefore, compared to recovering the molten raised portion, recovery can be easily achieved without temperature limitations. Furthermore, since the removal is done at a higher temperature than recovering the solidified raised portion, welding between the scraper and the raised portion is less likely to occur. In other words, welding prevention work can be reduced.

[0016] (3) The removal method described above may include, after step (d), a step of recovering at least a portion of the material as discharged removal material by means of a recovery section provided by the scraper and disposed behind the second surface, and recovering the removal material removed by the scraper.

[0017] By designing the structure in this way, the removed raised portions can be recovered using a scraper. Therefore, the risk of the removed raised portions falling back into the base material can be reduced.

[0018] (4) In the removal method described above, the scraper may have a protrusion protruding from the first surface. The step (c) may include: smoothing the surface of the molten pool after the material has been removed by bringing the top of the protrusion into contact with the surface of the base material.

[0019] By adopting this approach, the surface roughness of the solder beads after removal can be reduced.

[0020] (5) The welding described in the above-mentioned removal method can be welding used in the manufacture of batteries.

[0021] By using it in the welding process used in battery manufacturing, it is possible to prevent adverse conditions caused by interference between the weld beads and the components. Attached Figure Description

[0022] The features, advantages, and technical and industrial significance of exemplary embodiments of the present invention will now be described with reference to the accompanying drawings, in which the same reference numerals denote the same elements, and wherein:

[0023] Figure 1 This is an explanatory diagram showing the configuration of the apparatus used to remove weld beads during welding;

[0024] Figure 2 This is an explanatory diagram showing the shape of the scraper 200;

[0025] Figure 3 This is an illustrative diagram showing the removal of solder beads by the scraper 200;

[0026] Figure 4 This is an explanatory diagram showing the discharge of Wb13 removed by the scraper 200;

[0027] Figure 5 This is a flowchart illustrating the process of removing weld beads from a weld;

[0028] Figure 6 This is an illustrative diagram showing the formation of the molten pool Wb10 achieved by arc welding;

[0029] Figure 7 This is an explanatory diagram showing a scraper 200 moving toward the molten pool Wb10;

[0030] Figure 8 This is an explanatory diagram showing the end of a weld performed by welding electrode 100;

[0031] Figure 9 This is an explanatory diagram showing the base material Ob after the removal of solder balls;

[0032] Figure 10This is an explanatory diagram showing the configuration of the device 10a equipped with the scraper 200a;

[0033] Figure 11 This is an explanatory diagram showing the recovery of the removed material Wb13 by the recovery unit 280;

[0034] Figure 12 This is a flowchart illustrating the process of recovering the removed substance Wb13 by the recovery unit 280;

[0035] Figure 13 This is an explanatory diagram showing the configuration of the device 10b equipped with the scraper 200b;

[0036] Figure 14 This is an explanatory diagram showing the protrusion 290 of the scraper 200b;

[0037] Figure 15 This is an explanatory diagram showing the relationship between the protrusion 290 and the molten pool Wb10;

[0038] Figure 16 This is a flowchart illustrating the process of smoothing the molten pool Wb12 by the protrusion 290.

[0039] Figure 17 This is an explanatory diagram showing the cooling path 241.

[0040] Figure 18 This is an explanatory diagram showing the configuration of a device 10d equipped with a scraper 200d.

[0041] Figure 19 This is an explanatory diagram showing the configuration of the device 10e equipped with the scraper 200e.

[0042] Figure 20 This is an explanatory diagram showing the configuration of a device 10f equipped with a scraper 200f. Detailed Implementation

[0043] A. Implementation Method 1:

[0044] A1. Device Composition:

[0045] Figure 1 This is an explanatory diagram showing the configuration of an apparatus for removing solder beads as described in the first embodiment of this disclosure. In the following description, the z-axis direction is the vertical direction. The x-axis direction is the direction indicated by arrow AM10, which represents the direction of solder bead removal. The direction of arrow AM10 will be explained in detail later. The y-axis direction is the direction orthogonal to both the z-axis and the x-axis.

[0046] Figure 1The apparatus 10 shown performs welding of base material Ob and removal of weld beads produced by welding. The welding performed by apparatus 10 is consumable electrode welding. Specifically, it is MIG welding. In the welding of apparatus 10, the base material Ob is, for example, aluminum. The melting point Tm1 of the base material Ob is approximately 660°C when the raw material is aluminum. Apparatus 10 includes a welding electrode 100, a scraper 200, and a support 300.

