Fusion method

Abstract

The present invention provides a fusion bonding method that suppresses temperature variations across different regions. [Solution] A fusion method for fusing a second member to a first member comprises a placement step and a scanning step. The placement step is a step of placing a susceptor via a heat transfer member on the side of the second member that is opposite to the side of the first member that is to be repaired, according to the repair target location of the first member. The scanning step is a step of scanning a magnetic field generator along the surface of the susceptor from the side of the susceptor that is opposite to the side of the susceptor that is to be repaired, after the placement step is completed. The susceptor is a member that generates heat due to the magnetic field of the magnetic field generator in the scanning step.

Description

Technical Field

[0001] The present disclosure relates to a fusion method.

Background Art

[0002] For example, Non-Patent Document 1 below describes adhering a composite material patch to a repair location via a film-shaped adhesive for aircraft repair.

Prior Art Documents

Non-Patent Documents

[0003]

Non-Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the adhesion of the composite material patch or the like, it is necessary to heat the adhesive. Therefore, the inventor considered heating the adhesive by induction heating. However, in that case, it was found that there is a possibility of temperature variation for each heated region.

Means for Solving the Problems

[0005] The present disclosure provides a fusion method for fusing a second member to a first member. The fusion method includes an arrangement step and a scanning step. The arrangement step is a step of arranging a susceptor via a heat transfer member on the side opposite to the surface of the second member facing the repair target location among the second members arranged according to the repair target location of the first member. The scanning step is a step of scanning a magnetic field generator along the surface of the susceptor from the side opposite to the surface of the susceptor facing the heat transfer member after completion of the arrangement step. The susceptor is a member that generates heat by the magnetic field of the magnetic field generator in the scanning step.

Brief Description of the Drawings

[0006] [Figure 1] This diagram shows the configuration of an aircraft repair system according to the first embodiment. [Figure 2] This is a flowchart showing the procedure for repairing an aircraft according to the embodiment described above. [Figure 3] This is a flowchart showing a detailed procedure for some of the steps in the process shown in Figure 2. [Figure 4] Figure 3 is a cross-sectional view showing a part of the process. [Figure 5] Figure 3 is a cross-sectional view showing a part of the process. [Figure 6] Figure 3 is a heatmap showing a portion of the process. [Figure 7] This figure shows a part of the process shown in Figure 3. [Figure 8] This figure shows a part of the process shown in Figure 3. [Figure 9] This is a plan view illustrating the raster set in the process shown in Figure 3. [Figure 10] This is a heat map showing the effects of the embodiment. [Figure 11] This is a flowchart showing the procedure for the scanning pattern setting process according to the second embodiment. [Modes for carrying out the invention]

[0007] <First Embodiment> The first embodiment will be described below with reference to the drawings. "Repair system" Figure 1 shows the configuration of the aircraft repair system according to this embodiment. The airframe 10 is the airframe of the aircraft to be repaired. The material of the airframe 10 is, for example, carbon fiber reinforced thermoplastic (CFRTP). The solenoid coil 12 is a magnetic field generator for fusing repair patches to the repair location on the airframe 10 by electromagnetic induction heating. The solenoid coil 12 is attached to the robot arm 14. The robot arm 14 is fixed to the trolley 16. The trolley 16 is equipped with a control device 20.

[0008] The control device 20 comprises a PU 22, a storage device 24, and a communication device 26. The PU 22 is a processing unit that executes software processing such as a CPU or GPU. The storage device 24 stores a program consisting of commands that define the processing to be performed by the PU 22. The objects controlled by the control device 20 are the robot arm 14 and the solenoid coil 12. By executing the above program, the PU 22 controls the displacement of the robot arm 14 and the energization of the solenoid coil 12.

[0009] The robot arm 30 is responsible for moving predetermined components, such as placing the repair patch on the repair location of the machine body 10. The control device 32 controls the robot arm 30. The higher-level control unit 40 comprises a PU 42, a storage device 44, and a communication device 46. The PU 42 is a processing unit that executes software processing such as a CPU or GPU. The storage device 44 stores a program consisting of commands that define the processing to be executed by the PU 42. The objects controlled by the higher-level control unit 40 are the robot arms 14 and 30. The higher-level control unit 40 transmits command signals related to the control of the robot arm 14 to the control device 20 via the communication device 46. The higher-level control unit 40 also transmits command signals related to the control of the robot arm 30 to the control device 32 via the communication device 46. The higher-level control unit 40 performs the command signal transmission process by having the PU 42 execute the program stored in the storage device 44.

[0010] "Regarding the repair process" Figure 2 shows the steps of the repair process. In the following, each step is represented by a number preceded by an "S".

