Welding methods and corresponding welding equipment
The synchronized drive unit system in the welding apparatus allows for efficient welding of components with complex shapes by bypassing undercuts and reducing cycle times, enhancing production efficiency and flexibility.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- BRANSON ULTRASTICAL NIEDERLASSON DER EMERSON TECH GESELLSCHAFT MITT BESCHLENKTEL HAFTUNG & CO OHG
- Filing Date
- 2022-11-30
- Publication Date
- 2026-05-11
AI Technical Summary
Existing welding apparatuses face challenges in efficiently welding components with complex protrusions or undercuts due to indeterminate angular positions, leading to damage and longer cycle times, and require complex adaptations for different parts.
A welding method and apparatus that utilizes synchronized drive units, including a preheating device, to move components along multiple axes simultaneously, bypassing undercuts and reducing cycle times through continuous, diagonal movements controlled by an electronic cam disk.
The method and apparatus enable efficient welding of complex structures with reduced cycle times and increased flexibility for different parts, minimizing damage and optimizing production efficiency.
Smart Images
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Abstract
Description
Technical Field
[0001] The present invention relates to a welding method for welding a first component to a second component using a welding apparatus including an upper jig mounted on an upper support for receiving the first component, a lower jig mounted on a lower support for receiving the second component, and a preheating apparatus and a control apparatus for preheating the first and / or second components. Further, the present invention relates to each welding apparatus.
Background Art
[0002] A welding apparatus for welding a first component to a second component, which includes an upper jig mounted on an upper support for receiving the first component and a lower jig mounted on a lower support such as a lifting table for receiving the second component, is known in the prior art.
[0003] Usually, such an apparatus is used to weld two components, preferably made of a plastic material, to each other. The welding apparatus further includes a housing in which the lower jig and the upper jig are disposed. To achieve this purpose, the lower jig is fixed to a lifting table as the lower support, and the upper jig is firmly mounted on an upper jig plate as the upper support.
[0004] Furthermore, a known plastic welding apparatus may further include a preheating apparatus for preheating the first and second components before welding. In this regard, the preheating apparatus is usually coupled to the lifting table, but may be movable independently from the lifting table, for example, by directly fixing the preheating apparatus to the housing. The lower jig is moved in the direction of the upper jig by the lifting table as the lower support, and the first component in the lower jig can be welded to the second component in the upper jig, particularly by friction or vibration welding, or by infrared welding.
[0005] Such welding equipment is used, for example, in the automotive industry or in medical technology. In the automotive industry, applications for such welding equipment include the production of lights, as well as the production of other parts or groups of parts made from or containing plastic. Similarly, welding equipment may be used in the production of devices and / or groups of parts in medical technology or in the production of consumer goods.
[0006] The basic operation of a known welding apparatus equipped with a preheating device is as follows: First, the user places the second part on the lower fixture. Then, the first part is positioned on top of the second part within the lower fixture. Subsequently, the lifting table, including the lower fixture, and the part placed on it, move from their initial positions toward the upper fixture until the first part contacts the upper fixture. This movement occurs along only one axis perpendicular to the floor or ground on which the welding apparatus is placed.
[0007] Next, the lifting table returns along this vertical axis to a position where the preheating device can be positioned between the parts. For example, the lifting table returns to its initial position. The preheating device is then moved along a second axis perpendicular to the first axis, i.e., horizontal to the floor or ground, from the parking position to the alignment position between the parts to be welded. After positioning the preheating device between the two parts in the alignment position, the preheating device is moved by a new, separate vertical movement, i.e., a movement along an axis perpendicular to the floor or ground, to a preheating position, so that it can be heated where the two parts will be welded. Furthermore, after the preheating device has arrived at the preheating position, the lower fixture is moved along the first axis to a position adjacent to the preheating device. This position is also called the adjacent position.
[0008] After preheating, the lifting table is moved along the vertical axis to a position that allows the preheating device to be moved to the parking position. For example, the lifting table returns to its initial position. After the lifting table reaches the initial position, the preheating device is first returned to the aligned position along the vertical axis, and then to the parking position along the second horizontal axis.
[0009] To weld the first part to the second part, the lifting table is then moved along the first axis to the welding position. The welding of the first part to the second part is performed by friction welding, vibration welding, or by pressing preheated parts together.
[0010] After welding is complete, the lifting table returns along the vertical axis from the welding position to its initial position, along with the lower fixture positioned on it and the combined first and second parts. As soon as the lifting table reaches its initial position, the user can remove the combined first and second parts.
[0011] The first drawback of the welding apparatus described above, with respect to the preheating device, becomes apparent when heating and welding parts having complex protrusions or undercuts. In friction or vibration welding, protrusions or undercuts arise, in particular, from the indeterminate variable angular position of the parts being welded to each other. In particular, the two parts must be positioned in their respective fixtures in a manner that allows the friction or vibration welding force to be effectively transmitted to the joint of each part. This indeterminate angular position of the two parts relative to each other, along with the mobility of the fixtures along the vertical axis only, results in undercuts or protrusions depending on the parts being welded to each other. During movement along the vertical axis, these result in damage and / or destruction of at least one of the parts and / or one of the fixtures or preheating device.
[0012] Furthermore, moving the welding equipment takes time, resulting in longer cycle times.
