CN107379561A - 一种汽车车灯的激光透射焊接装夹***及其方法 - Google Patents
一种汽车车灯的激光透射焊接装夹***及其方法 Download PDFInfo
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Abstract
本发明提供了一种汽车车灯的激光透射焊接装夹***及其方法,该***包括激光发射***、控制***和夹紧***;所述的激光发射***包括激光发射器、激光控制器和机械臂;所述的控制***包括激光控制器、计算机、气压控制***;所述的夹紧***包括上模、底座、夹头、连杆、高速气缸、抽气通孔、真空发生器、车灯灯罩和车灯灯体。本发明采用激光作为能量,通过均匀分布的夹紧装置提供均匀的夹紧力,通过夹紧***和控制***可以调节夹紧力的大小并控制各个夹头的夹紧动作,从而实现了汽车车灯的激光透射焊接,提高了车灯的焊接效率和焊接质量。
Description
技术领域
本发明属于激光加工制造及聚合物的激光透射焊接领域,特别涉及用于汽车车灯灯体和灯罩的激光透射焊接的装夹***及其方法。
背景技术
近年来随着能源短缺、环境污染等问题的日益凸显,各国政府及汽车制造商对汽车节能环保的要求越来越高,实现汽车的轻量化已经成为当前世界汽车产业发展的趋势。热塑性聚合物及其复合材料具有成品质量轻、物理特性优良、成本低廉、节能抗震等优点,是实现汽车轻量化的重要途径,利用热塑性塑料零部件替代金属零部件,可以同时满足减轻整车重量、减震降噪和降低成本等方面的需求。
而在实际工业应用中,由于注塑、挤出加工工艺等方面原因,很多形状和结构复杂的车用塑料产品不能一次成型,需要对其进行连接,比如说汽车车灯。传统的车灯连接方法主要是通过胶粘接、摩擦焊接、热板焊接和超声波焊接等工艺方法。虽然这些方法可以发挥一定的作用,然而均存在一定的缺陷。例如,焊接效率较低,质量不稳定和外来物质的引入等。而激光透射焊接相比于传统的连接方法有着诸多的优点,比如,无接触、速度快、精度高、连接强度高、热影响区域小等,同时焊接过程所产生的振动应力和热应力小,这对保证聚合物性能具有重要意义,特别是对于汽车车灯的精密连接,激光焊接的优势将更加凸显。
然而在实际应用中,由于汽车车灯的形状较为复杂,而且其焊接位置位于车灯四周最***,在车灯焊接过程中既要保证车灯灯体和灯罩的夹紧,又要保证在焊接过程中夹具不会阻挡激光照射到待焊位置处,这就给车灯的激光透射焊接夹紧装置带来了难题,解决这一难题无疑将会推动激光透射焊接在汽车车灯方面的广泛应用。
莱丹公司发明的Globo焊接装置比较巧妙,其焊接头部有一个玻璃球,这个玻璃球既能对激光束聚焦,又能施加压紧力,其主要优点是能够实现任意三维焊缝的焊接,但是它采用的是单个点接触,容易导致焊接后应力集中,此外该玻璃球长时间滚动摩擦容易导致玻璃球表面磨损,使玻璃球光学性能变差,所以,迫切需要一种能克服以上缺点的装置。
发明内容
本发明针对现有技术的不足,设计了一种激光透射焊接汽车车灯的装夹***及其焊接方法,它可以通过计算机控制各个夹紧装置的自动夹紧及卸载,保证夹紧力均匀分布,避免出现应力集中的现象,提高车灯焊接件的效率和质量,而且通过各个夹紧装置与激光发射器运动轨迹的随动配合,保证夹紧装置在焊接过程中不会阻碍激光照射到待焊接平面上,保证了车灯焊接件的准确性与密封性。
本发明通过以下技术手段实现上述技术目的。
一种汽车车灯的激光透射焊接装夹***,包括激光发射***、夹紧***和控制***;
