Method and apparatus for manufacturing tailored weld blank

Abstract

To provide a method for manufacturing a tailored weld blank capable of uniformly applying heat input by laser beam irradiation to cut surfaces of a first plate material and a second plate material, suppressing underfill, and increasing welding strength.SOLUTION: The method for manufacturing a braze-welded blank includes an arrangement step of arranging a first sheet material and a second sheet material so as to form a butting surface in which a shear surface of the first sheet material and a fracture surface of the second sheet material are butted against each other, and a welding step of welding the butting surface by irradiating the butting surface from above with a laser beam whose irradiation angle is adjusted so that the laser beam is irradiated along an inclination of the fracture surface of the second sheet material forming the butting surface.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a manufacturing method and manufacturing apparatus for a tailored weld blank. [Background technology]

[0002] The manufacturing method of a tailored blank described in Patent Document 1 discloses a manufacturing method in which the shear surface of a first steel plate and the fracture surface of a second steel plate are butted together to reduce the gap between the steel plates, so that the height direction positions of the surfaces on the laser irradiation side are approximately aligned, and then a laser beam is irradiated. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 5428881 Summary of the Invention [Problem to be solved by the invention]

[0004] In the tailored blank manufacturing method described in Patent Document 1, when a laser beam is irradiated perpendicularly onto the surfaces of the first and second steel sheets, it is difficult to irradiate the laser beam uniformly from the top to the bottom of the cut surfaces of the first and second steel sheets, which can lead to poor welding. In addition, it is difficult to roughly align the height positions of the surfaces of the first and second steel sheets on the laser irradiated side, which can lead to poor welding known as "misalignment (plate steps)."

[0005] One aspect of the present invention aims to provide a manufacturing method and manufacturing apparatus for a tailored weld blank that enables heat input from laser beam irradiation to be evenly applied to the cut surfaces of the first and second sheet materials, thereby reducing underfill and increasing welding strength. [Means for solving the problem]

[0006] In order to solve the above problems, a manufacturing method of a tailored weld blank according to one embodiment of the present invention includes an arrangement step of arranging the first plate material and the second plate material so that a butt surface is formed where the shear surface of the first plate material and the fracture surface of the second plate material meet, and a welding step of welding the butt surface by irradiating from above with a laser beam whose irradiation angle is adjusted so that it irradiates along the slope of the fracture surface of the second plate material that forms the butt surface.

[0007] In addition, in order to solve the above-mentioned problems, a tailored weld blank manufacturing apparatus according to one embodiment of the present invention includes a stage on which a first plate material and a second plate material can be placed adjacent to each other on the same plane, a fixing mechanism that fixes each of the first plate material and the second plate material to the stage when a butt surface is formed by butting the shear surface of the first plate material and the fracture surface of the second plate material, an angle adjustment mechanism that can adjust the inclination angle of the stage with respect to the horizontal plane, and a controller, and after the first plate material and the second plate material are fixed to the stage by the fixing mechanism, the controller irradiates the butt surface with a laser beam from above along the vertical direction, thereby welding the butt surface, when the angle adjustment mechanism has adjusted the fracture surface of the second plate material to be a surface approximately parallel to the vertical direction. [Effects of the Invention]

[0008] According to one aspect of the present invention, heat input by laser beam irradiation can be applied evenly to the cut surfaces of the first plate material and the second plate material, thereby reducing underfill and increasing welding strength. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a diagram showing an example of a schematic configuration of a manufacturing apparatus for a tailored weld blank according to an embodiment of the present invention. [Figure 2] FIG. 2 is a diagram illustrating an example of a state in which a first plate material is placed on a stage of a manufacturing device. [Figure 3]FIG. 10 is a diagram illustrating an example in which a first plate material placed on a stage is fixed, and a second plate material is placed on the stage. [Figure 4] FIG. 10 is a diagram illustrating an example in which a first plate material and a second plate material are butted together. [Figure 5] 10A and 10B are diagrams illustrating an example of fixing a second plate member. [Figure 6] 10A and 10B are diagrams illustrating an example of welding butted surfaces by tilting the stage. [Figure 7] FIG. 10 is a diagram illustrating an example in which the stage is returned to the origin position and placed in a horizontal state. [Figure 8] FIG. [Figure 9] FIG. 2 is a cross-sectional view showing an example of a state in which a first plate material and a second plate material having approximately the same thickness are butted together. [Figure 10] 10 is a cross-sectional view showing an example of a state in which a first plate and a second plate are butted together when the thickness of the second plate is thinner than the thickness of the first plate. FIG. [Figure 11] 10A and 10B are diagrams illustrating an example of a state in which a laser beam is irradiated onto the butting surfaces of plate materials having approximately the same thickness while the stage is tilted. [Figure 12] 10A and 10B are diagrams illustrating an example of a state in which a laser beam is irradiated onto the butting surfaces of plate materials having different thicknesses while tilting the stage. [Figure 13] 10A and 10B are diagrams illustrating an example of a state in which a laser beam is irradiated onto abutting surfaces according to Modification 1. DETAILED DESCRIPTION OF THE INVENTION

[0010] [Embodiment] Hereinafter, one embodiment of the present invention will be described with reference to FIGS.

