Stationary Induction Coil for Thermoplastic Composite Welding
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Solution Overview
Problem
Existing induction welding techniques for thermoplastic composite (TPC) parts are inefficient due to the need for robotic manipulators and fixed weld recipes, which are not optimized for unique part geometries or electrical requirements.
Innovation Solution
A method and apparatus where an induction coil is integrated into a tool and remains stationary, matching the geometry of the parts, allowing for simultaneous welding of all sections of the weld joint, eliminating the need for robotic programming and fixed weld recipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robotic manipulator is used to move the induction coil along the weld joint, then the welding process can be automated, but the time required for motion programming and manipulation increases
Solution Approach 1:
Instead of moving the induction coil along the weld joint using a robotic manipulator, the invention inverts the approach by keeping the induction coil stationary and moving the workpiece or tooling along the coil. This eliminates the need for complex manipulator programming while maintaining automation capability.
Solution Approach 2:
The welding process is segmented into discrete stations or positions along the weld joint, with the induction coil remaining stationary at each position while the workpiece is positioned and welded sequentially. This segmentation eliminates the need for continuous manipulator movement programming.
2Adaptability or versatility
If a generalized geometry induction coil is used, then the equipment is simpler and more versatile, but the weld quality and efficiency for specific part geometries deteriorates
Solution Approach 1:
The induction coil is designed with specific local geometries tailored to match the particular part shapes and weld requirements. Different coils with optimized geometries can be selected for different part types, ensuring optimal weld quality for each specific application while maintaining overall system versatility through coil interchangeability.
3Ease of manufacture
If a fixed weld recipe is used, then the process is simpler and more consistent, but the adaptability to unique electrical requirements and part geometries deteriorates
Solution Approach 1:
The welding process parameters are made dynamic and adjustable rather than fixed. The system allows real-time modification of weld recipes including current, voltage, and heating parameters to adapt to unique part geometries and electrical requirements while maintaining process consistency through controlled parameter changes.
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
This approach significantly reduces the time required for welding by allowing simultaneous welding of all sections of the weld joint, improving efficiency and adaptability to unique part geometries and electrical requirements.
Implementation Method 1
an induction coil to heat the parts to their melt temperature
Implementation Method 2
utilizes an induction coil to heat the parts to their melt temperature, fusing the parts together
Implementation Method 3
heat the parts to their melt temperature, fusing the parts together
Data Source
AI summary
Thermoplastic composite laminate parts are induction welded along a weld joint into an integrated structure using an induction coil. The induction coil remains stationary during the welding process and is integrated into a tool configured to match the parts.