[0011] In the series of steps shown in Figure 2, first, a non-destructive inspection of the machine body 10 is performed (S10). Step S10 may include, for example, a step of inspecting the machine body 10 for internal damage using an ultrasonic flaw detection device. Next, scarf processing is performed to remove the damaged portion from the machine body 10 and process it into a predetermined shape (S12). Next, the size of the repair patch and the number of repair patches are determined according to the shape of the damaged area, which is the area to be repaired (S14). In other words, in this embodiment, the damaged area is repaired to the desired shape by stacking sheet-like repair patches on the area to be repaired. Note that the shapes of the multiple repair patches stacked may differ from each other. Step S14 includes a step of measuring the shape of the area to be repaired.

[0012] Next, the scanning pattern of the solenoid coil 12 is determined (S16). The scanning pattern is determined by defining the appropriate movement path of the solenoid coil 12 for fusing the repair patch.

[0013] Figure 3 shows the details of the process in S16. The series of processes shown in Figure 3 are executed by the higher-level control device 40. In the following, when the higher-level control device 40 outputs a command signal to the control device 20 to instruct the movement of the robot arm 14, and the control device 20 operates the robot arm 14, this is referred to as the higher-level control device 40 operating the robot arm 14. Similarly, when the higher-level control device 40 outputs a command signal to the control device 32 to instruct the movement of the robot arm 30, and the control device 32 operates the robot arm 30, this is referred to as the higher-level control device 40 operating the robot arm 30. In the following, the description that the process in which the PU22 of the control device 20 operates the robot arm 14 based on the command signal from the higher-level control device 40 is sometimes omitted.

[0014] In the series of processes shown in FIG. 3, first, PU42 laminates a release film 50 shown in FIG. 4 on the repair location of the airframe 10 by operating the robot arm 30 (S20). The release film 50 is a member for avoiding the repair patch from being fused to the airframe 10. The material of the release film 50 may be, for example, a fluororesin. Next, PU42 places a thermocouple 52 shown in FIG. 4 from above the release film 50 by operating the robot arm 30 (S22). The thermocouple 52 is arranged at a plurality of different positions of the repair target location.

[0015] Next, PU42 places one repair patch 54 shown in FIG. 4 by operating the robot arm 30 (S24). The repair patch 54 has, as an example, a two-layer structure of a film adhesive 54b and a repair member 54a. The repair member 54a is a sheet-like composite material of a reinforcing fiber such as a glass fiber, a carbon fiber, an aramid fiber, and a resin. Next, PU42 laminates a perforated release film 56 shown in FIG. 4 by operating the robot arm 30 (S26). The perforated release film 56 is, as an example, the release film 50 with holes made therein. Next, PU42 laminates a degassing cloth 58 shown in FIG. 4 by operating the robot arm 30 (S28). The degassing cloth 58 is, as an example, a sheet-like woven fabric or non-woven fabric.

[0016] Next, PU42 stacks the heat transfer material 60 shown in FIG. 4 by operating the robot arm 30 (S30). The heat transfer material 60 is a sheet-like metal member with high thermal conductivity. It is desirable that the material of the heat transfer material 60 has a higher thermal conductivity than the material of the susceptor 62. As an example, the material of the heat transfer material 60 may be copper or aluminum. The heat transfer material 60 desirably has a sufficient thickness. Ideally, the thickness of the heat transfer material 60 is not less than the radius of the solenoid coil 12. The thickness of the heat transfer material 60 may be less than the radius of the solenoid coil 12, but it is desirable to make it as thick as possible. The heat transfer material 60 has flexibility. In order to satisfy both the requirement of giving the heat transfer material 60 a sufficient thickness and the requirement of giving the heat transfer material 60 flexibility, the heat transfer material 60 is desirably a foil-like laminate.

[0017] Next, PU42 stacks the susceptor 62 shown in FIG. 4 by operating the robot arm 30 (S32). The susceptor 62 is a heat source that generates heat by induction heating. The susceptor 62 may be a magnetic material. The susceptor 62 has flexibility. In order to make the susceptor 62 a flexible member, the susceptor 62 may be configured with a metal mesh. As an example, the material of the susceptor 62 is iron. The material of the susceptor 62 may also be aluminum or copper. Note that the thickness of the susceptor 62 may be less than the thickness of the heat transfer material 60. It is desirable that the material of the susceptor 62 has a higher heat generation efficiency compared to the material of the heat transfer material 60. If the heat generation efficiency is low when the susceptor 62 is configured as a sheet-like member, the heat generation efficiency may be improved by configuring the susceptor 62 with a mesh structure.

[0018] Next, PU42 operates the robot arm 30 to laminate the heat insulating cloth 64 shown in Figure 5 (S34). Next, PU42 operates the robot arm 30 to laminate the bag film 66 shown in Figure 5 (S36). In step S36, the components laminated in steps S20 to S34 are covered by the machine body 10 and the bag film 66. Then, PU42 operates a vacuum pump (not shown) to reduce the pressure inside the space covered by the machine body 10 and the bag film (S38).

[0019] Then, PU42 operates the robot arm 14 to position the solenoid coil 12 opposite to a localized predetermined location among the areas to be repaired, and energizes the solenoid coil 12 (S40). Multiple predetermined locations are provided. The predetermined locations are set in the vicinity of the thermocouple 52.