[0011] [Outline of manufacturing equipment] The schematic configuration of a manufacturing apparatus 1 for a tailored weld blank (hereinafter also referred to as "TWB") according to one embodiment of the present invention will be described with reference to Fig. 1. Fig. 1 is a diagram showing an example of the schematic configuration of a manufacturing apparatus 1 for a TWB according to one embodiment of the present invention. In Fig. 1, a plan view of a workpiece holding device 10 as seen from above is shown on the upper side, and a central cross-sectional view of the workpiece holding device 10 along the X-axis direction as seen from the front side is shown on the lower side (the same applies to Figs. 2 to 7).

[0012] FIG. 1 shows the X-axis, Y-axis, and Z-axis directions, which are perpendicular to each other. Therefore, the X-axis and Y-axis directions are two perpendicular directions that form a plane with the Z-axis direction as its normal. The Z-axis direction is the vertical direction, and the upward direction is the Z-axis positive direction. The plane formed by the X-axis and Y-axis is a horizontal plane. When referring to directions, reference is made to the directional arrows shown in the figure (the same applies to other figures).

[0013] As shown in FIG. 1, the TWB manufacturing apparatus 1 includes a plate material holding device 10 that holds a first plate material 11 and a second plate material 12, an angle adjustment mechanism 20, and a controller 30.

[0014] [Schematic configuration of the plate material holding device] The plate material holding device 10 includes a flat stage 13 made of a metal such as iron or stainless steel and having a rectangular shape in plan view, a plurality of spacers 14, a plurality of positioning gauges 15, a pair of positioning pins 16, a pair of width adjustment pins 17, and a pair of clamps 18A, 18B. The first plate material 11 and the second plate material 12 are steel plates such as high-tensile steel plates, and are shaped by cutting processes such as pressing or shearing. The first plate material 11 and the second plate material 12 are held by the plate material holding device 10 with their cut surfaces abutting against each other.

[0015] The plurality of spacers 14 are arranged on the stage 13, are made of metal such as iron or stainless steel, and are shaped to be circular or rectangular in plan view. The upper end surfaces of the plurality of spacers 14 are shaped to be flat and parallel to the upper surface of the stage 13, and are shaped to have the same height in the vertical direction. Therefore, the lower surfaces of the first plate material 11 and the second plate material 12 placed on the plurality of spacers 14 are arranged on approximately the same plane. Note that the material and shape of the spacers 14 are not limited to those described above, and may be changed as appropriate depending on the design of the plate material holding device 10, the shapes of the first plate material 11 and the second plate material 12 to be placed, etc.

[0016] The multiple positioning gauges 15 abut against both side edges along the X-axis direction of the first plate material 11 and the second plate material 12 placed on top of the multiple spacers 14, and against the side edge along the Y-axis direction of the first plate material 11 on the opposite side of the second plate material 12, to position them.

[0017] The pair of positioning pins 16 are fitted into a pair of positioning holes 11A (see FIG. 2) in the first plate material 11 to position the first plate material 11. If it is difficult to set the positioning holes 11A in the first plate material 11, the first plate material 11 may be positioned using a plurality of positioning gauges 15 without providing the pair of positioning pins 16.

[0018] The pair of width adjustment pins 17 are provided so as to be movable a predetermined distance in the X-axis direction by an air cylinder or the like (not shown). The pair of width adjustment pins 17 are provided so as to be able to abut against a side edge along the Y-axis direction of the second plate material 12 placed on the upper side of the plurality of spacers 14 on the opposite side to the first plate material 11. Therefore, the pair of width adjustment pins 17 are driven by an air cylinder or the like (not shown) to press the second plate material 12 toward the first plate material 11, so that the cut surfaces of the second plate material 12 and the first plate material 11 butt against each other to form a butt surface.

[0019] The number of width-adjusting pins 17 is not limited to the above, and three or four pins 17 may be provided. Furthermore, the configuration is not limited to pressing the second plate material toward the first plate material 11, and a configuration may be used in which the first plate material 11 is pressed toward the second plate material 12. In this case, the pair of width-adjusting pins 17 only need to be provided so as to be able to abut against the side edge along the Y-axis direction of the first plate material 11 placed on top of the multiple spacers 14 on the opposite side to the second plate material 12.

[0020] The pair of clamps 18A are provided so as to be movable in the vertical direction by an air cylinder (not shown) or the like. The pair of clamps 18A are placed on a plurality of spacers 14 and press both side edges facing each other in the X-axis direction of the first plate material 11, which is positioned by a plurality of positioning gauges 15 and a pair of positioning pins 16, along the entire length of the Y-axis direction. In addition, a plurality of spacers 14 are arranged on the upper surface of the stage 13 at positions facing each clamp 18A. As a result, the first plate material 11 is sandwiched between each clamp 18A and the plurality of spacers 14 and fixed to the upper surface of the stage 13.

[0021] The pair of clamps 18B are provided so as to be movable in the vertical direction by an air cylinder (not shown) or the like. The pair of clamps 18B are placed on a plurality of spacers 14 and press both side edges facing each other in the X-axis direction of the second plate material 12, which is positioned by a plurality of positioning gauges 15 and a pair of alignment pins 17, along the entire length in the Y-axis direction. In addition, a plurality of spacers 14 are arranged on the upper surface of the stage 13 at positions facing each clamp 18B. As a result, the second plate material 12 is sandwiched between each clamp 18B and the plurality of spacers 14 and fixed to the upper surface of the stage 13. Each pair of clamps 18A, 18B functions as an example of a fixing mechanism.