[0047] The base metal Ob and the welding electrode 100 are heated to a temperature Tm4 that is lower than the melting point Tm3 of the scraper 200. This generates a molten pool Wb10, formed by the fusion of the base metal Ob and the welding electrode 100. More specifically, the molten pool Wb10 is generated on the base metal Ob by melting the base metal Ob and the welding electrode 100 themselves using an arc discharge Ar. That is, arc welding is performed by joining the base metal Ob and the welding electrode 100 themselves using the melting based on the arc discharge Ar. The welding electrode 100 is fed toward the base metal as welding progresses. The welding electrode 100 is, for example, aluminum alloy A5183 according to JIS Z3232. The melting point Tm2 of this welding electrode 100 is approximately 660°C. The melting point Tm3 of the scraper 200, described later, is approximately 3387°C. The heating temperature Tm4 for arc welding is between the melting point Tm2 and the melting point Tm3. For example, the heating temperature Tm4 in arc welding is approximately 2500℃. Electrode 100 is the welding torch of the welding robot. Electrode 100 generates an arc discharge Ar through the welding mechanism of the welding robot. Electrode 100 can move during welding via the robotic arm of the welding robot. To facilitate understanding of the technology, in Figure 1 The welding machine and robotic arm are omitted from the diagram. Figure 1 In this context, the direction of movement during welding is referred to as the AM10 direction.

[0048] The raised portion Wb11 is the part of the weld bead that protrudes from the surface Obs1 of the molten pool Wb10 compared to the base material Ob. During the melting of the molten pool Wb10, the scraper 200 removes at least a portion of the material constituting the raised portion Wb11 from the base material Ob. This function is performed by the movement of the scraper 200 during the melting of the molten pool Wb10. The portion of this material removed is referred to as the removed material Wb13. Furthermore, the scraper 200 causes the removed material Wb13 flowing on it to solidify by its movement. Based on this, the scraper 200 discharges the removed material Wb13 in a rearward direction Am20, opposite to the forward direction Am10, which is the moving direction of the scraper 200. This discharge is a relative action observed from the scraper 200. This discharge will be described in detail later. The moving direction Am10 of the scraper 200, which moves forward Am10, is the same as the moving direction Am10 of the welding electrode 100. Figure 1 In the middle, Am10 in front is the +x direction, and Am20 behind is the -x direction.

[0049] Figure 2 This is an explanatory diagram showing the shape of the scraper 200. The scraper 200 is made of a raw material having a melting point Tm3. For example, this raw material is tungsten. The melting point Tm3 is higher than the melting point Tm1 of the base material Ob, which is the object to be welded, and the melting point Tm2 of the welding electrode 100. The melting point of tungsten is approximately 3387°C. Therefore, as mentioned above, the melting point Tm3 is approximately 3387°C. The scraper 200 has a first surface 210s, a second surface 220s, a third surface 230s, and a fourth surface 240s.

[0050] The first surface 210s is the surface opposite to the base material Ob in the scraper 200 during the removal of solder balls. Figure 2 In this context, the direction opposite to the base material Ob is the -z direction. The second surface 220s and the third surface 230s are surfaces opposite to the first surface 210s. The second surface 220s and the third surface 230s slope in the -z direction from the rear Am20 of the scraper 200 towards the front Am10. The top tip 270s of the scraper 200 is defined by the connection between the first surface 210s and the second surface 220s. The second surface 220s has an edge 221s at the rear Am20 of the scraper 200. The third surface 230s has an edge 231s at the front Am10 of the scraper 200. Compared to the edge 231s at the front Am10 of the third surface 230s, the edge 221s at the rear Am20 of the second surface 220s is positioned above Am30 and behind Am20 during the movement of the scraper 200. As a result, on the side opposite to the first surface 210s, a step 260s is formed due to the height difference between the second surface 220s and the third surface 230s. Above Am30 is... Figure 2 The +z direction in the middle. The posture of the scraper 200 during movement is the posture when removing the material Wb13. Figure 2 The posture of the scraper 200 indicates the posture of the scraper 200 during movement.

[0051] The fourth surface 240s is a pair of surfaces located on either side of the first surface 210s, the second surface 220s, and the third surface 230s. That is, the fourth surface 240s is the left and right surface of the scraper 200, which serves as the front Am10 and the rear Am20.

[0052] like Figure 2As shown, the support portion 300 supports the scraper 200. More specifically, the support portion 300 supports the scraper 200 from both sides by connecting to the fourth surface 240s of the scraper 200. Its connection to the scraper 200 is called the connection portion 310. The end of the support portion 300 opposite to the end supporting the scraper 200 is connected to the robot arm of the welding robot. That is, the support portion 300 is connected to the scraper 200 and the robot arm. By configuring it in this way, the support portion 300 moves the scraper 200 in the direction of movement Am10 of the welding rod 100 along the welding movement based on the robot arm. To facilitate understanding of the technology, Figure 2 The robot arm is not shown in the diagram. The support portion 300 receives welding heat via the scraper 200. Therefore, the support portion 300 is made of a raw material with a melting point Tm3 to prevent melting. For example, the raw material of the support portion 300 is tungsten.