[0020] Figure 5 shows an example in which the solenoid coil 12 is positioned so that one of the thermocouples 52 is included within the area perpendicularly projected onto the repair patch 54. In step S40, the magnetic field generated by the solenoid coil 12 acts on the susceptor. This causes the susceptor 62 to heat up. The heat generated in the susceptor 62 is diffused into the heat transfer material 60.

[0021] Returning to Figure 3, PU42 determines, based on the temperature detected by the thermocouple 52, whether the heating criteria required for fusing the repair patch 54 to the machine body 10 are met (S42). For example, PU42 may determine that the criteria are not met if the area of ​​the repair patch 54 that is above a predetermined temperature is less than a predetermined area. The predetermined temperature is set to be above the temperature required for the film adhesive 54b of the repair patch 54.

[0022] If PU42 determines that the criteria are not met (S42: NO), it changes at least one of two parameters: the distance between the susceptor 62 and the solenoid coil 12, and the power consumption of the solenoid coil 12 (S44). Then, PU42 returns to step S40. Steps S40 to S44 are repeated until the criteria are met.

[0023] On the other hand, if PU42 determines that the criteria have been met (S42: YES), PU22 of the control device 20 sets the raster (S46). The raster is set to a region in which the temperature of the repair patch 54 rises above a predetermined temperature by induction heating using the solenoid coil 12.

[0024] Figure 6 illustrates the temperature distribution of the repair patch 54 due to induction heating by the solenoid coil 12. In Figure 6, a higher density of dots indicates a higher temperature. In Figure 6, the circular area enclosed by the dashed line represents the region where the temperature of the repair patch 54 has risen above a predetermined temperature. In this embodiment, since the raster is set to a rectangular shape, the raster may, for example, be set to a square inscribed in the circle drawn by the dashed line. Note that if the temperature distribution is not point-symmetric, the region where the temperature of the repair patch 54 has risen above a predetermined temperature may be elliptical instead of circular. In that case, PU22 may set the raster to a rectangle inscribed in an ellipse.

[0025] Returning to Figure 3, PU22 sets a scanning pattern for the solenoid coil 12 that can raise the temperature of the entire surface of the repair patch 54 to above a predetermined temperature (S48). PU22 sets the scanning pattern for the solenoid coil 12 by placing a raster without any gaps across the entire surface of the repair patch 54 facing the area to be repaired.

[0026] Figure 7 illustrates the arrangement of rasters using solid lines. Figure 7 shows an example where three square-shaped rasters are arranged side by side. The area enclosed by the dashed line in Figure 7 is the area where the temperature of the repair patch rises above a predetermined temperature. Also in Figure 7, the outline of the solenoid coil 12 is shown as a vertical projection onto the repair patch 54 using a double-dash line.

[0027] PU22 sets the scanning pattern to displace the center of the shape formed by perpendicularly projecting the solenoid coil 12 onto the repair patch 54 along a line connecting the centers of the raster. In other words, PU22 sets the movement path of the center of the solenoid coil 12 to a path along the line connecting the centers of the raster.

[0028] Figure 8 illustrates a scanning pattern. The curve in Figure 8 is a line connecting the centers of the raster 70. The scanning pattern shown in Figure 8 specifies that the movement path of the center of the solenoid coil 12 is the curve described above.

[0029] Furthermore, step S40 may, for example, be a step in which solenoid coils 12 are placed opposite each other on raster 70a and raster 70b in Figure 8 to perform localized heating treatment. Also, at least one of the two dimensions and shapes of raster 70 may differ between raster 70a and raster 70b. For example, if the arrangement of the heat transfer material causes heat diffusion in the upward and lateral directions of raster 70b to be smaller than heat diffusion in the downward direction in Figure 8, then raster 70b may have a vertically elongated rectangular shape, as illustrated in Figure 9. Note that Figure 9 shows an example in which raster 70a and 70b differ not only in shape but also in dimensions.

[0030] Incidentally, if repair patches 54 of different shapes are stacked on the area to be repaired, the scanning pattern will have a separate pattern for each repair patch 54 that is to be fused. Returning to Figure 3, PU22 heats the entire surface of the repair patch 54 by scanning the solenoid coil 12 according to the scanning pattern and energizing the solenoid coil 12 (S50). This process simulates the heating process of the repair patch 54 when it is actually fused to the repair target.

[0031] Based on the detected value of the thermocouple 52 as an input variable, PU22 determines in step S50 whether the temperature of the entire area of ​​the repair patch 54 has risen above a predetermined temperature (S52). For step S52, it is desirable that in step S22, several thermocouples 52 are placed in locations other than the thermocouple 52 used in step S40. Note that "the temperature of the entire area of ​​the repair patch 54 has risen above a predetermined temperature" does not mean that there is a time when the temperature of the entire area is above the predetermined temperature. "The temperature of the entire area of ​​the repair patch 54 has risen above a predetermined temperature" means that during step S50, the union of areas that have risen above the predetermined temperature includes the entire area of ​​the repair patch 54.