所述激光发射***包括激光发射器、激光控制器和机械臂;所述激光控制器对激光发射器进行控制;所述激光发射器设置在机械臂上,通过机械臂的运动带动激光发射器,所述机械臂与计算机连接在一起,通过计算机来控制机械臂的运动,进而带动激光发射器实现三维焊接;
所述夹紧***包括真空装置和夹紧装置;
所述真空装置包括上板、抽气通孔Ⅱ、底座、抽气通孔Ⅰ和真空发生器;所述底座位于工作台上,底座上开设有空腔A和抽气通孔Ⅰ,且空腔A与抽气通孔Ⅰ相连通;抽气通孔Ⅰ与真空发生器输出端相连通;所述上板设置在底座上,并通过连接螺钉连接;上板上开设有与车灯形状相同的凹模A,车灯包括车灯灯体与灯罩;上板上与凹模A对应位置处开设有抽气通孔Ⅱ,且抽气通孔Ⅱ与空腔A相通;
所述夹紧装置包括夹头、橡胶垫、支撑座、连杆Ⅰ、连杆Ⅱ和高速气缸;所述支撑座一端垂直固定在上板上,支撑座另一端通过销轴与夹头相连接;所述夹头中间开有通槽B,夹头可以在支撑座上沿着通槽B的轨迹移动;
所述夹头与连杆Ⅰ的一端通过销柱相连接;连杆Ⅰ的另一端与连杆Ⅱ一端均通过销轴连接到高速气缸上。
优选的,所述上板和底座之间设置有密封圈。
优选的,所述夹头与车灯灯罩之间设置有橡胶垫。
优选的,所述车灯灯罩为透光性较好的热塑性塑料,车灯灯体为吸光性较好的热塑性塑料。
优选的,所述夹紧装置有数个,且均匀分布在车灯灯罩的四周。
优选的,所述计算机与电磁阀、压力阀连接在一起,通过控制电磁阀来实现高速气缸的工作状态,通过压力阀控制高速气缸进而调节夹头施加压力的大小。
基于一种汽车车灯的激光透射焊接装夹***的焊接方法,具体包括如下步骤:
S1、接通电源,将计算机和激光控制器打开;
S2、将车灯灯体放置在上板的凹模A处,打开真空发生器,通过抽气通孔Ⅰ在底座的空腔处产生真空,并通过抽气通孔Ⅱ利用负压将车灯灯体固定在上板的凹模A处;
S3、将车灯灯罩放置在车灯灯体的上方,利用计算机控制压力阀和电磁阀,从而控制所有夹紧装置的高速气缸的活塞杆伸出,通过连杆Ⅰ和连杆Ⅱ的配合,推动夹头向下运动,对车灯灯体和车灯灯罩施加一定的夹紧力,完成夹紧过程;
S4、通过计算机控制机械臂运动到夹紧装置A和夹紧装置B的中间位置处,并控制夹紧装置B的电磁阀使得夹紧装置B的高速气缸活塞杆收回,通过连杆Ⅰ和Ⅱ的配合,将夹紧装置B的夹头拉回,避免夹紧装置B遮挡激光影响车灯的焊接,此时,除夹紧装置B之外,其他夹紧装置的夹头都处于施加夹紧力的状态;
S5、通过激光控制器设置焊接所需要的激光功率并打开激光发射器,输出激光能量,与此同时,通过对计算机编程控制机械臂沿着车灯指定的待焊接位置做三维运动,焊接过程从夹紧装置A和夹紧装置B的中间位置处开始;
S6、当机械臂带动激光发射器焊接到夹紧装置B和夹紧装置C的中间位置处,此时计算机控制电磁阀使得夹紧装置B的高速气缸伸出并带动夹头施加夹紧力、夹紧装置C的高速气缸收回并带动夹头拉回卸载夹紧力,以避免当激光发射器焊接到位置C时,夹紧装置C的夹头对激光的阻碍;
S7、以此类推,各夹紧装置的夹头随着机械臂带动激光发射器运动而不断地完成施压和卸压,保证各夹紧装置的夹头不会阻挡激光照射到所需的焊接平面,当激光发射器运动到焊接起始位置即夹紧装置A和B的中间位置处时,车灯的激光透射焊接完成;
S8、通过激光控制器关闭激光发射器,通过计算机控制所有电磁阀使得所有夹紧装置的高速气缸收回、夹头抬起,完成夹紧力的卸载,并关闭真空发生器,卸载负压对车灯灯体的吸引力,取下焊接在一起的车灯,完成焊接,由此进入下一个车灯的激光透射焊接周期。
本发明的有益效果是:
