Welding apparatus, system and method for joining thermoplastic panels

Abstract

A welding apparatus for joining thermoplastic panels (102, 103) comprises a carrier (1) with a welding area (100) open downwards towards parallel boundary lines (101) to be welded, transport means (2) to move the carrier along the boundary lines, an adjustment bracket (3) to hold two welding devices (4, 5) arranged to provide hot air, wherein each welding apparatus (4, 5) comprises a nozzle (6) in the welding area. Also disclosed are a system and a method for joining thermoplastic panels.

Description

[0001] Title: Welding apparatus, system and method for joining thermoplastic panels Technical field

[0002] The present disclosure relates to a welding apparatus for joining thermoplastic panels, a welding system for joining thermoplastic panels and a method for joining by welding. More specifically, the disclosure relates to a welding apparatus for joining thermoplastic panels, a welding system for joining thermoplastic panels and a method for joining by welding.

[0003] Background:

[0004] [001 JThermoplastic materials are extensively utilized in industrial applications due to their combination of strength, chemical resistance, and adaptability to diverse environments. These materials are characterized by their ability to soften and become pliable or moldable when heated and to solidify upon cooling. This reversible thermal behavior makes thermoplastics particularly well-suited for welding, allowingfor the creation of robust, leak-proof bonds between components.

[0005]

[0002] Welding thermoplastic materials involves the controlled application of heat to melt the material at the joint surfaces, followed by the application of pressure to fuse the molten areas together. Upon cooling, the material solidifies to form a continuous, high-strength bond. This process is widely used in manufacturing and construction industries for assembling, repairing, or modifying components made from thermoplastics.

[0006]

[0003] Common types of thermoplastic materials include polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS) and polycarbonate (PC).

[0007]

[0004] Each of these thermoplastic materials possesses unique physical and chemical properties that influence the choice of welding method, the required processing parameters, and the resulting joint strength. Welding methods must be tailored to the specific material type to achieve optimal results. For instance, polyethylene and polypropylene are often welded using hot air or extrusion welding techniques, while materials like polycarbonate and PVC may require other specialized methods.

[0008]

[0005] Various welding methods are used depending on the type of joint required and the specific application. These methods include butt fusion welding, extrusion welding, and hot air welding. Amongthese, hot air welding, often used for joining thermoplastic sheets, brackets, or similar components, requires precision and skill to achieve consistent results.

[0009]

[0006] In hot air or extrusion welding, a specialized welding gun is employed to provide controlled heat, enabling the fusion of thermoplastic materials. The process typicallybegins by aligning and securingthe materials to prevent movement during welding. For larger pieces, tack or spot welds are applied to hold the materials in place before the final weld. The welding gun must be carefully adjusted for each operation, with the temperature set within a range of 250°C to 350°C. The precise temperature depends on factors such as the thickness and type of HDPE, as well as ambient environmental conditions.

[0010]

[0007] During welding, the surfaces of the joint are preheated using hot air untilthe material begins to soften. A filler rod, made of thermoplastic, is then fed into the joint area and simultaneously heated. This process causes the filler rod and the base material to melt and blend together. A nozzle or roller is used to press the molten material into the joint, ensuring a uniform bond. Proper technique is critical during this process, as excessive heat can lead to material degradation or charring, while insufficient heat results in weak bonding. Maintaining a consistent pace is equally important; moving too quickly can weaken the weld, while moving too slowly risks overheating the material.

[0011]

[0008] After welding, the joint must cool at a controlled rate to solidify and strengthen the bond. Achieving high-quality welds requires precise control of several variables, includingtemperature, preheating, ambient conditions, alignment of the materials, and the angle, pressure, and speed of the welding gun.

[0012]

[0009] However, when performed manually, this process is labor-intensive and prone to variability. Even skilled operators can struggle to maintain consistent pressure and movement speed, leading to weld quality that is difficult to assess without destructive testing. Furthermore, manual operations do not allow for logging of key parameters, making it challenging to verify or replicate the welding process.

[0013]

[0010] To address these challenges, automated welding systems have been developed to improve consistency and efficiency. While such systems mitigate some issues associated with manual welding, they remain limited in their capabilities. For example, current automated systems are unable to perform dual-sided welding simultaneously. This limitation is particularly problematic when welding components such as frames to sheets at right angles. Welding one side at a time often results in uneven welds, as heating and cooling of the first side can cause warping or shifting of the material before the second side is welded. Additionally, sequential welding makes it difficult to ensure that both sides are welded with identical pressure, angle, speed, and feed rate.