[0032] If PU22 determines that the temperature in a portion of the repair patch 54 has not risen above a predetermined temperature, in other words, that the requirement for overall heating has not been met (S52: NO), it changes the scanning speed, which is the displacement speed of the solenoid coil 12 (S54). Then, PU22 repeats the process in S50 with the changed scanning speed.

[0033] On the other hand, if PU22 determines that the requirement for full-surface heating is met (S52: YES), it sets the scanning speed used at that time to the actual scanning speed in the fusion process of the repair patch 54 (S56).

[0034] Furthermore, if process S56 is completed, process S16 in Figure 2 will also be completed. If step S16 is completed, pretreatment for the fusion of the repair patch 54 is performed (S18). Step S18 may include a step of drying the area to be repaired on the aircraft body 10. Step S18 may include a step of sanding the surface of the area to be repaired on the aircraft body 10. Step S18 may include a step of cleaning the area to be repaired on the aircraft body 10.

[0035] Once step S18 is completed, the PU42 of the upper control unit 40 operates the robot arm 30 to apply one repair patch to the area of ​​the machine body 10 to be repaired (S24). Next, the PU42 performs the same steps as steps S26 to S38 in Figure 3. Then, the PU42 scans the solenoid coil 12 and energizes the solenoid coil 12 according to the scanning pattern set in step S48 and the scanning speed determined in step S56 (S60). In this step, the PU22 performs the same processing as in step S50.

[0036] Once process S60 is complete, the PU42 of the upper control unit 40 determines whether the required number of repair patches 54 have been stacked (S62). If the PU40 determines that the required number of patches has not yet been stacked (S62: NO), it returns to process S24. In process S24, which follows a negative determination in process S62, at least a portion of the repair patches 54 will not directly contact the aircraft body 10, but will be positioned in contact with repair patches 54 that have already been fused.

[0037] On the other hand, if it is determined that the required number of PU42 layers have been stacked (S62; YES), a non-destructive inspection of the area to be repaired is performed (S64). The step in S64 may be, for example, a step of inspecting whether or not there are any voids inside the machine body 10 using an ultrasonic flaw detection device.

[0038] If no abnormalities are found during the S64 process, the area to be repaired is painted (S66). Furthermore, when process S66 is completed, the series of processes shown in Figure 2 will be completed.

[0039] "The operation and effects of this embodiment" PU22 configured the scanning pattern of the solenoid coil 12 by placing the raster 70 without gaps across the entire area of ​​the repair patch 54. This allowed the temperature of the repair patch 54 to be raised above a predetermined temperature at least once across its entire area.

[0040] According to the embodiment described above, the following effects and benefits can be obtained. (1) In PU42, a heat transfer material 60 is placed between the susceptor 62 and the repair patch 54. This suppresses temperature unevenness in the repair patch 54 compared to when the heat transfer material 60 is not placed.

[0041] Figure 10 shows the temperature distribution of the repair patch 54 by induction heating using the solenoid coil 12. The heat map on the left side of Figure 10 shows the temperature distribution of the repair patch 54 when the heat transfer material 60 is not used. The heat map on the right side of Figure 10 shows the temperature distribution of the repair patch 54 when the heat transfer material 60 is used.

[0042] As shown in Figure 10, when the heat transfer material 60 is not used, the temperature in the central part is lower. This part corresponds to the central part of the solenoid coil 12 projected perpendicularly onto the repair patch 54.

[0043] (2) The material of the aircraft body 10 is CFRTP. Because CFRTP has a high melting point, the heating time for fusion tends to be long. If the heating time is long, the temperature of the aircraft body 10 may rise above the allowable temperature. For this reason, there is a particular advantage to sequentially fusing multiple sheet-like repair patches 54. (3) If flexibility is provided to the heat transfer material 60 and the susceptor 62, the heat transfer material and the susceptor 62 can be made to conform to the surface shape of the area to be repaired, even if the surface of the area to be repaired is curved.

[0044] <Second Embodiment> The second embodiment will be described below, focusing on the differences from the first embodiment, with reference to the drawings.

[0045] In the above embodiment, the fusion heating treatment of the repair patch 54 was performed by continuously displacing the solenoid coil 12 with the robot arm 14. In contrast, in this embodiment, the solenoid coil 12 is energized each time the solenoid coil 12 is positioned to cover the entire surface of the repair patch 54. That is, in this embodiment, the entire surface of the repair patch 54 is heated by repeatedly performing the steps of positioning the solenoid coil 12 to cover the raster and energizing the solenoid coil 12.

[0046] Figure 11 shows the detailed procedure of step S16 according to this embodiment. In the steps shown in Figure 11, the steps corresponding to the steps shown in Figure 3 are given the same step numbers for convenience.