利用激光作为能量,通过计算机-电磁阀-压力阀控制夹紧装置的高速气缸运动,并配合连杆Ⅰ和Ⅱ,控制夹头的施压和卸载,完成车灯焊接过程所需要的夹紧力;利用夹紧装置的随动原理,保证焊接位置处夹紧装置的夹头始终不会阻碍激光照射到车灯所需的待焊接位置,并且多个夹紧装置均匀分布在车灯四周,保证车灯焊接的可靠性。本发明的夹紧装置均通过计算机控制,可以大大节省人力,提高焊接效率和焊接质量。
附图说明
图1为本发明一种汽车车灯的激光透射焊接装夹***的结构示意图;
图2为本发明中夹紧装置的结构示意图;
图3为本发明中车灯和各个夹紧装置的位置分布的俯视图。
图中:
1-工作台;2-底座;3-抽气通孔Ⅰ;4-密封圈;5-连接螺钉;6-上板;7-电磁阀;8-压力阀;9-激光发射器;10-计算机;11-激光控制器;12-车灯灯罩;13-车灯灯体;14-抽气通孔Ⅱ;15-橡胶垫;16-夹头;17-支撑座;18-连杆Ⅰ;19-连杆Ⅱ;20-高速气缸。
具体实施方式
下面结合附图以及具体实施例对本发明作进一步的说明,但本发明的保护范围并不限于此。
结合附图1所示,一种汽车车灯的激光透射焊接装夹***,包括激光发射***、夹紧***和控制***;
所述的激光发射***包括激光发射器9、激光控制器11和机械臂;所述激光控制器11对激光发射器9进行控制;所述的激光发射器9位于机械臂上,通过机械臂的运动带动激光发射器9实现车灯的三维焊接;
所述的夹紧***包括真空装置和夹紧装置;
所述的真空装置是包括上板6、抽气通孔Ⅱ14、底座2、抽气通孔Ⅰ3和真空发生器;所述的底座2位于工作台1上,中间开有空腔,左侧开有抽气通孔Ⅰ3,并连接真空发生器,通过“真空发生器-抽气通孔Ⅰ3-空腔-抽气通孔Ⅱ14”产生的负压将车灯灯体13固定在上板6;所述的上板6的中间部分设计为车灯灯体13的凹模,并在上板6与车灯灯体13接触部分开有抽气通孔Ⅱ14,通过连接螺钉将上板6和底座2连接在一起,并在两者之间放置有密封圈4保证底座2的空腔的密封性;
车灯***包括车灯灯罩12和车灯灯体13;车灯灯罩12为透光性较好的热塑性塑料;所述的车灯灯体13为吸光性较好的热塑性塑料,并放置于上板6的凹模处。
所述的控制***包括计算机10、电磁阀7、压力阀8和激光控制器11;所述的计算机10与电磁阀7、压力阀8连接在一起,通过控制电磁阀7来实现高速气缸20的工作状态,通过压力阀8控制高速气缸20进而调节夹头16施加的夹紧力的大小;所述的机械臂与计算机10连接在一起,通过计算机10来控制机械臂的运动,进而带动激光发射器9实现车灯的三维焊接。
结合附图2所示,所述的夹紧装置是由夹头16、橡胶垫15、支撑座17、连杆Ⅰ18、连杆Ⅱ19和高速气缸20组成的;夹头16中间开有通槽,通过销柱与支撑座17连接,并保证夹头16在支撑座17上可以沿着通槽轨迹移动;所述的橡胶垫15位于夹头16下方;连杆Ⅰ18与夹头16通过销柱连接;连杆Ⅰ18、连杆Ⅱ19与高速气缸20也通过销柱连接在一起。
结合附图3所示,多个夹紧装置(编号A-X)均匀分布在车灯的四周,以保证施加夹紧力的均匀性。
一种汽车车灯的激光透射焊接装夹***的方法,具体包括以下步骤:
S1、接通电源,将计算机10和激光控制器11打开;
S2、将车灯灯体13放置在上板6的凹模处,打开真空发生器,通过抽气通孔Ⅰ3在底座2的空腔处产生真空,并通过抽气通孔Ⅱ14利用负压将车灯灯体13固定在上板6的凹模处;
S3、将车灯灯罩12放置在车灯灯体13的上方,利用计算机10-压力阀8-电磁阀7控制所有夹紧装置(编号A-X)的高速气缸20的活塞杆伸出,通过连杆Ⅰ18和连杆Ⅱ19的配合,推动夹头16向下运动,对车灯灯体13和灯罩12施加一定的夹紧力,完成夹紧过程;