[0013] In this field, several alternative methods have been developed by BRANSON to enable welding two parts with complex weld contours, including undercuts and / or protrusions, to each other.
[0014] According to the first example described in EP 2 837 492 A1 (European Patent Application Publication No. 2837492), a vibratory welding system comprises an upper support for an upper fixture and a lifting table for receiving a lower fixture. The lower fixture can be lifted by a vertical drive. The vibratory welding system also has at least one horizontal drive that can move the lower fixture horizontally. The vibratory welding system also has at least one swivel drive that can thereby swivel the lower fixture out of the horizontal plane.
[0015] There are basically two types of control mechanisms for each drive unit. In the first type, the lower fixture is moved independently of the other drive units by its respective vertical, horizontal, and swivel drive units. This means that movement in the horizontal plane, swivel outside the horizontal plane, and movement along the z-axis can occur simultaneously.
[0016] In contrast, in the second type, movement is produced by only one of the respective drive mechanisms. This means that only one procedure occurs, namely movement or rotation along the z, x, and y axes. Naturally, mixed types of these two types are possible.
[0017] Each of these devices or systems allows the control curve used to operate or start the drive mechanism to be adapted to different weld contours so that the device can be used for different parts, but there is no preheating device.
[0018] Other welding apparatuses having preheating devices are described in EP 3 009 254 A2 (European Patent Application Publication No. 3009254) and EP 3 020 532 A1 (European Patent Application Publication No. 3020532). The preheating device for the welding apparatus described in EP 3 009 254 A2 (European Patent Application Publication No. 3009254) comprises a support, at least one first preheating device, and a swivel device that can swivel at least one first preheating device from a starting position to a preheating position relative to a first surface of the support. In this way, undercuts of the first part can be bypassed and the first part can be heated by the first preheating device.
[0019] On the other hand, EP 3 020 532 A1 (European Patent Application Publication No. 3020532) describes a welding apparatus comprising first and second fixtures positioned on a first support and a second support, respectively. The first fixture is movable linearly in a first direction relative to the first support between a first position and a second position by a first drive mechanism. The movement along the first direction is defined by a first imaginary polar coordinate system whose origin is located at the first position of the first fixture. The z-axis, as the first z-axis, extends in the direction of the second support. The first inclination angle between the positive first z-axis in the direction of the second support and the first direction is 0 ≤ ν1 ≤ λ / 2, thereby allowing a first part in the first fixture to engage with a second part in the second fixture. In other words, the apparatus achieves diagonal movement.
[0020] The drawback of the apparatus disclosed in EP 3 009 254 A2 (European Patent Application Publication No. 3009254) and EP 3 020 532 A1 (European Patent Application Publication No. 3020532) is that each apparatus must be adapted to a single specific component and, consequently, to the manufactured composite. Furthermore, the construction is complex, costly, and involves long cycle times.
[0021] Accordingly, the object of the present invention is to provide a welding method for welding a first part to a second part that overcomes the above-mentioned drawbacks of welding apparatus having a preheating device. In particular, the present invention must provide a welding method that enables welding of complex structures, is applicable to different parts at the same time, and achieves a shorter cycle time compared to known methods. Another object is to provide a welding apparatus for each of these. In particular, the present welding apparatus enables preheating of parts having complex weld structures and welding of each of these parts, and is at least more easily applicable to different parts at the same time. [Overview of the project]
[0022] The above problems are solved by the welding method for welding a first component to a second component as described in independent claim 1, and by the welding apparatus for welding a first component to a second component as described in independent claim 10. Further preferred embodiments and developments can be found in the following description and drawings and in the appended claims.
[0023] The welding method of the present invention for welding a first part to a second part uses a welding apparatus comprising an upper jig mounted on an upper support for receiving the first part, a lower jig mounted on a lower support for receiving the second part, and a preheating device and control device for preheating the first and / or second parts. This welding method includes the steps of: moving upper and lower jigs relative to each other along a first axis from an initial position to an adjacent position using a first drive device, and moving a preheating device from a parking position to a preheating position using a second drive device at least partially and simultaneously; preheating the first and / or second parts with the preheating device; then moving the upper and lower jigs relative to each other along a first axis from an adjacent position to a separated position using a first drive device, and moving the preheating device from a preheating position to a parking position using a second drive device at least partially and simultaneously; moving the upper and lower jigs relative to each other along a first axis from a separated position to a welding position using a first drive device; welding the first and second parts to each other at the welding positions of the upper and lower jigs; and moving the upper and lower jigs relative to each other along a first axis from the welding position to an initial position using a first drive device.
[0024] For further understanding, the operation of each welding apparatus comprising an upper jig mounted on an upper support and a lower jig mounted on a lower support is described below regarding this welding method. The upper and lower jigs are movable relative to each other along a first axis. This is preferably achieved in such a way that the upper support to which the upper jig is advantageously firmly mounted is an upper jig plate, and the lower support to which the lower jig is mounted is a lifting table. As a result in such exemplary configurations, only the lifting table as the lower support is moved along the first axis. This configuration is particularly preferred in the case of a vibratory welding apparatus, as will be described in more detail below. Nevertheless, when an infrared welding method is used, mobility of the upper support may also be provided. For completeness, it should be noted that the first axis is preferably a vertical axis, i.e., perpendicular to the floor on which the welding apparatus is located. Furthermore, the first and second parts to be welded to each other are preferably made of plastic material.