[0047] In the series of steps shown in Figure 11, if the judgment in step S52 is negative (S52: NO), PU22 changes the sequential heating time (S54a). The sequential heating time is the time during which the magnetic field of the solenoid coil 12 is applied to the susceptor 62 while the solenoid coil 12 is positioned corresponding to one raster. If step S54a is completed, step S50 is executed according to the changed sequential heating time. On the other hand, if the judgment in step S52 is positive, PU22 determines the sequential heating time used at that time to be the actual sequential heating time in the fusion process of the repair patch 54 (S56a).

[0048] Thus, according to this embodiment, since the heating process is performed while sequentially displacing the solenoid coil 12, the repair patch 54 can be fused without using a robot arm 14 or the like that can displace the solenoid coil 12 with high precision.

[0049] <Correspondence> The correspondence between the items in the above embodiment and the items described in the "Solution" column below is as follows. Below, the correspondence is shown for each number of the solution described in the "Solution" column. [1,15] The first member corresponds to the machine body 10. The second member corresponds to the repair patch 54. The placement process corresponds to the processes S30 and S32 in Figure 2. The scanning process corresponds to the process S60. [2] The scanning pattern setting process corresponds to the process S16. [3,7] The temperature sensor corresponds to the thermocouple 52. The temporary placement process corresponds to the processes S30 and S32. The rehearsal heating process corresponds to the process S40. The specific process corresponds to the process S40. The "movement path setting process" corresponds to the process S48. [4] The raster setting process corresponds to the process S46. The raster placement process and the movement path setting process correspond to the process S48. [5] The heating time setting process corresponds to the process S54a. [6] The process of setting the movement speed corresponds to process S54. [8] The "process of changing the distance" corresponds to process S44. [9] The "process of changing the power consumption" corresponds to process S44.

[10] The items described in Solution 10 correspond to Figure 9.

[11] The items described in Solution 11 correspond to process S60 being executed after processes S36 and S38.

[12] The items described in Solution 12 correspond to repeating processes S24-S38 and S60 until a positive judgment is made in process S62.

[13] This corresponds to the material of the aircraft body 10 being CFRTP.

[14] This corresponds to the repair patch 54 consisting of film adhesive 54b and repair member 54a.

[0050] <Other Embodiments> Furthermore, this embodiment can be implemented with the following modifications. This embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0051] "Regarding the rehearsal heating process" In the above embodiment, in step S16, step S40 was performed followed by step S50, but this is not limited to this. For example, steps S40 and S50 may be combined. In that case, initially, the shape and dimensions of the raster should be set to default values, and rehearsal heating should be performed on the entire surface of the repair patch 54. Then, depending on the temperature detected by the thermocouple 52 at that time, the shape and dimensions of the raster may be changed, or the process in S44 may be performed. "Regarding tuning targets based on the rehearsal heating process" The parameters to be tuned during the rehearsal heating process are not limited to the dimensions of the raster, the shape of the raster, the distance between the susceptor and the magnetic field generator, the movement speed of the magnetic field generator, the heating time, and the power consumption of the magnetic field generator. The parameters to be tuned during the rehearsal heating process may also include the thickness of the heat transfer material.

[0052] "Regarding the raster setting process" It is not required that different raster shapes be set depending on the area. For example, the raster shape may be set to only one similar shape with different dimensions. Also, it is not required that the dimensions of the raster be changeable depending on the area. When scanning the entire surface of repair patch 54, all rasters may have the same shape and dimensions.

[0053] "Regarding the scanning pattern setting process" The process to which the result is reversed if a negative result is obtained in process S52 is not limited to processes S54 or S54a. For example, it may be process S44.

[0054] The scanning pattern setting step does not necessarily include adjusting both the distance between the solenoid coil 12 and the susceptor 62 and the power consumption of the solenoid coil 12 in accordance with the temperature detected by the thermocouple 52. The scanning pattern setting step may, for example, include adjusting only one of the two elements described above.

[0055] "Determining Repair Patch Size and Required Ply Count" In the above embodiment, step S14 was performed prior to the scanning pattern setting step, but the embodiment is not limited to this. For example, the scanning pattern setting step may include a step of appropriately fusing multiple repair patches, and the repair patch size and the required number of Ply particles may be determined according to the connection between the surface of the final repair patch and the surface of the machine body 10. Including the determination of the repair patch size and the required number of Ply particles in the scanning pattern setting step is particularly effective in the case described in the section "Regarding the scanning step for fusion" below. That is, it is particularly effective when the fusion step is a step of fusing a second member and a first member, which are pre-formed as a single stacked mass.

[0056] "Regarding the scanning process for fusion bonding" The fusion process between the first and second members does not necessarily include a step in which the solenoid coil 12 is scanned each time a plurality of repair patches are placed on the repair target. The fusion process may, for example, be a step in which the second member and the first member are fused together as a single mass that has been pre-laminated. This modification of the fusion process is particularly preferable when the first member is a thermosetting resin.