[0014] Document US 4094725 A discloses an apparatus for welding a pair of thermoplastic workpieces by means of hot gas blasting.

[0011] Despite advancements in thermoplastic welding, challenges remain in achieving consistent, high-quality bonds across a wide range of applications. These challenges include controlling the thermal profile during welding, ensuring alignment of the materials, and preventing defects such as voids, weak spots, or uneven bonding.

[0015] Addressing these issues is critical for the continued expansion of thermoplastic welding technologies and their use in increasingly demanding industrial applications.

[0016]

[0012] Accordingly, there is a need for an improved welding apparatus capable of dualsided welding. Such a system would ensure consistent pressure, temperature, feed speed, and movement along mirrored boundary lines. It would also eliminate the potential for material warping or misalignment during the welding process, while providing a reliable and repeatable means of logging and evaluating welding parameters. This innovation would address the shortcomings of existing manual and automated systems, enabling more precise and efficient welding of thermoplastic components.

[0017]

[0013] Summary

[0018] It is an object of the present disclosure to mitigate, alleviate or eliminate one or more of the above-identified deficiencies and disadvantages in the prior art and solve at least the above mentioned problem. According to a first aspect there is provided a welding apparatus for joining thermoplastic panels, the welding apparatus comprises: a carrier with at least a welding area open downwards towards one or more parallel boundary lines to be welded, and; transport means to move the carrier along the boundary line, and; at least an adjustment bracket to hold welding device, wherein the welding apparatus further comprising: two welding devices, each welding device attached via the adjustment brackets to the carrier, each welding device compromises at least a nozzle disposed within the welding area towards the boundary line.

[0019]

[0014] This enabling dual-sided welding with unparalleled precision. This invention ensures consistent pressure, temperature, feed speed, and synchronized movement along mirrored boundary lines. By preventing material warping and misalignment, it eliminates common flaws in the welding process.

[0020]

[0015] According to some embodiments, the adjustment bracket comprises: a first arched member and; a second arched member parallelly aligned with the first arched member, the first and second arched members defining a radius R from the boundary line, and each the welding comprises a slit ) along a length of the member, wherein the welding devices are arranged between the first and the second arched member.

[0021]

[0016] According to some embodiments, the adjustment bracket further comprises: a holding bracket, moveable along, and arranged between, the first and second archedmember, to hold the welding devices, locking members to lock the holding bracket at different positions in relation to the first and / or second arched members.

[0022]

[0017] Accordingto some embodiments, the apparatus further the welding comprises a pressure adjustment device, to exert a pressure on a part of the welding device in a first direction.

[0023]

[0018] Accordingto some embodiments, the apparatus further the welding comprises a further pressure adjustment device, to exert a predetermined pressure on a part of the welding device in a second direction, different than the first direction.

[0024]

[0019] According to some embodiments, the pressure adjustment device and / or the further pressure adjustment device is situated between respective the welding devices, or parts thereof, and respective adjustment brackets.

[0025]

[0020] Accordingto some embodiments, the carrier comprises: two frames parallel aligned and spaced apart, and a connecting element on a top section, connectingthe two frames.

[0026]

[0021] Accordingto some embodiments, the transport means comprises rollers and an actuator to drive the rollers, wherein the actuator can be a motor, a pu Uy, an linear actuator or a rotatable actuator.

[0027]

[0022] Accordingto some embodiments, the apparatus the welding comprises a centring device to centre a plate member to be welded between the welding devices.

[0028]

[0023] Accordingto some embodiments, the centring device comprises a fixed support member on a first side of side of a plate member to be welded, and movable member on a second side, wherein the movable member is movable in relation to a centre line between the welding devices.

[0029]

[0024] Accordingto some embodiments, the movable member is movable by an eccentric bolt or actuator.

[0030]

[0025] Accordingto some embodiments, wherein the apparatus the welding comprises a control system the welding comprises: a control unit; sensors to register; the temperature at the nozzle , pressure by the nozzle, angle of the nozzle, and; and speed of movement along the boundary line, a memory, to store the information from the sensors, a processor, to process the sensor data, wherein the control unit is adapted to read the sensor data, and to process the sensor data, and adjust the temperature at thenozzle and / or pressure by the nozzle and / or angle of the nozzle, and / or speed of movement alon the boundary line.