[0053] Furthermore, the support portion 300 can change its angle relative to the scraper 200. For example... Figure 2 As shown, the support portion 300 allows the connection portion 310 with the scraper 200 to rotate in the direction of arrow Am40. Therefore, by adjusting the angle of the support portion 300 relative to the scraper 200, the angle R1 of the scraper 200 relative to the base material Ob can be changed. By configuring it in this way, as... Figure 1 As shown, the support portion 300 can adjust the angle R1 of the insertion of the tip 270s of the scraper 200 relative to the base material Ob. That is, the support portion 300 can adjust the force required to remove the material Wb13 from the molten pool Wb10. This force is a vertically upward force from the surface Obs1 of the base material Ob. Figure 2 In this context, the force is in the +z direction. Based on this, the support 300 can adjust the distance between the base material Ob and the tip 270s of the scraper 200 by adjusting the angle R1. That is, the support 300 can adjust the amount of removed material Wb13 in the raised portion Wb11.

[0054] A2. Removal of weld beads:

[0055] Figure 3 This is an illustrative diagram showing the removal of solder beads by the scraper 200. Figure 3 The scraper 200 and the molten pool Wb10 are shown, located in Figure 2 The section at the location of section III-III. Figure 3The molten pool Wb10 shown is in the state during which the removed material Wb13 is melted by arc welding with electrode 100. During this state, scraper 200 moves in the moving direction Am10 of electrode 100. Therefore, the tip 270s of scraper 200 enters the raised portion Wb11, which is higher than the surface Obs1 of the base material Ob. Scraper 200 causes removed material Wb13 to leave the base material Ob. More specifically, scraper 200 places removed material Wb13 on the second surface 220s by inserting tip 270s into the raised portion Wb11. The second surface 220s of scraper 200 is inclined in the -z direction from the rear Am20 towards the front Am10 of scraper 200. Therefore, scraper 200 moves removed material Wb13 relatively rearward Am20 along the second surface 220s inclined in the -z direction. Therefore, the scraper 200 applies a force in the +z direction to the removed material Wb13. Thus, the scraper 200 removes the removed material Wb13.

[0056] As previously described, the scraper 200 removes the material Wb13 by moving it relatively rearward towards Am20. This relative movement of the material Wb13 is achieved by the scraper 200 advancing forward towards Am10 relative to the material Wb13. That is, this movement is not caused by applying a force toward Am20 to the material Wb13. In the following description, unless otherwise specified, the movement of the material Wb13 refers to the relative movement from the scraper 200.

[0057] A3. Solidification of weld beads:

[0058] like Figure 3 As shown, the removed material Wb13 flows on the scraper 200 due to the movement of the scraper 200. More specifically, the removed material Wb13 moves along the second surface 220s of the scraper 200. The removed material Wb13 reaches the step 260s by passing the edge 221s of Am20 behind the second surface 220s. Passing through the step 260s, the removed material Wb13 reaches the space between the second surface 220s and the third surface 230s. Air Ai1 flows in this space due to the movement of the scraper 200. Therefore, the scraper 200 and the removed material Wb13 are cooled by the flow of air Ai1. This cooling is achieved by the heat exchange between the removed material Wb13 and the air Ai1. Moreover, this cooling is achieved by the heat exchange between the scraper 200 and the air Ai1, generated by the heat conduction from the removed material Wb13 to the scraper 200. Therefore, the removed material Wb13 solidifies behind Am20 at the edge 221s of Am20 behind the second surface 220s and above Am30 on the third surface 230s.

[0059] A4. Removal of weld beads:

[0060] Figure 4 This is an illustrative diagram showing the discharge of Wb13 removed by the scraper 200. Figure 4 Showing will Figure 3 The state of the scraper 200 as viewed from the +z direction. The removed material Wb13 moves along the second surface 220s towards the rear Am20, opposite to the forward Am10, which is the moving direction of the scraper 200, by moving along the third surface 230s. Moreover, the removed material Wb13 is discharged from the rear Am20 of the scraper 200 by moving along the third surface 230s.

[0061] A5. Procedure for removing weld beads from welding:

[0062] Figure 5 This is a flowchart illustrating the process of removing solder beads from a weld. Figure 5 In step S100, the user prepares a scraper 200 made of raw material having a melting point Tm3. The melting point Tm3 is higher than the melting point Tm1 of the base material Ob (the object to be welded) and the melting point Tm2 of the welding electrode 100. That is, the scraper 200, through... Figure 1 It is installed in the device 10 as shown, so that it is usable during the melting of the molten pool Wb10.

