Device and method for continuous ultrasonic welding

Abstract

Device (100) for continuous ultrasonic welding, wherein materials are materially joined to one another under the action of welding ultrasound and pressure in a joining zone, characterized in that the device (100) has a consolidation module (112, 200, 300) for applying a consolidation pressure and an ultrasonic testing module (114, 206, 308) for material testing arranged on the consolidation module (112, 200, 300).

Description

[0001] The invention relates to a device for continuous ultrasonic welding, in which materials are bonded together in a joining zone under the influence of welding ultrasound and pressure. The invention also relates to a method for continuous ultrasonic welding.

[0002] From the document DE 10 2014 105 110 A1 a testing device is known for the non-destructive testing of components, in particular fiber composite components, which has a transmitting device for transmitting ultrasound and a receiving device for receiving ultrasound, wherein the transmitting device and the receiving device are each separately adjustable in translation and / or rotation.

[0003] From the document DE 102019 112 217 A1 a testing device is known for the non-destructive testing of components, the testing device comprising a carrier module, an ultrasonic transmitter module for transmitting ultrasound, an ultrasonic receiver module for receiving ultrasound and at least one actuator module, in which the ultrasonic transmitter module and / or the ultrasonic receiver module is / are movable with a degree of freedom f≥3 by means of the at least one actuator module.

[0004] From document DE 102019 109 263 A1, a method is known for non-destructively testing the quality of an ultrasonic weld produced by a welding process, comprising: recording a time-dependent measured variable over a period of time, wherein the measured variable is characteristic of a mechanical or electrical oscillation behavior of the welding process to be tested; evaluating a measured variable profile of the recorded time-dependent measured variable by applying Fourier analysis; comparing a result of the evaluation with a reference value in order to test the quality of the ultrasonic weld.

[0005] From the document DE 10 2010 050 387 A1 a method is known for monitoring and controlling a vibration welding system during a vibration welding process, wherein the welding system is designed to form a welded joint at interfaces of a workpiece by means of a mechanical high-frequency vibration, the method comprising: a set of sensory data is acquired during the formation of the welded joint using a plurality of sensors positioned with respect to the weld interfaces; a weld signature is formed using the sensory data; an existing feature set is extracted from the weld signature using a host system; the existing feature set is compared and correlated with validated information contained in a library via the host system; and a control action is executed if the existing feature set does not sufficiently match the information in the library.

[0006] The invention is based on the object of structurally and / or functionally improving a device mentioned above. Furthermore, the invention is based on the object of structurally and / or functionally improving a method mentioned above.

[0007] The object is achieved by a device having the features of claim 1. Furthermore, the object is achieved by a method having the features of claim 6. Advantageous embodiments and / or further developments are the subject of the subclaims.

[0008] The device can be designed for ultrasonic welding of joining partners. The materials can be the materials of the joining partners. The device comprises a consolidation module for applying consolidation pressure and an ultrasonic testing module arranged on the consolidation module for material testing. The device can comprise a work surface, a compaction module, an ultrasonic generator, a sonotrode, a drive device, and / or a control device.

[0009] The work surface can be designed and / or arranged to accommodate the joining partners for ultrasonic welding. The compacting module can be designed and / or arranged to press the joining partners against the work surface prior to heating and / or plasticizing, to press the joining contact surfaces of the joining partners together, to minimize a joining gap, and / or to hold the joining partners. The compacting module can have a compacting roller. The ultrasonic generator can be designed and / or arranged to generate ultrasonic welding vibrations. The sonotrode can be designed and / or arranged to introduce the ultrasonic welding vibrations into a joining zone in order to heat and / or plasticize the joining partners in the joining zone. The sonotrode can be designed and / or arranged to apply a welding pressure to the joining partners.

[0010] The consolidation module is designed and / or arranged to apply a consolidation pressure. The consolidation module can be designed and / or arranged to press the joining partners against the work surface during cooling and / or solidification, to press the joining contact surfaces of the joining partners together, and / or to hold the joining partners. The compaction module, the sonotrode, and / or the consolidation device can be structurally and / or functionally combined into a work module.

[0011] The drive device can be designed and / or arranged to move the compacting module, the sonotrode, and / or the consolidation module. The drive device can be arranged to move the work surface and / or the joining parts. The drive device can be designed and / or arranged to move the compacting module, the sonotrode, and / or the consolidation module, on the one hand, and the work surface and / or the joining parts, on the other hand, relative to one another.