[0031]

[0026] Accordin to a second aspect there is provided a welding system for joining thermoplastic panels, the system comprises a suspended girder suspended by two supports on either side of a welding area, and a welding apparatus according the first aspect, disposed in the suspended girder, the welding apparatus being movable between two supports of the suspended girder by the transport means.

[0032]

[0027] Accordingto some embodiments, the welding area is adapted for supporting a horizontal panel and the system further comprises a support jig adapted to vertically support a vertical panel to be welded to the horizontal panel.

[0033]

[0028] Accordingto some embodiments, the welding jig the welding comprises a holding and centring device comprises a fixed support member on a first side of side of a plate member to be welded, and movable member on a second side, wherein the movable member is movable in relation to a centre line between the parallel boundary lines to clamp down on, and centre, plate member to be welded.

[0034]

[0029] According to some embodiments, the system further comprises traversing means associated with the two supports on either side of a welding area, to move the suspended girder along tracks parallel on either side of the welding area.

[0035]

[0030] Accordingto some embodiments, the system comprises a gantry crane movable along tracks or the like on either side of the welding area adapted to move the welding jig and / or panels.

[0036]

[0031] Accordingto a third aspect there is provided a method for joining by welding, one or more panel to a horizontal panel, the method comprising the steps of: the first aspect aligning a first panel to a second panel to be welded, - weld, by a welding device according to the first aspect, or a welding system according to claims 13-17, the first panel to a second panel along boundary lines.

[0037]

[0032] According to some embodiments, the method the method comprises the step of controlling by the control system, that the welding is carried out in accordance with a set of criteria, and if not; adjust the temperature at the muzzle and / or pressure by the muzzle and / or angle of the muzzles, and / or speed of movement alongthe boundary line to be within a set of criteria.

[0038]

[0033] According to some embodiments, the method further comprises the step of logging, by the control system, the parameters of the weld.

[0034] Effects and features of the second and third aspects are to a large extent analogous to those described above in connection with the first aspect. Embodiments mentioned in relation to the first aspect are largely compatible with the second and third aspects.

[0039]

[0035] The present disclosure will become apparent from the detailed description given below. The detailed description and specific examples disclose preferred embodiments of the disclosure by way of illustration only. Those skilled in the art understand from guidance in the detailed description that changes and modifications may be made within the scope of the disclosure.

[0040]

[0036] Hence, it is to be understood that the herein disclosed disclosure is not limited to the particular component parts of the device described or steps of the methods described since such device and method may vary. It is also to be understood that the terminology used herein is for purpose of describing particular embodiments only, and is not intended to be limiting. It should be noted that, as used in the specification and the appended claim, the articles "a", "an", "the", and "said" are intended to mean that there are one or more of the elements unless the context explicitly dictates otherwise. Thus, for example, reference to "a unit" or "the unit" may include several devices, and the like. Furthermore, the words "comprising", "including", "containing" and similar wordings does not exclude other elements or steps.

[0041]

[0037] Effects and features of the second aspect are to a large extent analogous to those described above in connection with the first aspect. Embodiments mentioned in relation to the first aspect are largely compatible with the second aspect.

[0042]

[0038] The present disclosure will become apparent from the detailed description given below. The detailed description and specific examples disclose preferred embodiments of the disclosure by way of illustration only. Those skilled in the art understand from guidance in the detailed description that changes and modifications may be made within the scope of the disclosure.

[0043] Brief descriptions of the drawings

[0044]

[0039] The above objects, as well as additional objects, features and advantages of the present disclosure, will be more fully appreciated by reference to the following illustrative and non-limiting detailed description of example embodiments of the present disclosure, when taken in conjunction with the accompanying drawings.Figure 1 shows a perspective view according to an embodiment of the present disclosure.

[0045] Figure 2 shows a perspective view according to an embodiment of the present disclosure.

[0046] Figure 3 shows a front view according to an embodiment of the present disclosure. Figure 4 shows a perspective view according to an embodiment of the present disclosure.

[0047] Figure 5 shows a front view according to an embodiment of the present disclosure. Figure 6 shows a front view according to an embodiment of the present disclosure. Figure 7 shows a cross-sectional view according to an embodiment of the present disclosure.

[0048] Figure 8 shows a cross-sectional view according to an embodiment of the present disclosure.

[0049] Figure 9 shows a cross-sectional view according to an embodiment of the present disclosure.