[0025] For simplicity, we assume that the first component is already positioned in the upper fixture and the second component is already positioned in the lower fixture. Furthermore, the first component has a complex undercut, for example. In the concepts of this disclosure, an undercut is an element of each component that protrudes from the component so as to cover a region of the component depending on the orientation of the component in space. To further clarify the term undercut, we assume a U-shaped component or region of a component. When this U-shaped region is viewed from above or below, it does not contain an undercut because all regions are freely accessible. However, when the U-shaped region is viewed from the side, one leg, i.e., the front leg, covers the other leg, i.e., the rear leg. Thus, depending on the orientation of the component in space, one leg covers the other leg. Thus, each front leg represents an undercut with respect to this disclosure.
[0026] From the above explanation, it follows that the movement of a preheating device, preferably an infrared preheating device, toward a surface covered by an undercut, such as the surface to be heated, cannot be achieved by linear movement. Referring again to the exemplary U-shaped component and assuming that the preheating device is located on the left side of the component, the preheating device moves toward the component from the left side. The front leg of the U-shaped component is the left leg, which thus represents the undercut to be bypassed. The rear leg of the U-shaped component is the right leg. In this case, the preheating device collides with the front leg, so it cannot reach this right leg by movement in the direction of the rear leg alone. Therefore, for clarity, we assume that the undercut represents an imaginary point or curve that must be bypassed. Only after this bypass can the preheating device be positioned adjacent to the surface of the first component to be heated.
[0027] First, the upper and lower fixtures are positioned at a distance from each other that allows the preheating device to be placed between them. This position is called the initial position, and it may also be the starting position, i.e., the position of the upper and lower fixtures in the idle state of the plastic welding apparatus. Furthermore, it is assumed that the preheating device is positioned in a parking position, i.e., not between the upper and lower fixtures, so that it does not obstruct the movement of the upper and lower fixtures relative to each other.
[0028] Starting from the above point, first, the preheating device moves from the parking position to the preheating position by the second driving device. In the case of an exemplary U-shaped part, a simple movement along one axis may not be sufficient. Thus, in this example, the second driving device realizes a movement along a second axis perpendicular to the first axis, and a third driving device is further provided to move the preheating device along a third axis parallel to the first axis. Thus, the movement of the preheating device from the parking position to the preheating position occurs by operating or activating at least partially simultaneously the second driving device and the third driving device. For example, after the second driving device moves the preheating device a predetermined distance along the second axis, the third driving device is further operated or activated so that a movement along the third axis occurs. Thus, the combined movement is a diagonal movement. Thus, it is particularly preferred that the movement from the parking position to the preheating position is a continuous movement. A continuous movement, in this regard, defines a movement without intermediate stops or intermediate positions. Thus, to achieve this effect, the second and third driving devices are operated or activated at least partially simultaneously. As a result, the path of the preheating device is shorter compared to the prior art in which the preheating device is moved separately along each of the respective axes.
[0029] Furthermore, at least partially simultaneously with the movement of the preheating device from the parking position to the preheating position, relative movements along the first axis occur between the upper and lower jigs from the initial position to the adjacent position by the first driving device. Thus, at least one of the first driving device and the second and third driving devices is also operated or activated simultaneously. As a further result, further time savings can be achieved by these combinations or simultaneous movements.
[0030] To simultaneously achieve such movements, the drive devices are controlled together, for example, by an electronic cam disk. Thus, the drive devices are preferably electronically coupled or synchronized with each other. This may be achieved particularly by a control device. Thereby, each movement is dependent on the others. A further result of this process is that in the event of a failure of one drive device, it becomes apparent that the remaining drive devices are preferably automatically stopped by a common control such that damage to the first part, the second part and / or the welding device can be avoided.
[0031] After the preheating device reaches the preheating position and the upper and lower jigs are arranged in the adjacent positions, the preheating of the first and / or second parts by the preheating device occurs. To achieve this purpose, depending on the application, the preheating device is preferably an infrared preheating device. Further, the preheating device preferably has a first and / or second preheating device, where the first preheating device is arranged on the upper side facing the upper jig at the preheating position, and the second preheating device is arranged on the lower side facing the lower jig at the preheating position.
[0032] After preheating, the upper and lower jigs are moved relative to each other from the adjacent positions to a separation position, which may be an initial position or any intermediate position that enables the movement of the preheating device from the preheating position to the parking position. Thus, at least partially simultaneously, the preheating device is preferably continuously moved from the preheating position to the parking position as described above. Thus, the above movement is reversed.
[0033] The movement of the upper and lower fixtures may occur as soon as the preheating device no longer obstructs their movement to the welding position. For example, according to a preferred embodiment, the movement occurs either immediately after the preheating device no longer obstructs such movement or immediately after the preheating device arrives at the parking position. Welding of the first and second parts to each other then occurs at the welding positions of the upper and lower fixtures in a known manner. Preferably, the welding method is a vibration or friction welding method, or the welding method is an infrared welding method. In the latter case, the preheating device is an infrared preheating device, which simply presses the preheated first and second parts against each other during the welding process.