[0063] exist Figure 5 In step S110, the control unit of the welding robot in device 10 heats the base material Ob and the welding electrode 100 at a temperature Tm4 lower than the melting point Tm3 of the scraper 200. This generates a molten pool Wb10 formed by the fusion of the base material Ob and the welding electrode 100. In other words, the welding electrode 100 initiates the welding of the base material Ob.

[0064] Figure 6 This is an explanatory diagram illustrating the formation of a weld pool Wb10 achieved by arc welding. The electrode 100 melts the base metal Ob and the electrode 100 by applying an arc discharge of Ar to it. Thus, a weld pool Wb10 is formed on the base metal Ob. To facilitate understanding of the technique, in... Figure 6 The scraper 200 and the support 300 are omitted from the illustration.

[0065] exist Figure 5 In S120, the scraper 200 removes the material Wb13 from the base material Ob during the melting of the molten pool Wb10. This process is performed by moving the scraper 200 relative to the raised portion Wb11. The raised portion Wb11 is the portion of the weld bead that protrudes from the molten pool Wb10 compared to the surface Obs1 of the base material Ob.

[0066] Figure 7This is an explanatory diagram showing a scraper 200 moving towards the molten pool Wb10. The scraper 200 moves its tip 270s along the base material Ob towards the molten pool Wb10. Furthermore, the scraper 200... Figure 3 As shown, remove the weld bead remover Wb13 from the molten pool Wb10.

[0067] exist Figure 5 In S130, the scraper 200 causes the removed material Wb13 flowing on the scraper 200 to solidify by the movement of the scraper 200. This solidification is as follows: Figure 3 As shown, it is performed behind Am20 at the edge 221s of Am20 behind the second surface 220s and above Am30 of the third surface 230s.

[0068] exist Figure 5 In S140, the scraper 200 discharges the removed material Wb13 towards the rear Am20. The rear Am20 is the opposite direction to the front Am10, which is the direction of movement of the scraper 200 that discharges the removed material Wb13. This discharge is as follows... Figure 4 As shown, the removal material Wb13 is moved along the second surface 220s of the scraper 200, opposite to the first surface 210s facing the base material Ob. Furthermore, while S120 to S140 are described separately for ease of understanding, in actual welding, S120 to S140 are performed in parallel on different parts of the base material.

[0069] exist Figure 5 In step S150, the control unit of the welding robot confirms the remaining workpiece. This welding robot is equipped with welding rod 100. If there is remaining workpiece, the control unit of the welding robot moves the process to S120 to continue welding. If there is no remaining workpiece, the control unit of the welding robot ends the welding. The scraper 200 advances in the moving direction Am10 of the welding rod 100 while the molten pool Wb10 is melting. Therefore, the scraper 200 moves until the remaining molten pool Wb10 from which the removal of the remaining workpiece Wb13 has not yet ended disappears. Thus, the removal of the weld bead ends by the disappearance of the molten pool Wb10 due to the end of welding.

[0070] Figure 8This is an explanatory diagram showing the end of welding performed by welding electrode 100. The welding robot's control unit ends the welding by stopping the arc discharge Ar. Therefore, the generation of a new molten pool Wb10 stops. The scraper 200 continues to advance in the moving direction Am10 of the welding electrode 100 during the melting of the molten pool Wb10. Thus, the scraper 200 removes the remaining waste Wb13 from the molten pool Wb10 by continuously moving to the location where the welding electrode 100 has stopped welding. Since no new molten pool Wb10 is generated, the scraper 200 ends the removal of the weld beads.

[0071] Figure 9 This is an explanatory diagram showing the base material Ob after the removal of solder beads has been completed. Through the removal of solder beads by the scraper 200, the base material Ob residue is removed from the molten pool Wb10, leaving a molten pool Wb12 after the removal of the residue Wb13. Therefore, after the molten pool Wb12 solidifies, the base material Ob becomes a state where raised solder beads are no longer present.

[0072] By adopting this configuration, the weld bead removal method of this disclosure can shorten the cycle time compared to the method of removing the raised portion Wb11 after the weld bead has cooled. Furthermore, the weld bead removal method of this disclosure can remove the removed material Wb13 from the base material Ob without rotating the cutting tool. Therefore, the weld bead removal method of this disclosure can remove the removed material Wb13 from the base material Ob without scattering it. Consequently, compared to the case where the removed material Wb13 scatters around, the recovery of the removed material Wb13 is facilitated by discharging it to the rear Am20 of the scraper 200. Based on this, the weld bead removal method of this disclosure can solidify the molten removed material Wb13 on the scraper. That is, the weld bead removal method of this disclosure can recover the removed material Wb13 at a temperature lower than that of the molten removed material Wb13. Therefore, the solder ball removal method of this disclosure allows for easy recovery without temperature limitations, compared to the case of recovering molten residue Wb13. Furthermore, since the solder ball removal method of this disclosure removes the residue at a higher temperature than the case of recovering solidified residue Wb13, it is less likely to cause melting between the scraper 200 and the residue Wb13. In other words, the solder ball removal method of this disclosure reduces the need for melting prevention.