[0050] Figure 10 shows a perspective view according to an embodiment of the present disclosure.

[0051] Detailed description

[0052]

[0040] The present disclosure will now be described with reference to the accompanying drawings, in which preferred example embodiments of the disclosure are shown. The disclosure may, however, be embodied in other forms and should not be construed as limited to the herein disclosed embodiments. The disclosed embodiments are provided to fully convey the scope of the disclosure to the skilled person.

[0053]

[0041] Figure 1 shows a welding apparatus 10 for joining thermoplastic panels, the welding apparatus comprises a carrier 1 with at least a welding area 100 open downwards towards one or more parallel boundary lines 101 to be welded. A welding area 100 may be any area suitable for receiving the boundary line between two or more plates. The carrier comprises transport means 2 to move the carrier 1 along boundary lines 101 , a path or panels to be welded. Two welding devices 4, 5 are attached and adjustably fastened to the carrier 1 by at least an adjustment bracket 3. Each welding devices 4, 5 comprises a nozzle 6 to heat the welding area or boundary lines 101 to be welded and to feed welding material. Heat may be provided by a dedicated heating nozzle and the welding feed may be provided by a dedicated feeding nozzle. The nozzle 6may also comprise a roller to provide pressure to the welding area or boundary lines 101 to be welded. The adjustment bracket 3 holds the two welding devices 4, 5 in an adjustable manner, such that at least the angle of each nozzle 6 can be adjusted.

[0054] Furthermore, each nozzle 6 of each welding device 4, 5 are orientated to be disposed within a welding area 100 towards the boundary lines 101 to be welded. As further illustrated in fig. 1 , the adjustment bracket 3 further comprises a holding bracket 7, moveable along, and arranged by or between, at least one arched member 31 ,32, to hold the welding devices 4,5.

[0055]

[0042] Although the plates illustrated herein is shown as right angled vertical and horizontal plates 102, 103, it should be understood that the upright plate 102 can have an angle different from right angle to the bottom, or horizontally aligned, plate 103. To achieve this, each welding device 4, 5 can be individually adjusted.

[0056]

[0043] Figure 2 shows a welding apparatus 10 for joining a vertically aligned panell 02 to a horizontally aligned panel 103 of thermoplastic materials, such as, polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS) and polycarbonate (PC). The welding apparatus 10 is situated on top of the panels 102, 103 such that the carriers 1 welding area 100 is open downwards towards parallel boundary lines 101 to be welded. The boundary lines 101 are situated along the joint seams where the vertically aligned panell 02 meets the horizontally aligned panel 103 to be welded. As illustrated, several vertical panels 102 may welded to the horizontally aligned panel 103 to constitute a larger section. Such sections of thermoplastic panels can in tur be used to construct larger construction, such as floating units or land-based entities. In the illustrated example, each welding device 4, 5 may be attached to the adjustment bracket 3 via a holding bracket 7. The holding bracket 7 which may be a bracket or frame attached to each welding device 4, 5 by locking members 8 to lock the holding bracket 7 at different positions in relation to the at least one arched member 31 ,32.

[0057]

[0044] Figure 3 shows profile view of a welding apparatus 10 for joining a vertically aligned panel102 to a horizontally aligned panel 103 of thermoplastic materials, such as, polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS) and polycarbonate (PC). The welding apparatus 10 is situated on top of the panels 102, 103 such that the carriers 1 welding area 100 is open downwards towards parallel boundary lines 101 to be welded. To alter and adjust the angle of the nozzle 6 of the welding devices 4, 5 in relation to the horizontal plate 103, the adjustment bracket 3 may comprise an arched member 31 , arched in relation to a flat horizontal plane, wherein at least one slit 33, 34 is provided in the arched member. Each welding device 4, 5 can be positioned and fastened vi the locking members 8 along the slit 33, 34 to facilitate different positions along the arched member 31. The slit can be along the entire lengthof the arched member 31 , 32 or on sections of the length, such as on a section on each side of a central vertical plane. In a non-illustrated example, the slit 33 can be substituted for notches or the like that would facilitate the ability to lock the welding devices 4, 5 in different positions and, hence, different angles. As can be seen in fig. 3, each welding device is mirrored on either side of the vertical plate 102. This ensures the weld is carried out with equal pressure and angle for both boundary lines 101 to be welded. The carrier 1 may be comprise two frames 35, 36 parallel aligned and spaced apart, and a connecting element 37 as a top section, connecting the two frames.