[0057] "Regarding the fusion process" It is not mandatory for the fusion process to include all of the processes S18, S26, S28, S32-S38.

[0058] "Regarding susceptors and heat transfer components" It is not necessary for the materials of the susceptor 62 and the heat transfer material 60 to be different from each other. It is not essential to have a step of sequentially laminating the heat transfer material 60 and the susceptor 62 as a step prior to heating. For example, a step prior to heating may include a step of laminating a component in which the susceptor 62 and the heat transfer material 60 are bonded together to form an integrated unit, all at once. It is not essential that the heat transfer material 60 and the susceptor 62 are flexible. In particular, if the surface of the area to be repaired is flat and not curved, the heat transfer material 60 and the susceptor 62 may be rigid plate-shaped members or the like. "Regarding the first component" It is not mandatory for the airframe 10 to be made of CFRTP. For example, it may be made of a thermosetting resin.

[0059] The first component does not necessarily have to be an aircraft fuselage. The first component could be, for example, a ship's hull. Alternatively, the first component could be, for example, a car body. "About temperature sensors" • It is not mandatory for the temperature sensor to be a thermocouple 52. The temperature sensor may be, for example, a thermistor.

[0060] "Regarding magnetic field generators" It is not mandatory for the coil in the magnetic field generator to be a solenoid coil. For example, a planar coil or a toroidal coil may also be used. It is not essential that the magnetic field generator includes a solenoid coil. The magnetic field generator may be configured, for example, with a magnetron.

[0061] "others" The process in S18 may be performed prior to the process in S20 in the process in S16.

[0062] <Note> Solution 1. A fusion bonding method for fusing a second member to a first member, comprising a placement step and a scanning step, wherein the placement step is a step of placing a susceptor via a heat transfer member on the side of the second member that is positioned according to the repair target location of the first member and is opposite to the side facing the repair target location, and the scanning step is a step of scanning a magnetic field generator along the surface of the susceptor from the side of the susceptor that is opposite to the side facing the heat transfer member, and the susceptor is a member that generates heat due to the magnetic field of the magnetic field generator in the scanning step.

[0063] In the above method, the magnetic field of the magnetic field generator acts on the susceptor, causing it to heat up. The heat generated by the susceptor is then transferred to the second member via a heat transfer member. Therefore, compared to the case where the susceptor is placed in contact with the second member, it is possible to suppress temperature variations in different regions of the second member.

[0064] Solution 2. The fusion bonding method according to claim 1, wherein the method comprises a scanning pattern setting step which precedes the arrangement step, and the scanning pattern setting step is a step of setting the movement path of the magnetic field generator so that regions where the temperature of the second member becomes above a predetermined temperature due to scanning by the magnetic field generator overlap.

[0065] In the above method, the temperature of the second member can be raised to a predetermined temperature or higher over its entire range. Solution 3. The scanning pattern setting step comprises a temporary placement step of placing the heat transfer member and the susceptor on the side of the second member opposite to the side facing the release sheet, with the first member and the second member facing each other with a release sheet and a temperature sensor in between; a rehearsal heating step of applying the magnetic field of the magnetic field generator to the susceptor from the side of the susceptor opposite to the side facing the heat transfer member; and a identification step of identifying a region in which the temperature of the second member becomes equal to or above a predetermined temperature when the magnetic field generator is placed, based on the temperature detected by the temperature sensor as an input variable, and setting the movement path of the magnetic field generator based on the result of identifying the region in which the temperature becomes equal to or above the predetermined temperature, wherein the release sheet is a sheet for preventing the first member and the second member from being bonded together, and the fusion bonding method according to claim 2 above comprises a step of removing the release sheet and the temperature sensor from the repair target area prior to the placement step.

[0066] In the above configuration, prior to the placement and scanning processes, the temperature rise of the second member can be determined based on measured values ​​without actually fusing the first and second members together using a release sheet. Then, by executing the scanning process according to the movement path set based on the measured values, the temperature of the entire surface of the second member can be appropriately raised.

[0067] Solution 4. The fusion bonding method according to claim 3, wherein the scanning pattern setting step comprises: a raster setting step of setting a raster which is a rectangular region in which the temperature of the heat transfer member is above a predetermined temperature, based on the result of identifying the region in which the temperature is above a predetermined temperature; a raster arrangement step of arranging a plurality of rasters so as to cover the entire surface of the second member facing the first member; and a movement path setting step of setting a movement path of the magnetic field generator so as to pass through each of the plurality of rasters in which the region obtained by projecting the magnetic field generator onto the surface of the second member facing the first member passes.

[0068] In the method described above, setting the raster makes it easier to set an appropriate movement path for raising the temperature of the entire surface of the second component to a predetermined temperature or higher. Solution 5. The fusion method according to 3 or 4 above, wherein the scanning step is a step of sequentially arranging the magnetic field generator such that the area projected onto the surface of the second member facing the first member corresponds to each of the plurality of rasters, and the scanning pattern setting step includes a heating time setting step of setting the time for arranging the magnetic field generator to correspond to one of the rasters based on the detected value of the temperature sensor.