S4、通过计算机10控制机械臂运动到夹紧装置A和B的中间位置处,并控制夹紧装置B的电磁阀7使得B的高速气缸20活塞杆收回,通过连杆Ⅰ18和Ⅱ19的配合,将夹紧装置B的夹头16拉回,避免夹紧装置B遮挡激光影响车灯的焊接(此时,除夹紧装置B之外,其他夹紧装置的夹头16都处于施加夹紧力的状态);
S5、通过激光控制器11设置焊接所需要的激光功率并打开激光发射器9,输出激光能量,与此同时,通过对计算机10编程控制机械臂沿着车灯指定的待焊接位置做三维运动,焊接过程从夹紧装置A和B的中间位置处开始;
S6、当机械臂带动激光发射器9焊接到夹紧装置B和夹紧装置C的中间位置处,计算机10控制电磁阀7使得B的高速气缸20伸出并带动夹头16施加夹紧力、夹紧装置C的高速气缸20收回并带动夹头16拉回卸载夹紧力(此时,除夹紧装置C之外,其他夹紧装置的夹头16都处于施加夹紧力的状态),以避免当激光发射器9焊接到位置C时,夹紧装置C的夹头16对激光的阻碍;
S7、以此类推,各夹紧装置的夹头16随着机械臂带动激光发射器9运动而不断地完成施压和卸压,保证各夹紧装置的夹头16不会阻挡激光照射到所需的焊接平面,当激光发射器9运动到焊接起始位置(夹紧装置A和B的中间位置处)时,车灯的激光透射焊接完成;
S8、通过激光控制器11关闭激光发射器9,通过计算机10控制所有电磁阀7使得所有夹紧装置的高速气缸20收回、夹头16抬起,完成夹紧力的卸载,并关闭真空发生器,卸载负压对车灯灯体13的吸引力,取下焊接在一起的车灯,完成焊接,由此进入下一个车灯的激光透射焊接周期。
本发明中设计的一种汽车车灯的激光透射焊接装夹装置,通过计算机控制夹紧装置自动施加夹紧力,提高了工作效率,而且利用夹紧装置的随动原理,保证焊接位置处夹紧装置的夹头始终不会阻碍激光照射到车灯所需的待焊接位置,并且多个夹紧装置均匀分布在车灯四周,保证车灯焊接的可靠性。
所述实施例为本发明的优选的实施方式,但本发明并不限于上述实施方式,在不背离本发明的实质内容的情况下,本领域技术人员能够做出的任何显而易见的改进、替换或变型均属于本发明的保护范围。
Claims (7)
1.一种汽车车灯的激光透射焊接装夹***,其特征在于,包括激光发射***和夹紧***;
所述激光发射***包括激光发射器(9)、激光控制器(11)和机械臂;所述激光控制器(11)对激光发射器(9)进行控制;所述激光发射器(9)设置在机械臂上,通过机械臂的运动带动激光发射器(9),所述机械臂与计算机(10)连接在一起,通过计算机(10)来控制机械臂的运动,进而带动激光发射器(9)实现三维焊接;
所述夹紧***包括真空装置和夹紧装置;
所述真空装置包括上板(6)、抽气通孔Ⅱ(14)、底座(2)、抽气通孔Ⅰ(3)和真空发生器;所述底座(2)位于工作台(1)上,底座(2)上开设有空腔A和抽气通孔Ⅰ(3),且空腔A与抽气通孔Ⅰ(3)相连通;抽气通孔Ⅰ(3)与真空发生器输出端相连通;所述上板(6)设置在底座(2)上,并通过连接螺钉(5)连接;上板(6)上开设有与车灯形状相同的凹模A,车灯包括车灯灯体(13)与车灯灯罩(12);上板(6)上与凹模A对应位置处开设有抽气通孔Ⅱ(14),且抽气通孔Ⅱ(14)与空腔A相通;
所述夹紧装置包括夹头(16)、橡胶垫(15)、支撑座(17)、连杆Ⅰ(18)、连杆Ⅱ(19)和高速气缸(20);所述支撑座(17)一端垂直固定在上板(6)上,支撑座(17)另一端通过销轴与夹头(16)相连接;所述夹头(16)中间开有通槽B,夹头(16)可以在支撑座(17)上沿着通槽B的轨迹移动;所述夹头(16)与连杆Ⅰ(18)的一端通过销柱相连接;连杆Ⅰ(18)的另一端与连杆Ⅱ(19)一端均通过销轴连接到高速气缸(20)上。