[0034] For example, depending on an undercut present in a first part located within an upper jig, the lower jig, including a second part, must be positioned to be movable in space so that the lower jig can bypass the undercut in the first part. This is especially true for friction or vibration welding apparatuses, as the movement of the upper jig cannot be achieved by forces generated during friction or vibration welding. In these cases, it is particularly preferable to use, for example, a lower jig or lower support, as described in EP 2 837 492 A1 (European Patent Application Publication No. 2837492). In this regard, according to a particularly preferred embodiment, the control device controls preferably further drive devices, particularly preferably all drive devices, of the welding apparatus. As a result, with respect to the lower fixture or lower support of EP 2 837 492 A1 (European Patent Application Publication No. 2837492) for illustrative purposes, it is possible to activate or activate a drive for moving the lifting table in a horizontal plane and / or swiveling the lifting table at least partially simultaneously with activating or activating the first and / or second drive.
[0035] In the case of infrared welding equipment, since no frictional or vibratory welding force (i.e., vibrations in particular during the friction welding process) acts on the upper fixture, the upper fixture can be positioned to move freely in space.
[0036] Therefore, one advantage of the welding method of the present invention is that the path along which the elements of the welding apparatus move is shortened by avoiding intermediate stops or positions, and / or the movement of different elements occurs simultaneously. This results in time savings compared to the welding methods of the prior art. Thus, the welding process is made more efficient, i.e., the cycle time is shortened and the output is increased.
[0037] Furthermore, since the simultaneous movements of each drive unit are controlled by a common control so that they are electronically coupled or synchronized with one another, damage to the first component, the second component, and / or the welding apparatus can be reliably avoided in the event of a failure of one drive unit.
[0038] According to a preferred embodiment of this welding method, the control device controls and preferably electronically couples or synchronizes the first and second drive units so that they are operated or activated at least partially simultaneously. The control device that achieves the electronic coupling or synchronization of the movement or drive units may be a main control unit, i.e., a host control unit, or a control unit of one of the drive units that functions as a separate main control unit, i.e., a host control unit. A cost-effective embodiment can be realized using one of the existing control units. On the other hand, the use of a separate control unit as a main control unit, i.e., a host control unit, ensures sufficient processing capacity and greater variability to accommodate different applications.
[0039] In an advantageous embodiment of the welding method, a second drive unit is provided to move the preheating unit along a second axis perpendicular to the first axis, and a third drive unit is provided to move the preheating unit along a third axis parallel to the first axis. In this regard, according to a further preferred embodiment of the welding method, a control device controls the third drive unit, preferably electronically coupled or synchronized with the first and second drive units, to actuate or activate at least two of the first, second, and third drive units simultaneously. These embodiments have been described in detail in the above example having a U-shaped first component. A particular advantage is that this thus increases the flexibility of the welding method and the welding apparatus with respect to adapting to different parts to be welded together. Furthermore, as similarly described above, by actinguate or activating at least two drive units simultaneously, the time required to move the structural elements of the welding apparatus between two positions is reduced.
[0040] According to a preferred embodiment of this welding method, the first and second drive units are servo drive units. The servo drive units are used to follow a target movement specified by nominal position values in the form of a nominal path or nominal angle. This means that the servo drive units follow a specified target path or target angle with small deviations. Such a process requires measurement and comparison of actual values to compare set values with actual values. The servo drive units are, accordingly, drive units with electronic position, velocity, and / or torque control with high to very high requirements for dynamics, set range, and / or accuracy of movement. The term servo axis is often used instead of servo drive unit. The use of such servo drive units as the first and second drive units ensures reliable control of movement and, in the event of failure of one drive unit, the electronic coupling or synchronization of these drive units ensures a rapid interruption of movement of the drive units (especially all drive units).
[0041] In a further preferred embodiment of this welding method, one drive unit functions as a primary drive unit, and the remaining drive units function as secondary drive units, with the drive unit that is first actuated or activated by the control unit preferably designated as the primary drive unit. For example, to reach a preheating position, the preheating unit is first moved along a second axis by a second drive unit over a specified or predetermined distance. Upon reaching this distance, the control unit further actsuates or activates a third drive unit so that diagonal movement occurs. Furthermore, the first drive unit may be actuated or activated simultaneously so that its operation also depends on the second drive unit achieving the predetermined distance.
[0042] In a particularly preferred embodiment of this welding method, if one drive unit fails, the remaining drive units, i.e., the drive units that are at least partially operated or started simultaneously, are stopped by the control unit. Thus, by electronic coupling or synchronization of the drive units in the control unit, damage to the parts being welded and / or the welding apparatus can be avoided, even if the movement of the preheating unit, upper and / or lower fixtures is performed simultaneously.
[0043] The welding apparatus of the present invention for welding a first part to a second part using the welding method of the present invention comprises an upper jig mounted on an upper support for receiving the first part, a lower jig mounted on a lower support for receiving the second part, and a preheating device for preheating the first and / or second parts, wherein the upper and lower supports are movable relative to each other along a first axis between an initial position, an adjacent position, a separated position and a welding position by a first drive device, and the preheating device is movable between a parking position and a preheating position by a second drive device, wherein the welding apparatus comprises a control device that controls, preferably electronically coupled or synchronized, the first and second drive devices so that they are operated or started at least partially simultaneously. The control device that realizes the movement or electronic coupling or synchronization of the drive devices may be a main control device, i.e., a host control device, or a control device of one of the drive devices that functions as a separate main control device, i.e., a host control device. A cost-effective embodiment can be realized by using one of the already existing control devices. On the other hand, the use of a separate control device as a main control device, i.e., a host control device, ensures sufficient processing capacity and higher variability. The welding method of the present invention is carried out using the welding apparatus of the present invention. Accordingly, to avoid redundancy, the above description of the welding method of the present invention will be used to describe the technical effects and advantages obtained.