[0058]

[0045] Figure 4 shows the carrier without the welding devices 4, 5. In the illustrated embodiment, the adjustment bracket 3 comprises two arched members 31 , 32 to adjustably hold the welding device 4, 5 to the carrier 1 in a secure and accurate manner. The adjustment bracket 3 may comprise a first arched member 31 and a second arched member 32 pa rallelly aligned with the first arched member 31 , the first and second arched members 31 , 32 defining a radius Rfrom the boundary lines 101 . As further illustrated in fig.4, the transport means 2 may comprises wheels or rollers. Furthermore, an actuator may drive the rollers or wheels directly or via pullies, wherein the actuator can be a motor, a pully, n linear actuator or a rotatable actuator. As seen in the illustration on figs. 1-4, the transport means 2 are wheels that move along the plate 103.

[0059]

[0046] Figure 5 illustrated the adjustment bracket 3 of the welding device comprises: at least first arched member 31 defining a radius Rfrom the boundary line(s) 101 , and each slit 33 along a length of the member 31.

[0060]

[0047] Fig. 1 and 2 illustrates an adjustment devices to adjust the pressure and / or height of the nozzle 6 in relation to the vertical plate and horizontal plate, wherein the apparatus may further comprise a pressure adjustment device 9, to exert a pressure on a part of the welding devices in a first direction. In the illustrated example, the adjustment device 9 comprises a screw type device situated between the adjustment bracket 3 and part of the welding device 4, 5. The adjustment device 9 may comprise a screw type adjustment or an actuator type that exerts pressure and / or forces movement of the welding device 4, 5 and / or parts thereof, towards the boundary line(s) 101. Each welding device 4, 5 may comprise individual adjustment device 9. Furthermore, the welding apparatus may also comprise a height and / or pressure adjustment device to adjust the height and / or pressure of both welding devices 4, 5 equal and simultaneously. This may be achieved with a height adjustment mechanism 39. The height adjustment mechanism 39 may comprise a screw type adjustment or an actuator type that adjust the height of the adjustment bracket 3 on the carrier 1 in relation to the boundary line(s) 101. The height adjustment mechanism 39 may be situated between the adjustment bracket 3 and parts of the carrier 1 to adjust the distance between the adjustmentbracket 3 and parts of the carrier 1 , thereby regulating the height of both welding devices 4, 5.

[0061]

[0048] Figure 6 shows a welding apparatus 10 for joining thermoplastic panels, the welding apparatus comprises a carrier 1 with at least a welding area 100 open downwards towards one or more parallel boundary lines 101 to be welded. The carrier comprises transport means 2 to move the carrier 1 along a path or panel to be welded. Two welding devices 4, 5 are attached and adjustably fastened to the carrier 1 by at least an adjustment bracket 3. Each welding devices 4, 5 comprises a nozzle 6 to heat the welding area and / or boundary lines 101 to be welded and to feed welding material. Heat may be provided by a dedicated heating nozzle and the welding feed may be provided by a dedicated feeding nozzle, or both heating and feeding may be provided by a combined nozzle. It is understood that the nozzle 6 is an illustration of both types of nozzles. The nozzle 6 may also comprise a roller to provide pressure to the welding area or boundary lines 101. The adjustment bracket 3 holds the two welding devices 4, 5 in an adjustable manner, such that at least the angle of each nozzle 6 can be adjusted. Furthermore, each nozzle 6 of each welding device 4, 5 are orientated to be disposed within a welding area 100 towards the boundary lines 101 to be welded. As further illustrated in fig. 6, the transport means 2 may comprises wheels or rollers. Furthermore, an actuator may drive the rollers or wheels directly or via pullies, wherein the actuator can be a motor, a p u Uy, an linear actuator or a rotatable actuator. As seen in the illustration on fig. 6 the transport means 2 are wheels or rollers that move along a suspended path, such as a suspended girder 21.

[0062]

[0049] As further illustrated in fig. 7, the adjustment bracket 3 may further comprises a holding bracket 7 arranged by or between at bracket 3 and the welding devices 4,5.