[0012] The ultrasonic testing module can be designed and / or arranged to test the joining partners and / or the joining zone. The ultrasonic testing module can be designed and / or arranged to test the joining partners in the joining zone and / or outside the joining zone. The ultrasonic testing module can be designed and / or arranged to test the materials of the joining partners and / or the joining zone. The ultrasonic testing module can be designed and / or arranged to test the materials of the joining partners in the joining zone and / or outside the joining zone. The ultrasonic testing module can be designed and / or arranged to transmit and / or receive testing ultrasound. The ultrasonic testing module can have at least one ultrasonic transducer. The ultrasonic testing module can have an ultrasonic transducer arrangement.

[0013] The control device can be designed and / or arranged to control the ultrasonic generator, the drive device, and / or the ultrasonic testing module. The control device can have at least one processor, at least one main memory, at least one data memory, and / or at least one signal interface. The control device can be connected to the ultrasonic generator, the drive device, and / or the ultrasonic testing module in a signal-conducting manner.

[0014] In ultrasonic welding, the compaction module, the sonotrode, the consolidation module, and / or the ultrasonic inspection module, on the one hand, and the work surface and / or the joining partners, on the other hand, can be or are moved relative to each other in a welding direction. The ultrasonic inspection module can be arranged downstream of the sonotrode in relation to the welding direction.

[0015] The ultrasonic inspection module is arranged on the consolidation module. The ultrasonic inspection module can be arranged on a section of the consolidation module facing away from the sonotrode in the welding direction. The consolidation module can have a first end section facing the sonotrode and a second end section facing away from the sonotrode. The ultrasonic inspection module can be arranged on the second end section.

[0016] The ultrasonic testing module can be arranged and / or designed to introduce and / or receive testing ultrasound via a section of the consolidation module. The consolidation module can have a joining part contact section. The joining part contact section can be skid-like and / or plate-like. The joining part contact section can be made of a material or have a material selected for good thermal conductivity. The joining part contact section can be made of copper or a copper alloy, in particular brass, or can have copper or a copper alloy, in particular brass. The ultrasonic testing module can be arranged and / or designed to introduce and / or receive testing ultrasound via the joining part contact section. The joining part contact section can have a receptacle for the ultrasonic testing module.The ultrasonic testing module can be arranged on the holder of the joining part contact section.

[0017] The consolidation module can have a coupling section for the ultrasonic testing module. The coupling section can be firmly connected to the joining part contact section. The coupling section can be connected to the joining part contact section in a force-fitting, form-fitting, and / or material-fitting manner. The coupling section can initially be manufactured separately from the joining part contact section and subsequently connected to the joining part contact section. The coupling section can be screwed, riveted, glued, and / or welded to the joining part contact section. The coupling section can be manufactured on the joining part contact section. The coupling section can form part of the joining part contact section. The coupling section can be made of a material or have a material selected with regard to good ultrasound transmission capacity with respect to the materials of the joining partners.The coupling section can be made of a plastic, in particular a thermosetting or thermoplastic, or comprise a plastic, in particular a thermosetting or thermoplastic. The ultrasonic testing module can be arranged and / or designed to introduce and / or receive testing ultrasound via the coupling section. The coupling section can have a receptacle for the ultrasonic testing module. The ultrasonic testing module can be arranged on the receptacle of the coupling section.

[0018] The method can be designed and / or implemented for ultrasonic welding of joining partners. The method can be designed and / or implemented for thermal joining and / or material-to-material bonding. The joining partners can consist of a thermoplastic or contain a thermoplastic. The joining partners can consist of a composite material with a thermoplastic component or contain a composite material with a thermoplastic component. The composite material can be a fiber composite material. The composite material can comprise reinforcing fibers and a matrix material. The reinforcing fibers can be embedded in the matrix material.The composite material can comprise organic fibers such as aramid fibers, carbon fibers, polyester fibers, nylon fibers, polyethylene fibers, polymethyl methacrylate fibers, and / or inorganic fibers such as basalt fibers, boron fibers, glass fibers, ceramic fibers, and silica fibers. The reinforcing fibers can be long fibers and / or short fibers. The reinforcing fibers can be arranged in a directional manner. The reinforcing fibers can be arranged as bundles, woven fabrics, knitted fabrics, non-crimp fabrics, or mats. The matrix material can comprise a thermoplastic. The matrix material can comprise polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyphenylene sulfide (PPS), polysulfone (PSU), polyetherimide (PEI), and / or polytetrafluoroethylene (PTFE). The joining partners can consist of a metallic material or contain a metallic material. The joining partners can be, in particular, automotive components, aircraft components or components for space travel.