[0044] In a preferred embodiment of the welding apparatus, a second drive unit is provided to move the preheating unit along a second axis perpendicular to the first axis, and a third drive unit is provided to move the preheating unit along a third axis parallel to the first axis. Preferably, a control device controls the drive units so that at least two of the first, second, and third drive units are operated or driven simultaneously. These embodiments have been described in detail in the above example having a U-shaped first component. A particular advantage is that this thus increases the flexibility of the complete welding apparatus with respect to adapting to different parts to be welded together. Furthermore, as also described above, operating or activating at least two drive units simultaneously reduces the time required to move the structural elements of the welding apparatus between two positions.
[0045] The welding apparatus is preferably a vibration welding apparatus or an infrared welding apparatus. Further preferred, the first and second components are made of plastic material, thereby making the welding apparatus a plastic welding apparatus. Furthermore, the first and second drive units are preferably servo drive units. Since each of these embodiments has been discussed above with respect to each embodiment of the welding method, these descriptions are referred to above to avoid repetition.
[0046] The present invention will be described in detail below with reference to the drawings. In the drawings, the same reference numerals indicate the same elements and / or parts. [Brief explanation of the drawing]
[0047] [Figure 1] A welding apparatus having a preheating device in its initial position. [Figure 2] Figure 1 shows a welding apparatus with the preheating device positioned in an intermediate position. [Figure 3] Figure 1 shows a welding apparatus with the preheating device positioned in the preheating position. [Figure 4] Figure 1 shows a welding apparatus in which the preheating device is positioned in the preheating position and the lower jig is positioned in an adjacent position. [Figure 5] This diagram shows the movement of structural components of a welding apparatus relating to prior art. [Figure 6] This diagram shows the movement of structural components of a welding apparatus according to one embodiment of the welding method of the present invention. [Figure 7] A simplified diagram of an electronic cam disk is shown. [Figure 8] This shows the welding apparatus at time T1 / T1' in one embodiment of the welding method of the present invention. [Figure 9] This shows the welding apparatus at time T2 / T2' in one embodiment of the welding method of the present invention. [Figure 10] This shows the welding apparatus at time T3 / T3' in one embodiment of the welding method of the present invention. [Figure 11]This shows the welding apparatus at time T4 / T4' in one embodiment of the welding method of the present invention. [Figure 12] A flowchart of one embodiment of the welding method of the present invention is shown. [Modes for carrying out the invention]
[0048] In the following, one embodiment of the method of the present invention is described based on the functions of each welding apparatus. To enhance the understanding of the technical effects of this welding method, a known procedure is first illustrated in Figures 1 to 5.
[0049] The welding apparatus 1 comprises an upper jig 12 mounted on an upper support 10 and a lower jig 16 mounted on a lower support 14. The upper jig 12 and the lower jig 16 are movable relative to each other along a first axis 32 by a first drive device 30. In this example, the upper support 10 to which the upper jig 12 is firmly mounted is an upper jig plate, and the lower support 14 to which the lower jig 16 is mounted is a lifting table. As a result, in such an exemplary configuration, only the lifting table 14, which acts as the lower support, is moved along the first axis 32.
[0050] Furthermore, the welding apparatus 1 includes a preheating device 18 having a first preheating device 20 and a second preheating device 22. The first preheating device 20 is positioned on the upper side facing the upper jig 12 in the preheating position, and the second preheating device 22 is positioned on the lower side facing the lower jig 16 in the preheating position. Furthermore, the preheating device 18 includes a second drive device 40 for movement along a second axis 42. The second axis 42 is perpendicular to the first axis 32. Furthermore, a third drive device 50 is provided for movement of the preheating device 18 along a third axis 52. The third axis 52 is parallel to the first axis 32.
[0051] In Figure 1, the upper jig 12 and lower jig 16 of each welding apparatus 1 are positioned in their initial positions, i.e., starting positions. The preheating device 18 is positioned in the parking position.
[0052] An undercut exists due to the shape of the parts to be welded, which is reflected by the shapes of the upper jig 12 and the lower jig 16. An undercut is an element that protrudes from each part so as to cover a region of the part, depending on the orientation of the part in space. In this example, the upper jig 12 is formed like a roof with a gable, in other words it provides an inverted V shape. The lower jig 16 has a complementary shape. The first and second parts are formed so that they match the forms provided by the upper jig 12 and the lower jig 16. Furthermore, the first preheating device 20 and the second preheating device 22 also have shapes that match the forms provided by the respective jigs 12 and 16.