[0063]

[0050] Fig. 7 and 8 illustrates a various devices and controllers to adjust the pressure, and / or height, and / or distance of the nozzle 6 in relation to the vertical plate and horizontal plate, wherein the apparatus may further comprise a pressure adjustment device 9, to exert a pressure on a part of the welding devices in a first direction. In the illustrated example, the adjustment device 9 comprises an actuator type device situated between the adjustment bracket 3 and part of the welding device 4, 5. The adjustment device 9 may also comprise a screw type adjustment or an actuator type that exerts pressure and / or forces movement of the welding device 4, 5 and / or parts thereof, towards the boundary line(s) 101. Each welding device 4, 5 may comprise an individual adjustment device 9. In the illustrated example in fig. 8, the apparatus comprises comprising a further pressure adjustment device 91 , to exert a predetermined pressure on a part of the welding devices in a second direction, different than the first direction. Thus, the pressure adjustment device 9 and the further pressure adjustment device 91 can alter and adjust the pressure exerted by the nozzle towards the boundary lines 101to be welded in at least two directions. Both the adjustment device 9 and the further pressure adjustment device 91 can be situated between the adjustment brackets 3 and the welding device 4, 5 and / or parts thereof. Although the adjustment device 9 and the further pressure adjustment device 91 are only illustrated on one of the welding devices 4, it should be understood that both welding devices 4, 5 may be equal, however mirrored, and comprise the same features.

[0064] [051 JFigure 9 shows a centring device 11 to centre the plate member 102 to be welded between the welding devices 4, 5. The centring device 11 may comprises a fixed support member 12 on a first side of side of a plate member 102 to be welded, and a movable member 13 on a second side, wherein the movable member 13 is movable in relation to a centre line between the welding devices 4, 5. The movable member is movable by an eccentric bolt or actuator. In use, the movable member 13, such as an eccentric bolt, moves a contact surface 14 in in or out in relation to the plate 101 situated between the movable contact surface 14 and the fixed support member 12, to adjust the position of the welding devices 4, 5 in relation to the plate member 102, or by moving the plate member 102. The centring device 11 may be attached to the carrier 1 or adjustment bracket 3, as illustrated in figs. 6, 7 and 8 or it may be part of a standalone device that is situated around the plate member 102. The centring device 11 may form part of a support jig 25 adapted to support and hold the plate member 102 in relation to the horizontal plate member 103.

[0065]

[0052] Figure 10 shows a welding system 20 for joining thermoplastic panels, the system comprises a suspended girder 21 suspended by two supports 22, 23 on either side of a welding area 24, and a welding apparatus 10, as disclosed herein, in the suspended girder 21 , the welding apparatus 10 being movable between two supports of the suspended girder 21 by the transport means 2. The welding area 24 is adapted for supporting a horizontal panel 103 and the system may further comprise a support jig 25 adapted to vertically support a vertical panel 102 to be welded to the horizontal panel 103. The welding jig 25 may comprise a holding and centring device 11 comprises a fixed support member 12 on a first side of side of a plate member 102 to be welded, and movable member 13 on a second side, wherein the movable member 13 is movable in relation to a centre line between the parallel boundary lines 101 to clamp down on, and centre, plate member 102 to be welded. The system may further comprise traversing means associated with the two supports 22, 23 on either side of a welding area 24, to move the suspended girder 21 alongtracks 26 parallel on either side of the welding area 24. In addition, to move additional materials, the welding jig 25, vertical panels or horizontal panels 103, the system may comprise a gantry crane 27 movable along tracks or the like on either side of the welding area 24.

[0053] To ensure correct and stable operating parameters, the apparatus or system disclosed herein may comprise a control unit or control system. The welding apparatus may a control unit; sensors to register; the temperature at the nozzle, pressure by the nozzle, angle of the nozzle, and speed of movement along the boundary line, a memory, to store the information from the sensors, wherein the control unit is adapted to read the sensor data, and to process the sensor data, and adjust the temperature at the nozzle and / or pressure by the nozzle and / or angle of the nozzles, and / or speed of movement alongthe boundary line(s).

[0066]

[0054] The control system in the described welding apparatus functions as the central mechanism for ensuring precise and consistent thermoplastic welding. By integrating the various components, it continuously monitors and adjusts critical parameters to maintain optimal conditions throughout the welding process.

[0067]

[0055] At the heart of the system are sensors that measure key variables, including the temperature at the nozzle, the pressure applied by the nozzle, the angle of the nozzle relative to the boundary lines, and the speed of movement along the welding path.

[0068] These sensors provide real-time feedback, capturing the state of the welding process with high precision. The collected data is then stored in the system's memory, allowing both immediate processing and later analysis for quality assurance and process optimization.