[0073] B. Second implementation method:

[0074] Figure 10This is an explanatory diagram showing the device configuration of the apparatus 10a, which consists of a scraper 200a equipped with a recovery section 280. In the second embodiment, the scraper 200a has a recovery section 280 for recovering the removed material Wb13 at Am20 behind the second surface 220s. In the scraper 200a, the surface opposite to the first surface 210s is composed only of the second surface 220s. The second surface 220s will be described in detail later. Other aspects of the apparatus 10a are the same as those of the apparatus 10 in the first embodiment.

[0075] The recovery unit 280 recovers the removed material Wb13 removed by the scraper 200a. For example, the recovery unit 280 is a suction unit utilizing a vacuum pump. The recovery unit 280 recovers the removed material Wb13 by suction from Am20 behind the second surface 220s. Furthermore, the recovery unit 280 cools the removed material Wb13 by generating a flow of suction-based air Ai2. The recovery unit 280 can be connected to the scraper 200a with a nozzle portion serving as the suction inlet. For example, the recovery unit 280 is connected to the connection portion 310 between the scraper 200a and the support portion 300. To facilitate understanding of the technology, Figure 10 In the diagram, only the nozzle portion of the recovery unit 280 is shown. The scraper 200a, on the side opposite to the first surface 210s, is composed only of the second surface 220s. Therefore, the recovery unit 280 recovers the removed material Wb13 from the rear Am20 of the second surface 220s. Based on this, the fourth surface 240s is located opposite to the first surface 210s and the second surface 220s.

[0076] Figure 11 This is an explanatory diagram showing the recovery of removed material Wb13 by the recovery unit 280. During the removal of solder balls, the recovery unit 280 draws material from Am20 behind the second surface 220s. The removed material Wb13 discharged to Am20 behind the second surface 220s is recovered by the recovery unit 280. The movement of the removed material Wb13 based on the attraction of the recovery unit 280 is not a relative movement from the scraper 200. The removed material Wb13 is subjected to a force towards Am20 behind it by the attraction of the recovery unit 280, thereby moving to the recovery unit 280.

[0077] Figure 12 This is a flowchart illustrating the process of recovering the removed material Wb13 by the recovery unit 280. S141a is connected to... Figure 5 The processing after S140. During the removal of solder balls, the recovery unit 280 draws in Am20 from behind the scraper 200a. Therefore, the recovery unit 280 recovers the removed material Wb13 discharged to the rear of the scraper 200a. Upon entering... Figure 5 When welding is completed in S150, the recovery unit 280 ends the process because the removed material Wb13 is no longer discharged.

[0078] By adopting such a scheme, the method for removing solder balls by the device 10a can reduce the risk of the removed material Wb13 falling onto the base material Ob by recovering the removed material Wb13 using the recovery section 280 provided by the scraper 200a.

[0079] C. Third implementation method:

[0080] Figure 13 This is an explanatory diagram showing the device configuration of the device 10b, which is composed of a scraper 200b having a protrusion 290. In the third embodiment, the scraper 200b has a protrusion 290 protruding from the first surface 210s. Other aspects of the device 10b are the same as those of the device 10 in the first embodiment.

[0081] Figure 14 This is an explanatory diagram showing the protrusion 290 of the scraper 200b. The protrusion 290 smooths the surface of the molten pool Wb12 after the removed material Wb13 has left. This is achieved by having the tip 291s of the protrusion 290 abut against the surface Obs1 of the base material Ob. The protrusion 290, protruding from the first surface 210s, is formed from one of the four surfaces 240s having two surfaces toward the other. That is, the protrusion 290 is formed in a manner that intersects with the moving direction Am10 of the scraper 200. Moreover, the tip 291s of the protrusion 290 is formed in a manner that moves from the front Am10 toward the rear Am20 when the scraper 200 moves. More specifically, in a section perpendicular to the y-axis, the cross-sectional shape of the protrusion 290 is triangular. Therefore, as the scraper 200 moves, the fifth surface 292s of the protrusion 290 facing forward Am10 tilts in the +z direction from the rear Am20 toward the front Am10. Based on this, the top tip 291s is formed at a certain height h1 from the first surface 210s to the top tip 291s. The height h1 is designed to reach the surface Obs1 of the base material Ob when the solder ball is removed.