[0053] When the inverted V-shaped upper fixture 12 is viewed from below along the first axis 32, i.e., from the lower fixture 16, it does not contain an undercut because all areas are freely accessible. However, when the upper fixture 12 is viewed from the side, one side, i.e. the left side, covers the other side, i.e., the right side. Thus, depending on the orientation in space, one side covers the other side. Thus, each left side represents an undercut with respect to this disclosure. Therefore, for clarity, we assume that the undercut is an imaginary point or curve that represents the undercut and must be bypassed. Only after this bypass can the preheating device 18 be positioned next to the surface of the first component to be heated. Furthermore, from the above description, the movement of the preheating device 18 toward a surface covered by an undercut, such as the surface to be heated, cannot be made by a single linear movement.
[0054] This operation involves the user placing the second part on the lower jig 16 in the first step. Subsequently, the first part is placed on top of the second part within the lower jig 16. Then, the lower support 14, including the lower jig 16 and the part placed on it, moves from its initial position toward the upper jig 12 until the first part contacts the upper jig 12. This movement is caused by the first drive unit 30 along the first axis 32, which is perpendicular to the floor or ground on which the welding apparatus 1 is placed. The lower support 14 then returns along this perpendicular first axis 32 to a position (in this case, the initial position) where the preheating device 18 can be placed between the parts. For example, the lifting table returns to its initial position.
[0055] To bypass the undercut, in the second step, the preheating device 18 is moved by the second drive unit 40 from the parking position to the alignment position between the parts to be welded along the second axis 42, which is perpendicular to the first axis 32 and horizontal to the floor or ground. This position is shown in Figure 2. The respective movement curves over time, achieved by the second drive unit 40, are indicated by reference numeral 44 in Figure 5.
[0056] After positioning the preheating device 18 between the two parts in the alignment position, in the third step, the preheating device 18 is moved to the preheating position along the third axis 52 by a third drive unit 50. This position is shown in Figure 3. The corresponding movement curve over time, achieved by the third drive unit 50, is shown by reference numeral 54 in Figure 5.
[0057] In the fourth step, after the preheating device 18 arrives at the preheating position, the lower jig 16 is moved along the first axis 32 to a position adjacent to the preheating device 18. This position is also called the adjacent position and is shown in Figure 4. The time-dependent movement curve realized by the first drive device 30 is shown by reference numeral 34 in Figure 5.
[0058] Next, in step 5, preheating occurs, during which all structural elements of the welding apparatus are held in their respective positions. This can be seen in Figure 5 from the respective movement curves.
[0059] After preheating, the above movements are performed in the reverse order. Therefore, in the sixth step, the lower support 14 is returned along the first axis 32 to a position where the preheating device 18 can be moved to the parking position. The lower support 14 is returned to its initial position according to the movement curve 34 (see Figure 3).
[0060] Next, in the seventh step, the preheating device 18 is returned to the aligned position along the third shaft 52 by the third drive unit 50 (see Figure 2). In the eighth step, the preheating device 18 is moved to the parking position along the second shaft 42 by the second drive unit 40 (see Figure 1). Each movement and their sequence are also shown in Figure 5.
[0061] In order to weld the first part to the second part, the lower support 14 is moved to the welding position along the first axis 32 in the ninth step. The welding of the first part to the second part takes place in the tenth step.
[0062] After welding is complete, in the 11th step, the lower support 14, together with the lower jig 16 and the composite of the first and second parts positioned thereon, returns from the welding position along the first axis 32 to its initial position. As soon as the lower support 14 arrives at its initial position, the user can remove the composite of the first and second parts.
[0063] Based on the above and with respect to Figure 5, the activation of each drive unit occurs only once at a time, especially when welding very complex parts to avoid collisions. This applies to all types of drive units, namely servo drives, pneumatic drives, or hydraulic drives.
[0064] Next, with reference to Figures 6 to 12, one embodiment of the welding method of the present invention will be described in comparison to the welding method discussed above.
[0065] The welding apparatus 100 used here comprises an upper jig 112 mounted on an upper support 110 and a lower jig 116 mounted on a lower support 114. The upper jig 112 and the lower jig 116 are movable relative to each other along a first axis 132 by a first drive unit 130. Here, the upper support 110 to which the upper jig 112 is firmly mounted is an upper jig plate, and the lower support 114 to which the lower jig 116 is mounted is a lifting table. As a result, in such exemplary arrangements, only the lifting table, which is the lower support 114, is moved along the first axis 132.
[0066] This configuration is particularly preferred in the case of a vibratory welding apparatus. Nevertheless, when an infrared welding method is used, mobility of the upper support 110 may also be provided. For completeness, it should be noted that the first axis 132 is preferably a vertical axis, i.e., perpendicular to the floor on which the welding apparatus 100 is located. Furthermore, the first and second parts to be welded to each other are preferably made of plastic material.
[0067] The welding apparatus 100 also includes a preheating device 118 having a first preheating device 120 and a second preheating device 122. The first preheating device 120 is positioned on the upper side facing the upper jig 112 in the preheating position, and the second preheating device 122 is positioned on the lower side facing the lower jig 116 in the preheating position. Furthermore, the preheating device 118 is equipped with a second drive device 140 for movement along a second axis 142, which is perpendicular to the first axis 132. A third drive device 150 is also provided for movement of the preheating device 118 along a third axis 152, which is parallel to the first axis 132.