[0022] The number of clamps 18A and clamps 18B is not limited to the above, and three or four clamps 18A and clamps 18B may be provided. Furthermore, clamps 18A and clamps 18B are not limited to a configuration in which they press both side edges of first plate material 11 and second plate material 12, which face each other in the X-axis direction, along the entire length in the Y-axis direction. For example, they may be configured to partially press a plurality of locations on each of first plate material 11 and second plate material 12. In short, any configuration is acceptable as long as it allows first plate material 11 and second plate material 12 to be fixed to stage 13.

[0023] [Outline of angle adjustment mechanism] As shown in Fig. 1, the angle adjustment mechanism 20 is composed of a two-axis positioner. Specifically, the angle adjustment mechanism 20 includes a mounting plate 21, a first motor 22 that rotates the mounting plate 21 around an axis that passes through the approximate center of the mounting plate 21, and a second motor 23 that rotates the mounting plate 21 and the first motor 22 together around the Y axis. The first motor 22 and the second motor 23 are composed of, for example, an AC servo motor or a DC servo motor. The lower end of the angle adjustment mechanism 20 is attached to a base plate (not shown).

[0024] The mounting plate 21 is attached, for example, by bolting to the underside of the stage 13, at approximately the center between the pair of positioning pins 16. The motor shaft of the second motor 23 is arranged along the Y-axis direction. As a result, by driving the second motor 23, the angle adjustment mechanism 20 can rotate the stage 13 about the Y-axis via the first motor 22 and the mounting plate 21, and tilt the stage 13 at a predetermined angle, for example, approximately 0 to 15 degrees, with respect to the horizontal plane.

[0025] The angle adjustment mechanism 20 is not limited to being configured as a two-axis positioner. The angle adjustment mechanism 20 may be configured as a single-axis positioner, for example. The mounting plate 21 is attached to the underside of the stage 13 at approximately the center between the pair of positioning pins 16 by bolting or the like. When the angle adjustment mechanism 20 is configured as a single-axis positioner, it is sufficient that a structure connectable to a motor shaft is provided below the approximately center of the underside of the mounting plate 21. The motor shaft of the single-axis positioner may also be arranged along the Y-axis direction. The motor of the single-axis positioner is configured as, for example, an AC servo motor, a DC servo motor, or the like.

[0026] By connecting the motor shaft of the single-axis positioner to the mounting plate 21, the angle adjustment mechanism 20 can rotate the stage 13 around the Y axis via the mounting plate 21, and tilt it at a predetermined angle, for example, approximately 0 to 15 degrees, with respect to the horizontal plane.

[0027] [Electrical configuration of controller 30] Next, the electrical configuration of the controller 30 will be described with reference to Fig. 1. Fig. 1 shows a block diagram of an example of the electrical configuration of the controller 30. As shown in Fig. 1, the controller 30 includes a control unit 31, an angle adjustment unit 32, a laser irradiation unit 33, a clamp drive unit 34, a pin drive unit 35, a display 36, and an operation unit 37.

[0028] The control unit 31 is composed of, for example, a CPU (Central Processing Unit) 311, a ROM (Read Only Memory) 312, a RAM (Random Access Memory) 313, a storage unit 314, etc. The storage unit 314 is composed of, for example, a flash memory, an HDD (Hard Disk Drive), an SSD (Solid State Drive), etc. The CPU 311 executes various arithmetic processes based on various programs and various parameters stored in the ROM 312. The RAM 313 temporarily stores the results and data of the calculations of the CPU 311. The storage unit 314 stores in advance data such as the plate thicknesses and fracture surface angles of the first plate material 11 and the second plate material 12 described below.

[0029] The control unit 31 is electrically connected to an angle adjustment unit 32, a laser irradiation unit 33, a clamp drive unit 34, a pin drive unit 35, a display 36, and an operation unit 37. The operation unit 37 is composed of a plurality of button switches, and by pressing each button switch, an instruction signal corresponding to each button switch is output to the control unit 31. Note that the operation unit 37 is not limited to physical switches, and may be, for example, a display 36 having a touch sensor interface that accepts operation inputs.

[0030] For example, when a button switch that instructs tilting of stage 13 is pressed, a signal instructing tilting (hereinafter referred to as a "tilt instruction signal") is output to control unit 31. When a button switch that instructs starting laser irradiation is pressed, a signal instructing laser irradiation (hereinafter referred to as a "laser irradiation instruction signal") is output to control unit 31. When a button switch that instructs fixing clamp 18A is pressed, a signal instructing fixing clamp 18A (hereinafter referred to as a "fixing instruction signal") is output to control unit 31. When a button switch that instructs fixing clamp 18B is pressed, a signal instructing fixing clamp 18B (hereinafter referred to as a "fixing instruction signal") is output to control unit 31.

[0031] When the button switch that instructs the release of clamps 18A and 18B is pressed, a signal instructing the release of clamps 18A and 18B (hereinafter referred to as a "release instruction signal") is output to the control unit 31. When the button switch that instructs the shifting of the second plate material 12 to the width is pressed, a signal instructing the shifting to the width (hereinafter referred to as a "shifting instruction signal") is output to the control unit 31.

[0032] When tilt start information including the tilt angle of stage 13 is input from control unit 31, angle adjustment unit 32 drives second motor 23 to tilt stage 13 relative to the horizontal plane by the tilt angle included in the tilt start information. When origin return information is input from control unit 31, angle adjustment unit 32 drives second motor 23 to return stage 13 to the origin position where it is horizontal. Note that second motor 23 may be equipped with an encoder or the like that detects the amount of rotation of the motor shaft.