[0082] Figure 15 This is an explanatory diagram showing the relationship between the protrusion 290 and the molten pool Wb10. Figure 15 The scraper 200b and the molten pool Wb10 are shown, located in Figure 14 The cross-section at the location of the XV-XV section. For ease of understanding, the illustration of step 260s is omitted. Figure 15The diagram shows the molten material Wb121 on the surface of the molten pool Wb12. The molten material Wb121 will be explained later. When the scraper 200 moves, the tip 291s of the protrusion 290 contacts the surface Obs1 of the base material Ob. Therefore, the height h1 from the first surface 210s to the tip 291s is designed to reach the surface Obs1 of the base material Ob at this point.

[0083] Figure 16 This is a flowchart illustrating the process of leveling the molten pool Wb12 by the protrusion 290. Figure 16 S141b is connected to Figure 5 The processing after S140. For example... Figure 15 As shown, the protrusion 290 smooths the surface of the molten pool Wb12 after the removed material Wb13 has been removed from the raised portion Wb11. This unevenness is the molten material Wb121.

[0084] exist Figure 5 In step S140, the scraper 200 removes the material Wb13 by applying a force in the +z direction to it. Therefore, the scraper 200 does not apply a force in the -z direction to the raised portion Wb11. Consequently, when a gap is created between the tip 270s and the surface Obs1 of the base material Ob, molten material Wb121 remains on the surface of the molten pool Wb12. This gap is caused by the tip 270s moving away from the surface Obs1 due to the shaking during the movement of the scraper 200 and the resistance generated by the molten material during removal.

[0085] exist Figure 16 In S141b, the protrusion 290 is moved by the scraper 200 as... Figure 15 As shown, the molten material Wb121 is reached. The protrusion 290 uses its tip 291s to prevent the molten material Wb121 from moving rearward Am20 beyond the protrusion 290. Therefore, the protrusion 290 causes the molten material Wb121 to move along the fifth surface 292s. The fifth surface 292s slopes in the +z direction from rearward Am20 towards forward Am10 as the scraper 200 moves. Therefore, the protrusion 290 applies a -z force to the molten material Wb121 that contacts the fifth surface 292s by advancing forward Am10. That is, the protrusion 290 forms a smoothed molten pool Wb14 by applying pressure to the molten material Wb121. The process enters... Figure 5 When welding is completed at S150, the remaining molten pool Wb12 is leveled, thus ending the process.

[0086] By configuring the solder ball removal method by device 10b in this way, the surface roughness of the solder ball after removal can be reduced.

[0087] D. Fourth implementation method:

[0088] Figure 17 This is an explanatory diagram showing a scraper 200c equipped with a cooling channel 241. Figure 17 To facilitate understanding of the technology, the illustration of the support portion 300 is omitted. In the above embodiment, the scraper 200 causes the removed material Wb13 to solidify by causing air Ai1 to flow through the step 260s. However, the solidification of the removed material Wb13 is not limited to this method. The solidification of the removed material Wb13 can also be achieved by having a different shape than the step 260s. Furthermore, the solidification of the removed material Wb13 can be achieved by having both the step 260s and a different shape. For example, it can be exemplified by... Figure 17 The fourth embodiment of the scraper 200c shown is illustrated. The scraper 200c has a through hole connecting a fourth surface 240s, which has two surfaces. This through hole is referred to as a cooling path 241. The scraper 200c does not have a step 260s. Therefore, the surface opposite to the first surface 210s is formed only by the second surface 220s. Other aspects of the device 10c constructed from the scraper 200c are the same as those of the device 10 in the first embodiment.

[0089] Cooling passage 241 utilizes cooling water to cool the scraper 200. More specifically, cooling water flows within cooling passage 241 by injecting cooling water from one of the two openings of the through-hole towards the other. For example, in Figure 17 In this process, cooling water flows through cooling path 241 in the direction of arrow Am50, which is the +y direction. Cooling path 241 cools the scraper 200 by exchanging heat between the cooling water and the scraper 200. That is, the removed material Wb13 is cooled and solidified by passing through the scraper 200.

[0090] E. Fifth implementation method:

[0091] Figure 18 This is an explanatory diagram showing the device configuration of a device 10d consisting of a scraper 200d equipped with a recovery section 280a. Figure 18 To facilitate technical understanding, the support portion 300 is omitted from the illustration. In the second embodiment described above, the scraper 200a recovers the removed material Wb13 discharged from Am20 behind the second surface 220s using the recovery portion 280. However, the recovery of the removed material Wb13 is not necessarily limited to this method. For example, as Figure 18 The recovery unit 280a shown illustrates the fifth embodiment. The recovery unit 280a is constructed by bundling together multiple filamentous components. The recovery unit 280a recovers the removed material Wb13 in a molten state. Other aspects of the device 10d, which is composed of the scraper 200d, are the same as those of the device 10a in the second embodiment.