[0019] The joining partners can have mutually associated joining contact surfaces. The joining contact surfaces can be flat. The joining contact surfaces can be single- or multiply curved. The joining contact surfaces of the joining partners can abut one another. The joining zone can be arranged at the joining contact surfaces of the joining partners. The joining zone can extend from the joining contact surfaces of the joining partners into the joining partner material. The joining zone can be a zone to be welded or a welded zone. The joining zone can be a zone connecting the joining partners.

[0020] The method can be designed and / or implemented to join at least two joining partners together. The method can be designed and / or implemented to join a first joining partner and a second joining partner together. The joining partners can be arranged with their joining contact surfaces against one another, pressed against one another, moved relative to one another, positioned relative to one another, and / or held relative to one another. The welding ultrasonic vibrations can be high-frequency mechanical vibrations. The welding ultrasonic vibrations can be waves. The welding ultrasonic vibrations can have a predetermined frequency. The predetermined frequency can be adjustable. The welding ultrasonic vibrations can have a modulatable or modulated amplitude. The welding ultrasonic vibrations can be impedance-adaptable or impedance-adapted.

[0021] The materials can be joined together under the influence of welding pressure. Ultrasonic material testing can be performed using a reflected sound method. Ultrasonic material testing can be performed continuously. Ultrasonic material testing can be performed in conjunction with ultrasonic welding. Ultrasonic material testing can be performed intermittently. To perform ultrasonic material testing, a test ultrasound can be initiated and / or recorded.

[0022] The joining zone can be inspected. At least one other material zone can be inspected. The joining partners can be inspected completely. The frequency of the test ultrasound can be set. The frequency of the test ultrasound can be set taking the welding ultrasound into account. The frequency of the test ultrasound can be set in such a way that adverse interactions between the test ultrasound and the welding ultrasound are avoided.

[0023] In summary and in other words, the invention thus results, among other things, in an investigation of a joining zone during ultrasonic welding with the aid of ultrasonic sensors.

[0024] Ultrasonic sensors can be used to direct an ultrasonic signal into the joining zone of a weld and receive the returned echo. A sensor array can transmit an ultrasonic signal and receive its echo. The sensors can enable a signal cascade to be sent into the joining zone, allowing the entire length of the zone to be scanned. Furthermore, it can be possible to obtain a 3D resolution of the material, allowing the entire material to be examined and visualized, not just the joining zone. The examination process can be performed in parallel with the creation of the weld seam. The sensors can be set to a dedicated measurement frequency or be insensitive to the frequency range of the welding process.In addition, the sensors can be mounted on the consolidation module, which moves over the material after the welding process, and their signal can be transmitted via the consolidation module into the joining zone and the reflected signal can be received so that the inspection can be carried out in-line.

[0025] The invention increases process efficiency. Efforts, such as time and / or costs, are reduced. Test quality is increased. The scope of testing can be expanded.

[0026] In the following, embodiments of the invention are described in more detail with reference to figures, which show schematically and by way of example: Fig. 1 a device for continuous ultrasonic welding with an ultrasonic testing module, Fig. 2 a consolidation module of a device for continuous ultrasonic welding with a joining part contact section and an ultrasonic testing module and Fig. 3 a consolidation module of a device for continuous ultrasonic welding with a joining part contact section, a coupling section and an ultrasonic testing module.

[0027] Fig. 1 shows a device 100 for the continuous ultrasonic welding of joining partners 102, 104. The device has a work surface, a compacting module 108, an ultrasonic generator, a sonotrode 110, a consolidation module 112, an ultrasonic testing module 114, a drive device and a control device.