[0033] When information indicating the start of welding (hereinafter referred to as "welding start information") is input from the control unit 31, the laser irradiation unit 33 outputs welding instruction information that instructs a laser welding robot (not shown) to irradiate the butt surfaces of the first plate material 11 and the second plate material 12 with a laser beam from above in the vertical direction to weld them. Furthermore, when a welding end signal indicating the end of laser welding is input from the laser welding robot (not shown), the laser irradiation unit 33 outputs welding end information indicating the end of laser welding to the control unit 31.

[0034] Note that laser welding of the butt surfaces of the first plate material 11 and the second plate material 12 is not limited to welding by a laser welding robot. For example, a laser welding device may be used instead of a laser welding robot. Specifically, the laser welding device may include an oscillator that oscillates a laser beam, a transmission system that transmits the laser beam, and a processing head that is movable in the Y-axis direction while irradiating the transmitted laser beam from above along the vertical direction. When welding start information indicating the start of welding is input from the control unit 31, the laser irradiation unit 33 may output welding instruction information to the laser welding device (not shown) to irradiate the butt surfaces of the first plate material 11 and the second plate material 12 with a laser beam to perform welding.

[0035] When welding instruction information is input from the laser irradiation unit 33, the laser welding device may move in the Y-axis direction to perform welding while irradiating a laser beam vertically from above onto the butt surfaces of the first plate material 11 and the second plate material 12 via the processing head. Furthermore, when welding of the butt surfaces of the first plate material 11 and the second plate material 12 is completed, the laser welding device (not shown) may output a welding end signal indicating the end of laser welding to the laser irradiation unit 33. When the welding end signal is input from the laser welding device (not shown), the laser irradiation unit 33 may output welding end information indicating the end of laser welding to the control unit 31.

[0036] When clamp driver 34 receives fixation instruction information for clamp 18A from control unit 31, it lowers the pair of clamps 18A to fix the first plate material 11 to the stage 13. When clamp driver 34 receives fixation instruction information for clamp 18B from control unit 31, it lowers the pair of clamps 18B to fix the second plate material 12 to the stage 13. When clamp driver 34 receives release instruction information for each of clamps 18A, 18B from control unit 31, it raises each of the pair of clamps 18A, 18B. In this way, clamp driver 34 releases the fixation of first plate material 11 and second plate material 12 to stage 13, making the first plate material 11 and second plate material 12 removable from stage 13.

[0037] When width-shifting instruction information is input from the control unit 31, the pin driving unit 35 moves the pair of width-shifting pins 17 in the negative direction of the X axis via a driving mechanism (not shown) to press the second plate material 12 toward the first plate material 11. In this way, the pin driving unit 35 forms a butt surface where the cut surfaces of the first plate material 11 and the second plate material 12 butt against each other. Furthermore, when width-shifting release information is input from the control unit 31, the pin driving unit 35 moves the pair of width-shifting pins 17 in the positive direction of the X axis via a driving mechanism (not shown) to release the pressure on the second plate material 12.

[0038] The display 36 is a display screen such as a liquid crystal display or an organic EL (Electro Luminescence) display, and displays images.

[0039] It is also possible to provide the workpiece holding device 10 with a clamp driver 34 and a pin driver 35, the angle adjustment mechanism 20 with an angle adjuster 32, and a laser welding robot (not shown) with a laser irradiation unit 33. In place of the controller 30, various instruction signals may be sent and received from a mobile terminal carried by the worker to the angle adjuster 32, the laser irradiation unit 33, the clamp driver 34, and the pin driver 35. This improves the operability of the TWB manufacturing apparatus 1.

[0040] [TWB manufacturing method] Next, a method for manufacturing a TWB using the TWB manufacturing apparatus 1 configured as described above will be described with reference to FIGS.

[0041] [Placement of first plank] First, the placement of the first plate material 11 on the stage 13 of the manufacturing apparatus 1 will be described with reference to Fig. 2. As shown in Fig. 2, the stage 13 constituting the plate material holding device 10 of the manufacturing apparatus 1 is positioned above the angle adjustment mechanism 20, and the first plate material 11 is placed above each spacer 14 on the stage 13. The first plate material 11 is placed on the stage 13 by an operator or a robot.

[0042] In the process of shearing the first plate material 11 by pressing and shearing, positioning holes 11A are drilled in two locations at the same time as cutting the portions to be welded by irradiating with a laser beam. The first plate material 11 is then positioned by inserting each positioning pin 16 into each positioning hole 11A. Note that if it is difficult to set the positioning holes 11A, the first plate material 11 may be positioned using a positioning gauge 15, utilizing the contour of the first plate material 11.

[0043] Here, the cut surfaces of the first plate 11 and the second plate 12 by shear cutting will be described with reference to Fig. 8. Note that the cut surfaces of the first plate 11 and the second plate 12 are similar, so the cut surface of the first plate 11 will be described with reference to Fig. 8, and the cut surface of the second plate 12 will not be described. As shown in Fig. 8, the cut surface of the first plate 11 by pressing and shearing has a shear surface A1 formed along the cutting direction, followed by a fracture surface B1. The fracture surface B1 is inclined inward by a fracture surface angle θ with respect to the cutting direction.