[0092] The recovery unit 280a utilizes capillary action to recover the molten residue Wb13. More specifically, the recovery unit 280a uses capillary action to adsorb the residue Wb13 that has infiltrated between the tubes by contacting a bundle of multiple tubes with the molten residue Wb13. The recovery unit 280a is made of raw materials having a melting point Tm3. For example, the recovery unit 280a is a bundle of tungsten wires. The thickness and number of tungsten wires are determined experimentally using the molten residue Wb13. Since the scraper 200d does not have a step 260s, the molten residue Wb13 flows along the second surface 220s. Figure 18 As shown, the recovery unit 280a is disposed on the second surface 220s in the flow path of the removed material Wb13. By configuring it in this way, the recovery unit 280a contacts the removed material Wb13 flowing on the second surface 220s of the scraper 200d, and recovers it by adsorption using capillary effect.

[0093] F. Sixth Implementation:

[0094] Figure 19 This is an explanatory diagram showing the device configuration of a device 10e consisting of a scraper 200e equipped with a recovery section 280b. Figure 19 To facilitate understanding of the technology, the diagram of the support portion 300 is omitted. Figure 19 This is the sixth method for recovering the removed material Wb13. The recovery section 280b is a container for storing the removed material Wb13. Since the scraper 200e can also recover the removed material Wb13 in the molten state using the recovery section 280b, it does not have a step 260s. Therefore, the surface opposite to the first surface 210s is only composed of the second surface 220s. Other aspects of the device 10e composed of the scraper 200e are the same as those of the device 10a in the second embodiment.

[0095] The recovery unit 280b recovers the removed material Wb13 removed by the scraper 200e. More specifically, the recovery unit 280b is capable of accumulating the removed material Wb13 inside the recovery unit 280b. The recovery unit 280b is made of a raw material having a melting point Tm3. For example, the recovery unit 280b is a container made of tungsten. The recovery unit 280b is disposed behind the scraper 200e of the removed material Wb13 at Am20. The recovery unit 280b is connected to the rear of the second surface 220s in a manner connected to the flow path of the removed material Wb13. By configuring it in this way, the recovery unit 280b can recover the removed material Wb13 discharged from the second surface 220s.

[0096] G. Implementation Method 7:

[0097] Figure 20This is an explanatory diagram showing the device configuration of the apparatus 10f, which consists of a scraper 200f. The scraper 200f is filamentous. For example, the scraper 200f is a tungsten wire. Therefore, since the raw material is tungsten, the melting point Tm3 of the scraper 200f is approximately 3387°C. Moreover, the diameter d1 of this tungsten wire is smaller than the height h2 of the raised portion Wb11 from the surface Obs1 of the base material Ob. Figure 20 To facilitate understanding of the scraper 200f, the diameter d1 is shown as larger than the height h2. The scraper 200f is supported by connecting the two ends of the filamentous body to the connecting portion 310 of the support portion 300 in the first embodiment. Other aspects of the device 10f constituted by the scraper 200f are the same as those of the device 10 in the second embodiment.

[0098] By configuring the scraper 200f in this way, its main body can be placed between the removed material Wb13 and the surface Obs1. Therefore, the scraper 200f causes the removed material Wb13 to leave the parent material Ob during the melting of the molten pool Wb10. Furthermore, the scraper 200f can discharge the removed material Wb13 beyond its main body rearward. Therefore, the seventh embodiment can remove the removed material Wb13 from the parent material Ob without scattering it. Therefore, in the seventh embodiment, compared to the case where the removed material Wb13 scatters around, the recovery of the removed material Wb13 is facilitated by discharging it to the rear Am20 of the scraper 200f.

[0099] H. Other implementation methods:

[0100] In the above embodiment, the welding that generates the molten pool Wb10 is a consumable electrode welding. However, welding can also be a non-consumable electrode welding. For example, it can be laser welding. In the case of laser welding, the molten pool Wb10 is generated by a welding wire and a laser from a laser scanner. More specifically, the laser scanner heats the base material Ob and the welding wire to a temperature Tm4 by irradiating them with a laser. Thus, the laser scanner generates a molten pool Wb10 formed by the fusion of the base material Ob and the welding wire. The welding wire is, for example, A5183 aluminum alloy according to JIS Z3232. The welding wire is moved along the laser by a robotic arm. By connecting the support 300 to the robotic arm, the scraper 200 removes the weld beads in the same way as the device 10.