[0068] Furthermore, the welding apparatus 100 includes a control device for controlling, preferably electronically coupling or synchronizing, the first drive unit 130, the second drive unit 140, and the third drive unit 150. The control device may be a main control device, i.e., a host control device, or one of the drive units 130, 140, or 150 that functions as a separate main control device, i.e., a host control device. A cost-effective embodiment can be realized by using one of the existing control devices. On the other hand, the use of a separate control device as a main control device, i.e., a host control device, ensures sufficient processing capacity and higher variability to accommodate different applications.
[0069] Furthermore, with respect to the drive units 130, 140, and 150, they are implemented as servo drive units. The use of such servo drive units ensures reliable control of the movement, and the control unit, as discussed below, can achieve a rapid interruption of the movement of the drive units (especially all drive units) in the event of a failure of one drive unit. In addition, servo drive units offer faster movement compared to pneumatic or hydraulic drive units, while simultaneously reducing noise and energy consumption.
[0070] In Figure 8, the upper jig 112 and lower jig 116 of each welding apparatus 100 are positioned in the initial position, or starting position. The preheating device 118 is positioned in the parking position.
[0071] The first step S1 is identical to the first step described above for positioning the first and second parts within the upper jig 112 and the lower jig 116. At the end of the first step S1, the welding apparatus 100 is shown in Figure 8 and is in the position indicated by the reference numeral T1 in Figures 6 and 7. In this regard, Figure 7 illustrates a simplified electronic cam disk used by the control device to control the movement of the drive units 130, 140 and 150.
[0072] Next, in the second step S2, the movement of the preheating device 18 from the parking position to the preheating position by the second drive unit 140 and the third drive unit 150 occurs without any intermediate positions. To achieve this, the second drive unit 140 and the third drive unit 150 are controlled by a control device so that they are operated or activated at least partially simultaneously.
[0073] For example, with respect to Figures 6 and 7, after the second drive unit 140 moves the preheating device 18 along the second shaft 142 over a predetermined distance (see reference numeral T2 in Figures 6 and 7 and the position shown in Figure 9), the third drive unit 150 is further activated or started so that movement along the third shaft 152 occurs. Thus, the movement is continuous, and the combined movement is diagonal. Continuous movement in this respect defines movement without intermediate stops or intermediate positions.
[0074] Furthermore, when the first drive unit 130 is activated or driven at the start of reference numeral T2, movement of the lower support 114 along the first shaft 132 occurs (see Figures 6 and 7).
[0075] To facilitate understanding, Figure 10 shows the location of reference numeral T3 in Figures 6 and 7. At the end of the second step S2, the welding apparatus 100 shows the configuration of Figure 11 corresponding to reference numeral T4.
[0076] As a result of the procedures of this process, the path of the preheating device 118 is shorter compared to the welding method described above, in which the preheating device 18 is moved separately along each of the axes. A further reduction in the time required before preheating can occur in the part to be welded in step S3 is achieved by the movement of the lower support 114 from its initial position to an adjacent position, simultaneously with the control device activating or starting the third drive unit 150 of the preheating device 118.
[0077] As described above, in order to achieve such movements simultaneously, the drive units 130, 140, and 150 are controlled together, for example, by an electronic cam disk. Therefore, the drive units 130, 140, and 150 are preferably coupled or synchronized with each other. This is achieved by a control device. This makes each movement dependent on the others so that in the event of failure of one drive unit 130, 140, or 150, the remaining drive units are more preferably automatically stopped by common control. Thus, damage to the first component, the second component, and / or the welding apparatus 100 can be avoided.
[0078] Furthermore, in this example, the second drive unit 140 functions as the main drive unit, while the remaining drive units 130 and 150 function as secondary drive units. This is due to the fact that the second drive unit 140 is activated or started first without the remaining drive units being activated or started. Thus, the remaining drive units are activated or started by the control unit only after the second drive unit 140 has achieved a predetermined distance indicated by the symbol T2.
[0079] Next, preheating occurs in step S3. To achieve this objective, the preheating device is preferably an infrared preheating device, depending on the application.
[0080] Subsequently, in step S4, the above movements are performed in the reverse order, as indicated by the labels T3', T2', and T1' in Figure 6. Thus, the lower jig 116 is moved along the first axis 132 from an adjacent position to a separated position which may be an initial position or any intermediate position that allows the preheating device 118 to move to the parking position. Thus, at least partially simultaneously, the preheating device 118 is moved, preferably continuously, from the preheating position to the parking position as described above. At the end of step S4, the welding device 100 is positioned as shown in Figure 8.
[0081] Next, in steps S5 to S7, steps 9 to 11 described above are performed. Thus, the lower jig 116 is moved to the welding position, the parts are welded together, and the lower jig 116 is returned to its initial position so that the user can remove the combined first and second parts that have been manufactured.