[0044] Next, an example of a state in which the first plate material 11 is placed on the spacer 14 of the stage 13 will be described with reference to Figs. 9 and 10. The thickness of the first plate material 11 is set to be equal to or greater than the thickness of the second plate material 12. Fig. 9 shows a case in which the thickness of the first plate material 11 and the thickness of the second plate material 12 are substantially the same. Fig. 10 shows a case in which the thickness of the first plate material 11 is greater than the thickness of the second plate material 12.

[0045] 9 and 10, the first plate material 11 is placed on the spacer 14 of the stage 13 so that the shear surface A1 of the portion to be welded by irradiating with the laser beam faces downward. Therefore, the fracture surface B1 of the portion to be welded by irradiating with the laser beam of the first plate material 11 placed on the stage 13 is inclined by a fracture surface angle θ toward the negative X-axis direction with respect to the vertical direction.

[0046] [Fixing the 1st plate and placing the 2nd plate] Next, the fixation of the first plate material 11 and the arrangement of the second plate material 12 will be described with reference to FIGS. 1 and 3. As shown in FIGS. 1 and 3, when a button switch (not shown) of the operation unit 37 that instructs the clamps 18A to be fixed is pressed and a fixation instruction signal for the clamps 18A is input from the operation unit 37, the control unit 31 outputs fixation instruction information for the clamps 18A to the clamp drive unit 34. When the fixation instruction information for the clamps 18A is input from the control unit 31, the clamp drive unit 34 lowers the pair of clamps 18A to fix the first plate material 11 to the stage 13. The pair of clamps 18A press both side edges of the first plate material 11 that face each other in the X-axis direction along the entire length of the first plate material 11 along the Y-axis direction. As a result, the first plate material 11 is sandwiched between the clamps 18A and the multiple spacers 14 and fixed to the upper surface of the stage 13.

[0047] Next, the second plate material 12 is placed on a spacer 14 of the stage 13 so that the portion to be welded by irradiating with the laser beam faces the first plate material 11. The second plate material 12 is placed on the stage 13 by an operator or a robot. As a result, the first plate material 11 and the second plate material 12 are arranged so that the lower surface of the first plate material 11 and the lower surface of the second plate material 12 are adjacent and on approximately the same plane. In addition, the second plate material 12 is positioned in the Y-axis direction by a positioning gauge 15 using the contour of the second plate material 12.

[0048] 9 and 10, the state in which the second plate material 12 is placed on the spacer 14 of the stage 13 will be described. As shown in FIGS. 9 and 10, the second plate material 12 is placed on the spacer 14 of the stage 13 so that the fracture surface B2 of the portion to be welded by irradiating with the laser beam faces downward. The second plate material 12 is also placed on the spacer 14 of the stage 13 so that the shear surface A2 of the second plate material 12 faces upward. Therefore, the fracture surface B2 of the portion to be welded by irradiating with the laser beam of the second plate material 12 placed on the stage 13 is inclined by the fracture surface angle θ toward the positive direction of the X-axis with respect to the vertical direction.

[0049] Match Next, the butting of the shear surface A1 of the first plate 11 and the fracture surface B2 of the second plate 12 will be described with reference to FIGS. 1 and 4. As shown in FIGS. 1 and 4, when a button switch (not shown) of the operation unit 37 that instructs the second plate 12 to be moved widthwise is pressed and a widthwise positioning instruction signal is input from the operation unit 37, the control unit 31 outputs widthwise positioning instruction information to the pin drive unit 35. When the widthwise positioning instruction information is input from the control unit 31, the pin drive unit 35 moves the pair of widthwise positioning pins 17 in the negative direction of the X-axis via a drive mechanism (not shown) to press the second plate 12 toward the first plate 11. This forms an butting surface where the shear surface A1 of the first plate 11 and the fracture surface B2 of the second plate 12 are butted together, and the gap between the first plate 11 and the second plate 12 at the location where the laser beam is irradiated can be made uniform and small.

[0050] Here, the butting of the shear surface A1 of the first plate 11 and the fracture surface B2 of the second plate 12 will be described with reference to Figures 9 and 10. As shown in Figures 9 and 10, the butting surface where the shear surface A1 of the first plate 11 and the fracture surface B2 of the second plate 12 butt together is inclined by a fracture surface angle θ toward the positive X-axis direction with respect to the vertical direction (Z-axis direction). Furthermore, the butting surface where the fracture surface B1 of the first plate 11 and the shear surface A2 of the second plate 12 butt together is inclined by a fracture surface angle θ toward the negative X-axis direction with respect to the vertical direction (Z-axis direction).

[0051] [Second plate fixed] Next, the fixing of the second plate material 12 will be described with reference to Figures 1 and 5. As shown in Figures 1 and 5, when a button switch (not shown) of the operation unit 37 that instructs the fixing of the clamps 18B is pressed and a fixing instruction signal for the clamps 18B is input from the operation unit 37, the control unit 31 outputs fixing instruction information for the clamps 18B to the clamp driving unit 34. When the fixing instruction information for the clamps 18B is input from the control unit 31, the clamp driving unit 34 lowers the pair of clamps 18B to fix the second plate material 12 to the stage 13. The pair of clamps 18B press both side edges of the second plate material 12 that face each other in the X-axis direction along the entire length along the Y-axis direction.

[0052] Therefore, the second plate material 12 is clamped by each clamp 18B and the plurality of spacers 14 and fixed to the upper surface of the stage 13. In addition, the lower surfaces of the first plate material 11 and the second plate material 12 are arranged and fixed so that they are adjacent to each other on approximately the same plane. This makes it possible to easily arrange the lower surfaces of the first plate material 11 and the second plate material 12 so that they are aligned with each other.