[0069] Since the above method includes a heating time setting step, the duration for which the magnetic field generator is placed in one location can be set to an appropriate value in order to raise the temperature of the second component to a predetermined temperature or higher. Solution 6. The fusion method according to 3 or 4 above, wherein the scanning step is a step of continuously moving the magnetic field generator, and the scanning pattern setting step includes a movement speed setting step which sets the movement speed of the magnetic field generator based on the value detected by the temperature sensor when the magnetic field generator is displaced along the movement path set by the movement path setting step.

[0070] In the above method, by providing a step for setting the movement speed, an appropriate movement speed can be set to raise the temperature of the second member to a predetermined temperature or higher. Solution 7. The fusion method according to any one of 3 to 6 above, wherein the rehearsal heating step includes a step of selectively positioning the magnetic field generator to correspond to a part of and multiple localized areas of the area to be repaired.

[0071] In the above method, by selecting a representative point of the second component during the rehearsal heating process and heating only that representative point, the time required for the rehearsal heating process can be shortened compared to the case where the magnetic field generator is scanned over the entire area.

[0072] Solution 8. The fusion method according to any one of claims 3 to 7, wherein the scanning pattern setting step includes a step of changing the distance between the susceptor and the magnetic field generator based on the result of identifying a region that is above a predetermined temperature, and the rehearsal heating step is performed according to the changed distance.

[0073] The magnetic flux density acting on the susceptor changes depending on the distance between the susceptor and the magnetic field generator, which in turn changes how the temperature of the second component rises. Therefore, in the above method, by changing the distance based on the detection results of the temperature sensor and further performing the rehearsal heating process, it is possible to find an appropriate distance for heating the second component to the desired temperature.

[0074] Solution 9. The fusion method according to any one of 3 to 8 above, wherein the scanning pattern setting step includes a step of changing the power consumption of the magnetic field generator based on the result of identifying a region that is above a predetermined temperature, and the rehearsal heating step is performed according to the changed power consumption.

[0075] The magnetic flux density acting on the susceptor changes depending on the power consumption of the magnetic field generator, which in turn changes how the temperature of the second component rises. Therefore, in the above method, by changing the power consumption based on the detection results of the temperature sensor and further executing the rehearsal heating process, it is possible to find the appropriate power consumption for heating the second component to the desired temperature.

[0076] Solution 10. The fusion method according to any one of 4 to 9 above, wherein the raster placement step includes the step of arranging the rasters such that at least one of two of the shapes and dimensions differs from each other depending on the area.

[0077] If the degree of heat diffusion differs from area to area of ​​the repair target, the areas where the temperature rises above a predetermined temperature may differ from local area to local area of ​​the second component. Therefore, in the above method, by setting at least one of the above two parameters to multiple values, it is possible to raise the temperature of the second component above the predetermined temperature over its entire surface while reducing the areas where the net time spent above the predetermined temperature during the scanning process becomes excessively long.

[0078] Solution 11. The fusion bonding method according to any one of the above 1 to 10, wherein the arrangement step includes a step of covering the second member, the heat transfer member, and the susceptor with a bag film and depressurizing the area to be repaired, and the scanning step is a step performed with the susceptor covered by the bag film.

[0079] In the above method, the first and second members can be fused together while the gas is removed from between them, thereby improving the adhesion between the first and second members.

[0080] Solution 12. The fusion method according to any one of claims 1 to 11, wherein the second member is a sheet-like member, and the sheet-like second member is laminated onto the area to be repaired by repeating the arrangement step and the scanning step multiple times.

[0081] The heating time required to fuse a sheet-like second member to the first member is shorter compared to the case where a member with the same thickness as the laminated second member is fused to the first member in one go. Therefore, it is possible to suppress excessive temperature increases in unintended areas due to heating for fusion.

[0082] Solution 13. The fusion method described in 12 above, wherein the first member comprises a thermoplastic resin. If the first component is made of thermoplastic resin, and the heating time for fusing it with the second component is excessively long, the temperature of the first component is likely to rise beyond the acceptable range. Therefore, the value of solution 12 described above is particularly high.

[0083] Solution 14. The fusion method according to any one of 1 to 13 above, wherein the two members include a repair member embedded in the repair location and a sheet-like adhesive sandwiched between the repair member and the first member.

[0084] In the above method, the application of a sheet-like adhesive makes it easier to firmly bond the first member and the repair member. Solution 15. The fusion method described in any one of the above 1 to 14, wherein the first member is the fuselage of an aircraft.