2.根据权利要求1所述的一种汽车车灯的激光透射焊接装夹***,其特征在于,所述上板(6)和底座(2)之间设置有密封圈(4)。
3.根据权利要求1所述的一种汽车车灯的激光透射焊接装夹***,其特征在于,所述夹头(16)与车灯灯罩(12)之间设置有橡胶垫(15)。
4.根据权利要求1所述的一种汽车车灯的激光透射焊接装夹***,其特征在于,所述车灯灯罩(12)为透光性较好的热塑性塑料,车灯灯体(13)为吸光性较好的热塑性塑料。
5.根据权利要求1所述的一种汽车车灯的激光透射焊接装夹***,其特征在于,所述夹紧装置有数个,且均匀分布在车灯灯罩(12)的四周。
6.根据权利要求1所述的一种汽车车灯的激光透射焊接装夹***,其特征在于,所述计算机(10)与电磁阀(7)、压力阀(8)连接在一起,通过控制电磁阀(7)来实现高速气缸(20)的工作状态,通过压力阀(8)控制高速气缸(20)进而调节夹头(16)施加压力的大小。
7.根据权利要求1至6任一项所述的基于一种汽车车灯的激光透射焊接装夹***的焊接方法,其特征在于,具体包括如下步骤:
S1、接通电源,将计算机(10)和激光控制器(11)打开;
S2、将车灯灯体(13)放置在上板(6)的凹模A处,打开真空发生器,通过抽气通孔Ⅰ(3)在底座(2)的空腔处产生真空,并通过抽气通孔Ⅱ(14)利用负压将车灯灯体(13)固定在上板(6)的凹模A处;
S3、将车灯灯罩(12)放置在车灯灯体(13)的上方,利用计算机(10)控制压力阀(8)和电磁阀(7),从而控制所有夹紧装置的高速气缸(20)的活塞杆伸出,通过连杆Ⅰ(18)和连杆Ⅱ(19)的配合,推动夹头(16)向下运动,对车灯灯体(13)和车灯灯罩(12)施加一定的夹紧力,完成夹紧过程;
S4、通过计算机(10)控制机械臂运动到夹紧装置A和夹紧装置B的中间位置处,并控制夹紧装置B的电磁阀(7)使得夹紧装置B的高速气缸(20)活塞杆收回,通过连杆Ⅰ(18)和Ⅱ(19)的配合,将夹紧装置B的夹头(16)拉回,避免夹紧装置B遮挡激光影响车灯的焊接,此时,除夹紧装置B之外,其他夹紧装置的夹头(16)都处于施加夹紧力的状态;
S5、通过激光控制器(11)设置焊接所需要的激光功率并打开激光发射器(9),输出激光能量,与此同时,通过对计算机(10)编程控制机械臂沿着车灯指定的待焊接位置做三维运动,焊接过程从夹紧装置A和夹紧装置B的中间位置处开始;
S6、当机械臂带动激光发射器(9)焊接到夹紧装置B和夹紧装置C的中间位置处,此时计算机(10)控制电磁阀(7)使得夹紧装置B的高速气缸(20)伸出并带动夹头(16)施加夹紧力、夹紧装置C的高速气缸(20)收回并带动夹头(16)拉回卸载夹紧力,以避免当激光发射器(9)焊接到位置C时,夹紧装置C的夹头(16)对激光的阻碍;
S7、以此类推,各夹紧装置的夹头(16)随着机械臂带动激光发射器(9)运动而不断地完成施压和卸压,保证各夹紧装置的夹头(16)不会阻挡激光照射到所需的焊接平面,当激光发射器(9)运动到焊接起始位置即夹紧装置A和夹紧装置B的中间位置处时,车灯的激光透射焊接完成;
S8、通过激光控制器(11)关闭激光发射器(9),通过计算机(10)控制所有电磁阀(7)使得所有夹紧装置的高速气缸(20)收回、夹头(16)抬起,完成夹紧力的卸载,并关闭真空发生器,卸载负压对车灯灯体(13)的吸引力,取下焊接在一起的车灯,完成焊接,由此进入下一个车灯的激光透射焊接周期。
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