[0053] [Stage tilt / welding] Next, angle adjustment for tilting the stage 13 constituting the workpiece holding device 10 relative to the horizontal plane will be described with reference to Figures 1 and 6. As shown in Figures 1 and 6, when a button switch (not shown) for instructing tilting of the stage 13 of the operation unit 37 is pressed and a tilt instruction signal is input from the operation unit 37, the control unit 31 outputs tilt start information including the tilt angle α of the stage 13 to the angle adjustment unit 32. The tilt angle α is an angle approximately equal to the fracture surface angle θ of the fracture surface B2 of the second workpiece 12, and is input to the control unit 31 via the operation unit 37 and stored in advance in the memory unit 314.

[0054] When tilt start information is input from the control unit 31, the angle adjustment unit 32 drives the second motor 23 of the angle adjustment mechanism 20 so that the side edge of the stage 13 on the second plate material 12 side moves downward. The angle adjustment unit 32 then tilts the stage 13 with respect to the horizontal plane by an inclination angle α that is approximately equal to the fracture surface angle θ of the fracture surface B2 of the second plate material 12, and stops the second motor 23. As a result, the first plate material 11 and the second plate material 12, which are fixed in a butted state on the stage 13, are arranged at an incline with respect to the horizontal direction so that the fracture surface B2 of the second plate material 12 is in a plane that is approximately parallel to the vertical direction.

[0055] 11 and 12, the lower surfaces of the first plate 11 and the second plate 12 are arranged adjacent to each other on approximately the same plane, and are inclined with respect to the horizontal plane by an inclination angle α that is approximately equal to the fracture surface angle θ of the fracture surface B2 of the second plate 12. As a result, the fracture surface B2 of the second plate 12 that abuts against the shear surface A1 of the first plate 11 is arranged to be a plane that is approximately parallel to the vertical direction. Furthermore, the fracture surface B1 of the first plate 11 that abuts against the shear surface A2 of the second plate 12 is arranged to be a plane that is approximately parallel to the vertical direction.

[0056] 1 and 6, when a button switch (not shown) of the operation unit 37 that instructs the start of laser irradiation is pressed and a laser irradiation instruction signal is input from the operation unit 37, the control unit 31 outputs welding start information indicating the start of welding to the laser irradiation unit 33. When the welding start information indicating the start of welding is input from the control unit 31, the laser irradiation unit 33 outputs welding instruction information to an unillustrated laser welding robot to irradiate the butt surfaces of the first plate material 11 and the second plate material 12 with a laser beam L1 from above along the vertical direction to weld them.

[0057] Incidentally, angle adjustment unit 32 may stop second motor 23 and output a tilt end signal indicating that tilt driving of stage 13 has ended to control unit 31. Then, when a tilt end signal indicating that second motor 23 has stopped and that tilt driving of stage 13 has ended is input from angle adjustment unit 32, control unit 31 may output welding start information indicating the start of welding to laser irradiation unit 33.

[0058] When welding instruction information is input from the laser irradiation unit 33, the laser welding robot (not shown) irradiates the butt surface where the shear surface A1 of the first plate material 11 and the fracture surface B2 of the second plate material 12 are butted with a laser beam L1 from above along the vertical direction to perform welding. Then, when the laser welding robot (not shown) completes laser welding over the entire length from one end to the other in the Y-axis direction of the butt surface where the shear surface A1 of the first plate material 11 and the fracture surface B2 of the second plate material 12 are butted, it outputs a welding end signal indicating the end of laser welding to the laser irradiation unit 33. When the welding end signal is input from the laser welding robot (not shown), the laser irradiation unit 33 outputs welding end information indicating the end of laser welding to the control unit 31.

[0059] Here, an example of welding by irradiating a laser beam L1 from above along the vertical direction with a second plate 12 abutting against the shear surface A1 of a first plate 11 and arranged so that the fracture surface B2 is substantially parallel to the vertical direction will be described with reference to FIGS. 11 and 12. Note that FIGS. 11 and 12 correspond to FIGS. 9 and 10, respectively. As shown in FIGS. 11 and 12, the laser beam L1 is irradiated from above along the vertical direction along the fracture surface B2 of the second plate 12 abutting against the shear surface A1 of the first plate 11. Furthermore, the laser beam L1 is irradiated from above along the vertical direction along the fracture surface B1 of the first plate 11 abutting against the shear surface A2 of the second plate 12.

[0060] This allows the heat input by the irradiation of the laser beam L1 to be uniformly applied to the cut surfaces of the first plate material 11 and the second plate material 12, thereby melting them. As a result, the metal (molten metal) molten by the irradiation of the laser beam L1 can flow smoothly from the gap between the cut surfaces of the first plate material 11 and the second plate material 12 along the fracture surface B2 of the second plate material 12 to the lower surface on the vertically downward side (in the direction of arrow 41), thereby suppressing underfill and increasing the welding strength. Furthermore, because the lower surfaces of the first plate material 11 and the second plate material 12 are arranged adjacent to each other on approximately the same plane, welding defects such as misalignment (plate steps) can be suppressed.

[0061] [Return to origin position] Next, an example of returning stage 13 to the origin position and to a horizontal state will be described with reference to Figures 1 and 7. As shown in Figures 1 and 7, when welding end information indicating the end of laser welding is input from laser irradiation unit 33, control unit 31 outputs origin return information to angle adjustment unit 32 instructing stage 13 to return to the origin position and to be in a horizontal state.