[0028] The joining partners 102, 104 are placed and fixed on the work surface for ultrasonic welding. Using the drive device, the compacting module 108, the sonotrode 110, and the consolidation module 112 are moved in the welding direction 116. The compacting module 108, which has a compacting roller, presses the joining partners 102, 104 together with their joining contact surfaces against the work surface before heating and / or plasticizing. Ultrasonic welding vibrations, generated by the ultrasonic generator, are introduced into the joining zone by the sonotrode 110 while applying welding pressure. In the joining zone, the materials of the joining partners 102, 104 heat up and begin to soften, increasing the damping coefficient. The increase in the damping coefficient leads to higher internal friction, which further accelerates the temperature rise. The plasticized materials bond together.With the help of the consolidation module 112, the joining partners 102, 104 are pressed together with their joining contact surfaces during cooling and solidification and are pressed together against the work surface. The ultrasonic testing module 114 continuously tests the joining zone and, if necessary, other material zones by introducing test ultrasonic waves and recording reflected test ultrasonic waves. After the materials have cooled and solidified, the joining partners 102, 104 are welded together, creating a weld seam.

[0029] Fig. 2 shows a consolidation module 200, such as consolidation module 112 according to Fig. 1. The consolidation module 200 has a plate-shaped joining part contact section 202 made of brass with a first end section facing the sonotrode and a second end section 204 facing away from the sonotrode. A shoulder is provided at the second end section 204, to which an ultrasonic testing module 206, such as the ultrasonic testing module 114 according to Fig. 1. For ultrasonic material testing, the ultrasonic testing module 206 introduces test ultrasonic waves into the joining partners via the joining part contact section 202, and reflected test ultrasonic waves are recorded via the joining part contact section 202.

[0030] Fig. 3 shows a consolidation module 300, such as consolidation module 112 according to Fig. 1. The consolidation module 300 has a plate-shaped joining part contact section 302 made of brass with a coupling section 304 made of a plastic. The coupling section 304 is firmly connected to the joining part contact section 302 and forms an end section 306 of the joining part contact section 302 facing away from the sonotrode. A shoulder is provided on the coupling section 304, to which an ultrasonic testing module 308, such as the ultrasonic testing module 114 according to Fig. 1. For ultrasonic material testing, the ultrasonic testing module 308 is used to introduce test ultrasonic waves into the joining partners via the coupling section 304, and reflected test ultrasonic waves are recorded via the coupling section 304.

[0031] "May" refers in particular to optional features of the invention. Accordingly, there are also further developments and / or embodiments of the invention that additionally or alternatively comprise the respective feature(s).

[0032] If necessary, isolated features may also be selected from the combinations of features disclosed here and used in combination with other features to define the subject matter of the claim, dissolving any structural and / or functional connection that may exist between the features. Reference symbol 100 device 102 joining partners 104 joining partners 108 Compaction module 110 Sonotrode 112 Consolidation module 114 Ultrasonic testing module 116 Welding direction 200 Consolidation Module 202 Joining part contact section 204 final section 206 Ultrasonic testing module 300 Consolidation Module 302 Joining part contact section 304 coupling section 306 final section 308 Ultrasonic testing module

Claims

[1] Device (100) for continuous ultrasonic welding, wherein materials are joined together in a joining zone under the influence of welding ultrasound and pressure, characterized by that the device (100) has a consolidation module (112, 200, 300) for applying a consolidation pressure and an ultrasonic testing module (114, 206, 308) for material testing arranged on the consolidation module (112, 200, 300). [2] Device (100) according to claim 1, characterized by that the device (100) has a sonotrode (110) for introducing welding ultrasound and the ultrasonic testing module (114, 206, 308) is arranged downstream of the sonotrode (110) with respect to a welding direction (116). [3] Device (100) according to claim 2, characterized bythat the consolidation module (112, 200, 300) has a first end section facing the sonotrode (110) and a second end section (204, 306) facing away from the sonotrode (110), and the ultrasonic testing module (114, 206, 308) is arranged on the second end section (204, 306). [4] Device (100) according to at least one of the preceding claims, characterized by that the ultrasonic testing module (114, 206) is arranged and / or designed to introduce and / or receive testing ultrasound over a portion of the consolidation module. [5] Device (100) according to at least one of the preceding claims, characterized by that the consolidation module (112, 300) has a coupling section (304) and the ultrasonic testing module (114, 308) is arranged and / or designed to introduce and / or receive testing ultrasound via the coupling section (304). [6] Continuous ultrasonic welding process, characterized bythat, using a device (100) according to at least one of the preceding claims, materials are joined together in a joining zone under the action of welding ultrasound and pressure, and an ultrasonic material test is carried out. [7] Method according to claim 6, characterized by that ultrasonic material testing is carried out continuously. [8] Method according to at least one of claims 6 to 7, characterized by that the joining zone and at least one other material zone are tested.

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