[0085] In aircraft repair, there is often a high demand for adhesion with the second component. Therefore, the value of implementing the above-mentioned rehearsal heating process, etc., prior to actually fusing the second component to the first component is particularly significant. [Explanation of symbols]

[0086] 10…Aircraft 12…Solenoid coil 14…Robot arm 16... Trolley 20...Control device 30…Robot arm 32...Control device 40…Higher-level control unit 50…Release film 52… Thermocouple 54... Repair patch 54a... Repair parts 54b…Film adhesive 56…Release film 58... Degassing cloth 60… Heat transfer material 62... Susceptor 70, 70a, 70b… Raster

Claims

1. A fusion method for fusing a second member to a first member, It has a placement step and a scanning step, The arrangement step is to arrange a susceptor via a heat transfer member on the side of the second member that is opposite to the side facing the repair target, according to the repair target location of the first member. The scanning step is a step of scanning the magnetic field generator along the surface of the susceptor, starting from the side of the susceptor opposite to the side facing the heat transfer member, after the completion of the arrangement step. The susceptor is a component that generates heat due to the magnetic field of the magnetic field generator in the scanning process, in a fusion bonding method.

2. The process includes a scanning pattern setting step, which is a step preceding the arrangement step. The fusion bonding method according to claim 1, wherein the scanning pattern setting step is a step of setting the movement path of the magnetic field generator so that regions where the temperature of the second member becomes above a predetermined temperature due to scanning by the magnetic field generator overlap.

3. The scanning pattern setting step is, With the first member and the second member facing each other with a release sheet and a temperature sensor in between, a preliminary arrangement step is taken to place the heat transfer member and the susceptor on the side of the second member opposite to the side facing the release sheet, A rehearsal heating step in which the magnetic field of the magnetic field generator is applied to the susceptor from the side of the susceptor opposite to the side facing the heat transfer member, The process includes a step of identifying a region in which the temperature of the second member becomes equal to or above a predetermined temperature, based on the temperature detected by the temperature sensor as an input variable, and This is a step of setting the movement path of the magnetic field generator based on the result of identifying the region where the temperature exceeds the predetermined temperature. The release sheet is a sheet that prevents the first member and the second member from being bonded together. The fusion bonding method according to claim 2, further comprising the step of removing the release sheet and the temperature sensor from the repair target area prior to the arrangement step.

4. The scanning pattern setting step is, Based on the results of identifying the region where the temperature exceeds the predetermined temperature, a raster setting step is performed to set a raster which is a rectangular region where the temperature of the heat transfer member is above the predetermined temperature. A raster placement step involves arranging a plurality of rasters so as to cover the entire surface of the second member facing the first member, A movement path setting step of setting the movement path of the magnetic field generator such that the region projected onto the surface of the second member facing the first member passes through each of the plurality of rasters, A fusion method according to claim 3, comprising the characteristics described herein.

5. The scanning step is a step of sequentially arranging the magnetic field generators such that the region obtained by projecting the magnetic field generator onto the surface of the second member facing the first member corresponds to each of the plurality of rasters, The fusion bonding method according to claim 4, wherein the scanning pattern setting step includes a heating time setting step that sets the time for positioning the magnetic field generator in relation to one of the rasters based on the detected value of the temperature sensor.

6. The scanning step is a step of continuously moving the magnetic field generator, The fusion bonding method according to claim 4, wherein the scanning pattern setting step includes a movement speed setting step in which the movement speed of the magnetic field generator is set based on the value detected by the temperature sensor when the magnetic field generator is displaced along the movement path set by the movement path setting step.

7. The fusion bonding method according to claim 3, wherein the rehearsal heating step includes a step of selectively positioning the magnetic field generator to correspond to a portion of the repair target area and a plurality of localized areas.

8. The scanning pattern setting step is, The process includes changing the distance between the susceptor and the magnetic field generator based on the result of identifying the region where the temperature exceeds the predetermined temperature, The fusion method according to claim 3, comprising the rehearsal heating step performed according to the modified distance.

9. The scanning pattern setting step is, The process includes changing the power consumption of the magnetic field generator based on the result of identifying the region where the temperature exceeds the predetermined temperature, The fusion method according to claim 3, comprising the rehearsal heating step performed in accordance with the modified power consumption.

10. The fusion method according to claim 4, wherein the raster placement step includes the step of arranging rasters in which at least one of two characteristics, shape and dimensions, differs from each other, depending on the region.

11. The arrangement step includes covering the second member, the heat transfer member, and the susceptor with a bag film and depressurizing the area to be repaired, The fusion method according to claim 1, wherein the scanning step is performed while the susceptor is covered by the bag film.

12. The second member is a sheet-like member, The fusion bonding method according to claim 1, wherein the arrangement step and the scanning step are repeated multiple times to laminate the sheet-like second member onto the area to be repaired.

13. The fusion method according to claim 12, wherein the first member comprises a thermoplastic resin.

14. The fusion bonding method according to claim 1, wherein the second member includes a repair member embedded in the area to be repaired and a sheet-like adhesive sandwiched between the repair member and the first member.

15. The fusion bonding method according to claim 1, wherein the first member is the fuselage of an aircraft.

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