[0062] When origin return information is input from the control unit 31, the angle adjustment unit 32 drives the second motor 23 of the angle adjustment mechanism 20 so that the side edge of the stage 13 on the side of the second plate material 12 rises upward. Then, as shown in the lower part of Fig. 7, the angle adjustment unit 32 drives the second motor 23 to rotate the stage 13 counterclockwise by an inclination angle α that is approximately equal to the fracture surface angle θ of the fracture surface B2 of the second plate material 12 to bring the stage 13 to a horizontal state, and returns the stage 13 to the origin position.

[0063] Thereafter, when a button switch (not shown) of operation unit 37 that instructs release of clamps 18A and 18B is pressed and a release instruction signal for clamps 18A and 18B is input from operation unit 37, control unit 31 outputs release instruction information for clamps 18A, 18B to clamp driver 34. When release instruction information for clamps 18A, 18B is input from control unit 31, clamp driver 34 raises each of the pair of clamps 18A, 18B. This releases first plate material 11 and second plate material 12 from stage 13, making it possible to remove first plate material 11 and second plate material 12, which have been welded together, from plate holding device 10, completing the production of the TWB.

[0064] [Variations] A modification of the above embodiment will be described. In the following description, for the sake of convenience, the same reference numerals will be used to designate components having the same functions as those described in the above embodiment, and the description thereof will not be repeated.

[0065] [Variation 1] This configuration is not limited to tilting the first plate material 11 and the second plate material 12 so that the butt surface where the shear surface A1 of the first plate material 11 and the fracture surface B2 of the second plate material 12 are butted together becomes a surface that is approximately parallel to the vertical direction, and irradiating the laser beam L1 onto the butt surface from above along the vertical direction. For example, the first plate material 11 and the second plate material 12 may be arranged horizontally with the shear surface A1 of the first plate material 11 and the fracture surface B2 of the second plate material 12 butted against each other. The irradiation angle of the laser beam L1 may be tilted so as to be approximately parallel to the butt surface between the first plate material 11 and the second plate material 12, and the butt surface between the first plate material 11 and the second plate material 12 may be irradiated from above.

[0066] 1 and 5, the control unit 31 fixes the first plate material 11 and the second plate material 12 onto the stage 13 using a pair of clamps 18A, 18B. However, the control unit 31 may maintain the horizontal state of the stage 13 without tilting the stage 13 with respect to the horizontal plane.

[0067] When a button switch (not shown) of the operation unit 37 for instructing the start of laser irradiation is pressed and a laser irradiation instruction signal is input from the operation unit 37, the control unit 31 may output second welding start information indicating the start of welding to the laser irradiation unit 33, instead of the welding start information indicating the start of welding. When the second welding start information is input from the control unit 31, the laser irradiation unit 33 may output the second welding instruction information to a laser welding robot (not shown). The second welding instruction information is instruction information that instructs the laser beam L1 to be irradiated from above onto the butt surfaces of the first plate material 11 and the second plate material 12, with the laser beam L1 tilted in the X-axis direction toward the first plate material 11 by an inclination angle α that is approximately equal to the fracture surface angle θ of the fracture surface B2 of the second plate material 12.

[0068] An example of laser welding that a laser welding robot (not shown) performs when second welding instruction information is input will now be described with reference to Fig. 13. As shown in Fig. 13, when the laser welding robot (not shown) receives second welding instruction information from the laser irradiation unit 33, it tilts the laser beam L1 in the X-axis direction toward the first plate material 11 by an inclination angle α that is approximately equal to the fracture surface angle θ of the fracture surface B2 of the second plate material 12. The laser welding robot then irradiates the laser beam L1 from above onto the butt surfaces where the shear surface A1 of the first plate material 11 and the fracture surface B2 of the second plate material 12 are butted together, and the butt surfaces where the fracture surface B1 of the first plate material 11 and the shear surface A2 of the second plate material 12 are butted together, thereby welding the plates.

[0069] This allows the heat input by the irradiation of the laser beam L1 to be uniformly applied to the cut surfaces of the first plate material 11 and the second plate material 12, thereby melting them. As a result, the metal (molten metal) molten by the irradiation of the laser beam L1 can flow smoothly from the gap between the cut surfaces of the first plate material 11 and the second plate material 12 along the fracture surface B1 of the first plate material 11 to the underside (in the direction of arrow 42), thereby suppressing underfill and increasing the welding strength. Furthermore, because the undersides of the first plate material 11 and the second plate material 12 are arranged adjacent to each other on approximately the same plane, welding defects such as misalignment (plate steps) can be suppressed.

[0070] Thereafter, when the laser welding robot (not shown) has completed laser welding over the entire length from one end to the other end in the Y-axis direction of the butt surface where the shear surface A1 of the first plate material 11 and the fracture surface B2 of the second plate material 12 are butted together, it may output a welding completion signal to the laser irradiation unit 33 indicating the completion of laser welding.

[0071] [Variation 2] Also, for example, instead of the second motor 23, the angle adjustment mechanism 20 may have a shaft member that is rotatable by a handle turned by an operator, arranged along the Y-axis direction, and this shaft member attached to the first motor 22. Then, when the operator turns the handle to rotate the shaft member, the stage 13 may be rotated about the Y-axis via the first motor 22 and the mounting plate 21, and tilted at a predetermined angle, for example, approximately 0 to 15 degrees, with respect to the horizontal plane.