[0082] List of symbols 1. Welding equipment 10 Upper support 12 Upper jig 14 Lower support 16 Lower jig 18 Preheating device 20 First preheating device 22 Second preheating device 30 First drive unit 32. The first axis 34 Movement sequence realized along the first axis 32 by the first drive unit 30 40 Second drive unit 42 The second axis 44 Movement sequence realized along the second axis 42 by the second drive unit 40 50 Third drive unit 52 The Third Axis 54 Movement sequence realized along the third axis 52 by the third drive unit 50 100 welding equipment 110 Upper support 112 Upper jig 114 Lower support 116 Lower jig 118 Preheating device 120 First preheating device 122 Second preheating device 130 First drive unit 132 The first axis 134 Movement sequence realized along the first axis 132 by the first drive unit 130 136 Simplified electronic cam disc for movement realized along the first shaft 132 by the first drive unit 130 140 Second drive unit 142 The second axis 144 Movement sequence realized along the second axis 42 by the second drive unit 40 146 Simplified electronic cam disc for movement realized along the second shaft 142 by the second drive unit 140 150 Third drive unit 152 The Third Axis 154 Movement sequence realized along the third axis 152 by the third drive unit 150 156 Simplified electronic cam disc for movement realized along the third shaft 152 by a third drive unit 150
Claims
1. A welding method for welding a first part to a second part using a welding apparatus (100) equipped with an upper jig (112) mounted on an upper support (110) for receiving a first part, a lower jig (116) mounted on a lower support (114) for receiving a second part, and a preheating device (118) and control device for preheating the first part and / or the second part, a. In step (step S2), the upper jig (112) and the lower jig (116) are moved continuously relative to each other along the first axis (132) from an initial position to an adjacent position by the first drive device (130), and at least partially simultaneously with the continuous movement of the upper jig (112) and the lower jig (116) relative to each other, the preheating device (118) is moved from the parking position to the preheating position by the second drive device (140). In the parking position, the preheating device (118) is not positioned between the upper jig (112) and the lower jig (116), the second drive device (140) moves the preheating device (118) along the second axis (142) perpendicular to the first axis (132), and a third drive device (150) is provided to move the preheating device (118) along the third axis (152) parallel to the first axis (132), b. A step (step S3) of preheating the first component and / or the second component with the preheating device (118), and thereafter c. The process (step S4) of moving the upper jig (112) and the lower jig (116) continuously relative to each other along the first axis (132) from the adjacent position to the separated position by the first drive device (130), and at least partially simultaneously with the continuous movement of the upper jig (112) and the lower jig (116) relative to each other, the process of moving the preheating device (118) from the preheating position to the parking position by the second drive device (140), d. A step (step S5) of moving the upper jig (112) and the lower jig (116) relative to each other along the first axis (132) from the separated position to the welding position using the first drive device (130), e. A step (step S6) of welding the first part and the second part to each other at the welding positions of the upper jig (112) and the lower jig (116), f. A step (step S7) of moving the upper jig (112) and the lower jig (116) relative to each other along the first axis (132) from the welding position to the initial position by the first drive device (130), Methods that include...
2. The welding method according to claim 1, wherein the control device controls the first drive unit (130) and the second drive unit (140) to operate or start at least partially simultaneously.
3. The welding method according to claim 1, wherein the control device controls the third drive unit (150) together with the first drive unit (130) and the second drive unit (140), and operates at least two of the first drive unit (130), the second drive unit (140), and the third drive unit (150) simultaneously.
4. The welding method according to one of claims 1 to 3, wherein the welding method is a vibration welding method or an infrared welding method.
5. The welding method according to one of claims 1 to 3, wherein the first part and the second part are made of a plastic material.
6. The welding method according to one of claims 1 to 3, wherein the first drive device (130) and the second drive device (140) are servo drive devices.
7. The welding method according to one of claims 1 to 3, wherein one drive unit (130, 140, 150) functions as a main drive unit and the remaining drive units (130, 140, 150) functions as secondary drive units.
8. A welding method according to one of claims 1 to 3, wherein in the event of a failure of one drive unit (130, 140, 150), the control device stops the remaining drive units, i.e., the drive units (130, 140, 150) that are at least partially operated simultaneously.
9. A welding apparatus (100) for welding a first component to a second component using the welding method described in claim 1, a. An upper jig (112) attached to the upper support (110) for receiving the first component, b. A lower jig (116) attached to the lower support (114) for receiving the second component, c. A preheating device (118) for preheating the first and / or second component, d. The upper (110) and the lower support (114) are movable relative to each other along the first axis (132) between an initial position, an adjacent position, a separated position and a welded position by a first drive device (130), e. The preheating device (118) is movable between the parking position and the preheating position by a second drive device (140), and in the parking position, the preheating device (118) is not positioned between the upper jig (112) and the lower jig (116), f. The welding apparatus (100) includes a control device that controls the first drive unit (130) and the second drive unit (140) to be operated at least partially simultaneously so that the continuous movement of the upper jig (112) and the lower jig (116) relative to each other between the initial position and the adjacent position and the continuous movement of the preheating device (118) between the parking position and the preheating position occurs at least partially simultaneously, g. The second drive unit (140) moves the preheating device (118) along the second axis (142) perpendicular to the first axis (132), and a third drive unit (150) is provided to move the preheating device (118) along the third axis (152) parallel to the first axis (132). A welding apparatus (100) equipped with the following.
10. The welding apparatus (100) according to claim 9, wherein the control device controls the drive devices (130, 140, 150) so that at least two of the first drive device (130), the second drive device (140), and the third drive device (150) are operated simultaneously.
11. The welding apparatus (100) according to one of claims 9 to 10, wherein the welding apparatus (100) is a vibration welding apparatus or an infrared welding apparatus.
12. The welding apparatus (100) according to one of claims 9 to 10, wherein the first and second parts are made of plastic material.
13. The welding apparatus (100) according to one of claims 9 to 10, wherein the first drive unit (130) and the second drive unit (140) are servo drive units.