Composite Welding End Effector with Cooling Air Jets
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Solution Overview
Problem
Induction welding of large thermoplastic composite components faces challenges in generating fast, controlled, and uniform heating and cooling along the weld line to produce high-strength joints.
Innovation Solution
A welding system with an end effector that includes a leading roller and follower rollers, along with cooling air jets to control temperature and pressure, ensuring uniform heating and cooling by using a robotic arm to position the end effector for precise movement and pressure application during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If induction welding is used to join thermoplastic composite components, then welding speed and productivity can be improved, but controlling uniform heating and cooling along the entire weld line becomes difficult
Solution Approach 1:
The cooling system is segmented into multiple independent cooling zones along the weld line, with separate cooling channels positioned at different locations. This allows independent control of cooling in each zone to achieve uniform cooling across the entire weld line while maintaining high welding speed
Solution Approach 2:
Different cooling rates and temperatures are applied to different sections of the weld line based on local requirements. The system adjusts cooling parameters locally along the weld line to compensate for variations in heat generation, ensuring uniform cooling despite differences in welding conditions at various positions
2Loss of time
If fast cooling is applied after induction welding, then cycle time is reduced and productivity increases, but the crystalline lattice structure of thermoplastic materials may not form properly, reducing joint strength
Solution Approach 1:
The cooling channels are pre-positioned and pre-cooled before the welding process begins. During welding, cooling is immediately applied to specific zones as the heat front passes, eliminating the need for prolonged cooling periods while ensuring proper crystalline structure formation. The system anticipates where cooling is needed and applies it at the optimal moment
Solution Approach 2:
Cooling is applied periodically in a controlled sequence along the weld line rather than continuously across the entire line. The system activates cooling zones in a timed sequence that matches the progression of the welding heat, providing cooling only when and where needed to form proper crystalline structure while minimizing total cooling time
3Strength
If consolidation pressure is applied during welding to improve joint strength, then welding quality improves, but the complexity of the end effector increases
Solution Approach 1:
The consolidation pressure application is merged with the existing roller support structure. The rollers serve dual functions: providing mechanical support during welding and applying consolidation pressure through integrated pressure control. This eliminates the need for separate pressure application mechanisms, reducing end effector complexity while maintaining joint strength
Solution Approach 2:
The roller components are designed to perform multiple functions: supporting the workpiece, applying consolidation pressure, and potentially providing cooling. This multi-functionality reduces the number of separate components needed in the end effector, simplifying the overall device while ensuring proper joint strength through controlled pressure application
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves controlled heating and cooling, resulting in high-strength welds by maintaining the crystalline lattice structure of thermoplastic materials, enhancing joint integrity and stability.
Implementation Method 1
Heat for melting a TPC component matrix at a joint interface can be applied by various means, such as by induction welding
Implementation Method 2
at least one first cooling air jet positioned to direct a first stream of cooling air toward the at least one follower roller
Data Source
AI summary
An end effector for welding composite components includes an end effector housing and a welding member mounted to the end effector housing. The end effector further includes a leading roller mounted to the end effector housing forward of the welding member and at least one follower roller mounted to the end effector housing aft of the welding member. The end effector further includes at least one first cooling air jet positioned to direct a first stream of cooling air toward the at least one follower roller.