[0072] [summary] A manufacturing method of a tailored weld blank according to aspect 1 of the present invention includes an arrangement step of arranging the first plate material and the second plate material so that a butt surface is formed where the shear surface of the first plate material and the fracture surface of the second plate material meet, and a welding step of welding the butt surface by irradiating from above with a laser beam whose irradiation angle is adjusted so that it irradiates along the slope of the fracture surface of the second plate material that forms the butt surface.

[0073] According to the above-described method for manufacturing a tailored weld blank, a laser beam is irradiated at an angle adjusted so that it is irradiated at an inclination angle relative to the vertical direction of the fracture surface of the second plate material forming the butt surface. This allows the heat input from the laser beam to be applied evenly to both cut surfaces, suppressing underfill and increasing weld strength.

[0074] In a manufacturing method of a tailored weld blank according to aspect 2 of the present invention, in the above-mentioned aspect 1, the positioning process includes an angle adjustment process of positioning the first plate material and the second plate material at an angle with respect to the horizontal direction so that the fracture surface of the second plate material that forms the butt surface is a plane that is approximately parallel to the vertical direction.

[0075] According to the above-described manufacturing method for a tailored weld blank, the fracture surfaces that form the butt joints are planes that are approximately parallel to the vertical direction. This allows the molten metal (molten metal) irradiated from above along the vertical direction by the laser beam to flow smoothly from the gap between the cut surfaces of the first and second sheets to the underside of the sheets, further reducing underfill.

[0076] A manufacturing method for a tailored weld blank according to aspect 3 of the present invention is the same as that according to aspect 1 or 2 above, wherein the arranging step includes a step of arranging the first plate material and the second plate material so that the lower surfaces of the first plate material and the second plate material are adjacent and on approximately the same plane.

[0077] According to the above-described method for manufacturing a tailored weld blank, the lower surfaces of the first plate material and the second plate material can be easily aligned and positioned, and welding defects such as misalignment (plate step) can be suppressed.

[0078] A manufacturing apparatus for a tailored weld blank according to a fourth aspect of the present invention includes a stage on which a first plate material and a second plate material can be placed adjacent to each other on the same plane, a fixing mechanism that fixes each of the first plate material and the second plate material to the stage when a butt surface is formed by butting the shear surface of the first plate material and the fracture surface of the second plate material, an angle adjustment mechanism that can adjust the inclination angle of the stage with respect to a horizontal plane, and a controller. After the first plate material and the second plate material are fixed to the stage by the fixing mechanism, the controller irradiates the butt surface from above along the vertical direction with a laser beam to weld the butt surface when the angle adjustment mechanism adjusts the fracture surface of the second plate material to be a surface that is approximately parallel to the vertical direction.

[0079] With the above-described tailored weld blank manufacturing device, the fracture surfaces that form the butt joints are generally parallel to the vertical direction. This allows the molten metal (molten metal) irradiated from above along the vertical direction by a laser beam to flow smoothly from the gap between the cut surfaces of the first and second sheets to the underside of the sheets, thereby reducing underfill. It also allows heat input to be evenly applied to the cut surfaces of the first and second sheets, increasing weld strength. The undersides of the first and second sheets can be easily aligned, reducing welding defects such as misalignment (sheet steps).

[0080] [Additional Notes] The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in different embodiments are also included in the technical scope of the present invention. [Explanation of symbols]

[0081] 1. Tailored weld blank manufacturing equipment 11 First plate material 12 Second plate material 13 Stages 18A, 18B clamp 20 Angle adjustment mechanism 30 Controllers A1, A2 shear plane B1, B2 fracture surface L1 laser beam

Claims

1. an arrangement step of arranging the first plate material and the second plate material so that a butt surface is formed where the shear surface of the first plate material and the fracture surface of the second plate material are butted against each other; a welding process of welding the butt surfaces by irradiating from above with a laser beam, the irradiation angle of which is adjusted so as to irradiate along the inclination of the fractured surface of the second plate material forming the butt surfaces; A method for manufacturing a tailored weld blank, comprising:

2. The placing step includes: an angle adjusting step of arranging the first plate material and the second plate material at an angle with respect to a horizontal direction so that the fracture surface of the second plate material forming the butt surface is a surface approximately parallel to a vertical direction, A method for manufacturing a tailored weld blank according to claim 1.

3. The placing step includes: and arranging the first plate member and the second plate member so that a lower surface of the first plate member and a lower surface of the second plate member are adjacent to each other on substantially the same plane. A method for manufacturing a tailored weld blank according to claim 1 or 2.

4. a stage on which the first plate material and the second plate material can be placed adjacent to each other on the same plane; a fixing mechanism that fixes each of the first plate material and the second plate material to the stage in a state in which an abutting surface is formed by abutting the shear surface of the first plate material and the fracture surface of the second plate material; an angle adjustment mechanism capable of adjusting an inclination angle of the stage relative to a horizontal plane; a controller; The controller a manufacturing device for a tailored weld blank, wherein after the first plate material and the second plate material are fixed to the stage by the fixing mechanism, the angle adjustment mechanism is adjusted so that the fracture surface of the second plate material is approximately parallel to the vertical direction, and a laser beam is irradiated from above along the vertical direction onto the butt surfaces to weld the butt surfaces.

Images