[0069]

[0056] A processor analyses the sensor data in real time, identifying any deviations from the desired welding parameters. Using pre-programmed algorithms or dynamic models, the processor calculates adjustments to restore or maintain optimal conditions. The control unit, acting as the central hub, interprets the processor’s outputs and implements necessary corrections. For instance, if the sensors detect a drop in temperature at the nozzle, the control unit increases the heating element's output to ensure consistent bonding. Similarly, if excess pressure is applied, the system reduces the force to prevent material deformation or warping.

[0070]

[0057] I n addition to controlling temperature and pressure, the system dynamically adjusts the angle of the nozzle to align with the boundary lines. This ensures uniform bonding and eliminates defects caused by misalignment. The system also regulates the speed of movement along the welding path, preventing overheating or insufficient bonding caused by inconsistent feed rates. The system may also regulate the centring device.

[0071]

[0058] By continuously reading sensor data and executing real-time adjustments, the control system creates a closed feedback loop that ensures the welding process remains consistent and efficient. This automated approach not only reduces variabilityand the likelihood of defects but also enhances production speed and costeffectiveness by minimizing the need for manual intervention. The control system transforms sensor data into precise adjustments that maintain optimal welding conditions. By addressing key challenges such as thermal regulation, material alignment, and consistent pressure, it enables the apparatus to meet the stringent demands of modern industrial applications, ensuring high-quality and reliable thermoplastic welding.

[0072]

[0059] I n addition to real-time monitoring and control, the welding apparatus is equipped with a robust data logging system that records the details of each weld performed. This feature eliminates the need for destructive testing by providing a comprehensive, traceable record of the welding parameters for quality assurance and compliance purposes.

[0073]

[0060] As the sensors continuously measure temperature, pressure, angle, and speed during the welding process, this data is not only processed for real-time adjustments but also stored in the apparatus's memory. The system logs precise information about how each weld was performed, includingthe exact date and time of the operation, the parameters used, and any deviations that may have occurred during the process. This creates a detailed ledger of welding activity, allowing operators or quality inspectors to review the performance of each weld without physically testing the welded materials.

[0074]

[0061] By maintaining a precise digital record of each weld, the system offers several advantages. First, it provides full traceability, ensuring that any issues identified later in the production process can be linked back to the specific conditions under which the weld was made. Second, it enables compliance with industry standards or regulatory requirements that mandate detailed documentation of manufacturing processes.

[0075] Finally, it supports continuous improvement by allowing engineers to analyse historical data and refine the welding process based on observed trends or recurring issues.

[0076]

[0062] This logging capability significantly enhances efficiency and quality control by reducing the reliance on destructive testing methods, such as cutting samples from finished products to evaluate weld integrity. Instead, inspectors can rely on the detailed data logged by the apparatus to verify that each weld meets the required specifications.

[0077]

[0063] This approach not only saves material and labour costs but also ensures that the structural integrity of the final product remains intact, making it an essential feature for advanced thermoplastic welding applications.

[0078]

[0064] The person skilled in the art realizes that the present disclosure is not limited to the preferred embodiments described above. The person skilled in the art further realizesthat modifications and variations are possible within the scope of the appended claims. Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed disclosure, from a study of the drawings, the disclosure, and the appended claims.

Claims

Claims1. A welding apparatus (10) for joining thermoplastic panels, the welding apparatus comprises:a carrier (1 ) with at least a welding area (100) open downwards towards parallel boundary lines (101) to be welded, and;transport means (2) to move the carrier (1) along the boundary lines (101), and;at least an adjustment bracket (3) to hold welding device(s) (4, 5), wherein the welding apparatus further comprising:two welding devices (4, 5), each welding device (4, 5) attached via the adjustment brackets (3) to the carrier (1 ), each welding device compromises at least a nozzle (6) disposed within the welding area (100).

2. The welding apparatus according to claiml , wherein the adjustment bracket (3) comprising:a first arched member (31 ) and;a second arched member (32) parallelly aligned with the first arched member (31 ), the first and second arched members (31 , 32) each defining a radius R from respective boundary lines (101 ), and each comprising a slit (33, 34) along a length of the member (31),wherein the welding devices (4, 5) are arranged between the first and the second arched member (31 , 32).