[0101] In the above embodiment, the melting point Tm1 of the base metal Ob and the melting point Tm2 of the welding electrode 100 are approximately 660°C because they are made from aluminum. The melting point Tm3 of the scraper 200 is approximately 3387°C because it is made from tungsten. The heating temperature Tm4 for arc welding is approximately 2500°C. However, the temperatures are not limited to these conditions. The melting point Tm3 of the scraper 200 only needs to be higher than the melting point Tm1 of the base metal Ob and the melting point Tm2 of the welding electrode 100. The heating temperature Tm4 for arc welding only needs to be lower than the melting point Tm3 of the scraper 200. For example, the following configuration can be illustrated: The base metal Ob is mild steel with a melting point Tm1 of approximately 1500°C. The welding electrode 100 is a titanium-calcium type welding electrode according to JIS Z3211E4303. The melting point Tm2 of this welding electrode 100 is approximately 1500°C. The scraper 200 is a ceramic with a melting point Tm3 of approximately 2700℃. The heating temperature Tm4 for arc welding is approximately 2000℃.

[0102] In the above embodiments, the protrusion 290 is a component of the scraper 200b of the third embodiment. However, the protrusion 290 may also be included as a component of the scraper in other embodiments besides the seventh embodiment. For example, the scraper 200a of the second embodiment may also include both the retraction section 280 and the protrusion 290.

[0103] In the second embodiment described above, the scraper 200a with the recovery section 280 may also have the step 260s as in the first embodiment.

[0104] In the third embodiment described above, the scraper 200b with the protrusion 290 may also include a recovery section for recovering the removed material Wb13, as in other embodiments. For example, the scraper 200b may also include the recovery section 280 as in the second embodiment.

[0105] In the fourth embodiment described above, the scraper 200c, which includes the cooling path 241, may also include a recovery unit for recovering the removed material Wb13, as in other embodiments. For example, the scraper 200c may also include the recovery unit 280 as in the second embodiment.

[0106] In the sixth embodiment described above, the scraper 200e, which includes the recovery section 280b, may also include the step 260s as in other embodiments. In this case, the recovery section 280b is connected to the rear of the third surface 230s in a manner that connects to the flow path of the removed material Wb13.

[0107] In the seventh embodiment described above, the scraper 200f, which is a filamentous main body, may also include the recovery section 280 of the second embodiment or the recovery section 280b of the sixth embodiment. In this case, the scraper 200f recovers the removed material Wb13 by connecting the recovery section 280 or the recovery section 280b to the connecting section 310.

[0108] The above-described embodiments can be used in various manufacturing processes that require the removal of solder beads. For example, the above-described embodiments can be used in the manufacture of batteries. More specifically, the above-described embodiments, when used in the manufacture of battery casings, can prevent interference between components caused by solder beads.

[0109] This disclosure is not limited to the embodiments described above, and can be implemented through various configurations without departing from its spirit. For example, the technical features of the embodiments corresponding to the technical features in the various methods described in the Summary of the Invention section can be appropriately replaced or combined to solve some or all of the above-described problems, or to achieve some or all of the above-described effects. In addition, any technical feature that is not described as an essential component in this specification can be appropriately omitted.

Claims

1. A method for removing weld beads from a weld, comprising: (a) The process of preparing a scraper made of raw materials having a melting point higher than that of the base material to be welded and the welding rod; (b) A process of generating a molten pool by heating the base material and the welding electrode at a temperature lower than the melting point of the scraper; (c) A process of moving the scraper relative to a raised portion of the weld bead that is raised above the surface of the base material from the molten pool during the melting of the molten pool, thereby using the scraper to remove at least a portion of the material constituting the raised portion from the base material; as well as (d) A process in which at least a portion of the material is discharged toward a rearward direction opposite to the forward direction of movement of the scraper in step (c) by moving the material along a second surface opposite to the first surface of the scraper that faces the base material. The scraper also has a third surface disposed on the side opposite to the first surface. The rear edge of the second surface is positioned above and behind the front edge of the third surface during the movement of the scraper. The process (d) includes: The process of solidifying at least a portion of the material flowing on the scraper in the area behind the edge of the second surface and above the third surface by means of the movement of the scraper.

2. The method for removing weld beads according to claim 1, The method for removing the weld beads after the welding process (d) includes: (e) A process of recovering at least a portion of the material as discharged waste by means of a recovery section provided by the scraper and disposed behind the second surface, and recovering the waste removed by the scraper.

3. The method for removing weld beads according to claim 1 or 2, The scraper has a protrusion that protrudes from the first surface. The process (c) includes: The process of smoothing the surface of the molten pool after the material leaves by contacting the top of the protrusion with the surface of the base material.

4. The method for removing weld beads according to claim 1, The welding is used in the manufacture of batteries.

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