3. The welding apparatus according to claims 2, wherein the adjustment bracket (3) further comprises:a holding bracket (7), moveable along, and arranged between, the first and second arched member (31 , 32), to hold the welding devices (4, 5),locking members (8) to lock the holding bracket (7) at different positions in relation to the first and / or second arched members (31 , 32).

4. The welding apparatus according to any one of the previous claims, the apparatus further comprising a pressure adjustment device (9), to exert a pressure on a part of the welding device(s) in a first direction.

5. The welding apparatus according to any one of the previous claims, the apparatus further comprising a further pressure adjustment device (91 ), to exert a predetermined pressure on a part of the welding device(s) in a second direction, different than the first direction.

6. The welding apparatus according to any one of the previous claims, wherein the pressure adjustment device (9) and / or the further pressure adjustmentdevice (91 ) is situated between respective the welding devices (4, 5), or parts thereof, and respective adjustment brackets (3).

7. The welding apparatus according to any one of the previous claims, wherein the carrier (1) comprises:two frames (25, 36) parallel aligned and spaced apart, and a connecting element (37) on a top section, connecting the two frames.

8. The welding apparatus according to any one of the previous claims, wherein the transport means (2) comprises rollers and an actuator to drive the rollers, wherein the actuator can be a motor, a pu Uy, an linear actuator or a rotatable actuator.

9. The welding apparatus according to any one of the previous claims, the apparatus comprising a centring device (11 ) to centre a plate member (102) to be welded between the welding devices (4, 5).

10. The welding apparatus according to any one of the previous claims, wherein the centring device (11 ) comprises a fixed support member (12) on a first side of side of a plate member (102) to be welded, and movable member (13) on a second side, wherein the movable member (13) is movable in relation to a centre line between the welding devices (4, 5).11.The welding apparatus according to any one of the previous claims, wherein the movable member is movable by an eccentric bolt or actuator.

12. The welding apparatus according to any one of the previous claims, wherein the apparatus comprising a control system comprising:a control unit;sensors to register; the temperature at the nozzle (6),pressure by the nozzle (6), angle of the nozzle (6), and;and speed of movement alongthe boundary line,a memory, to store the information from the sensors,a processor, to process the sensor data,wherein the control unit is adapted to read the sensor data, and to process the sensor data, and adjust the temperature at the nozzle (6) and / or pressure by the nozzle (6) and / or angle of the nozzle (6), and / orspeed of movement alongthe boundary lines (101).

13. A welding system (20) for joining thermoplastic panels, the system comprises a suspended girder (21 ) suspended by two supports (22, 23) on either side of a welding area (24), and a welding apparatus (10) according any one of claims 1- 12, disposed in the suspended girder (21 ), the welding apparatus (10) being movable between two supports of the suspended girder (21 ) by the transport means (2).

14. The welding system according to claim 13, wherein the welding area (24) is adapted for supporting a horizontal panel (103) and the system further comprises a support jig (25) adapted to vertically support a vertical panel (102) to be welded to the horizontal panel (103).

15. The welding system according to any one of claims 13-14, wherein the welding jig (25) comprising a holding and centring device (11 ) comprises a fixed support member (12) on a first side of side of a plate member (102) to be welded, and movable member (13) on a second side, wherein the movable member (13) is movable in relation to a centre line between the parallel boundary lines (101) to clamp down on, and centre, plate member (102) to be welded.

16. The welding system according to any one of claims 13-15, wherein the system further comprises traversing means associated with the two supports (22, 23) on either side of a welding area (24), to move the suspended girder (21 ) along tracks (26) parallel on either side of the welding area (24).

17. The welding system according to any one of claims 13-16, wherein the system comprises a gantry crane (27) movable along tracks or the like on either side of the welding area (24) adapted to move the welding jig (25) and / or a horizontal panels (103).

18. A method for joining by welding, one or more panel to a horizontal panel, the method comprising the steps of:aligning a first panel (102) to a second panel (103) to be welded,- weld, by a welding device according to claims 1 -12, or a welding system according to claims 13-17, the first panel (102) to a second panel (103) along boundary lines (101).

19. The method of claim 18, wherein the method comprisingthe step of controlling by the control system, that the welding is carried out in accordance with a set of criteria, and if not; adjust the temperature at the nozzle (6) and / or pressure by the nozzle (6) and / or angle of the nozzle (6), and / or speed of movement along the boundary line(s) to be within a set of criteria.

20. The method of claim 18 or 19, wherein the method further comprises the step of logging, by the control system, the parameters of the weld.

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