CN107471653A - 使用超声波脉冲检视和修理粘接剂连结的接头 - Google Patents

使用超声波脉冲检视和修理粘接剂连结的接头 Download PDF

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CN107471653A
CN107471653A CN201710426540.XA CN201710426540A CN107471653A CN 107471653 A CN107471653 A CN 107471653A CN 201710426540 A CN201710426540 A CN 201710426540A CN 107471653 A CN107471653 A CN 107471653A
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joint
bonding agent
coverage
ultrasonic
workpiece
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CN107471653B (zh
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P-C.王
J.F.阿里内兹
S.M.史密斯
Z.刘
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GM Global Technology Operations LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8292—Testing the joint by the use of ultrasonic, sonic or infrasonic waves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/951—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/24—Apparatus or accessories not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/24—Apparatus or accessories not otherwise provided for
    • B29C73/30—Apparatus or accessories not otherwise provided for for local pressing or local heating
    • B29C73/34—Apparatus or accessories not otherwise provided for for local pressing or local heating for local heating
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22—Details, e.g. general constructional or apparatus details
    • G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
    • G01N29/265—Arrangements for orientation or scanning by relative movement of the head and the sensor by moving the sensor relative to a stationary material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/0261—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using ultrasonic or sonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B29C65/782—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined
    • B29C65/7823—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint
    • B29C65/7826—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint said distance pieces being non-integral with the parts to be joined, e.g. particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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Abstract

一种检视和修理组件中接头的方法。通过第一工件和第二工件形成接头。粘接剂置于第一和第二工件之间以限定接头。组件包括超声波焊接装置，其包括配置为将超声波能量输送到接头的超声波焊炬。控制器操作性地连接到超声波焊接装置。控制器包括处理器和实体的非瞬时存储器，在该存储器上记录有指令，所述指令用于执行检视和修理粘接剂连结的接头的方法。控制器被编程为经由超声波焊接装置将第一超声波脉冲(P1)输送到接头，且至少部分地第一超声波脉冲(P1)确定粘接剂覆盖度(AC)。

Description

使用超声波脉冲检视和修理粘接剂连结的接头
技术领域
本发明通常涉及使用超声波脉冲检视和修理粘接剂连结的接头。
背景技术
在许多行业，采用粘接剂连结来将许多不同类型的材料连结在一起。例如，粘接剂连结用于连结聚合物复合物，其是轻质的、顺应的且耐久的。所采用的粘接剂可以具有随时间消失的部分。期望用于确定粘接剂连结的接头的状态的检视方法，其包括随后对有缺陷的接头进行修理。
发明内容
一种检视和修理组件中接头的方法。通过第一工件和第二工件形成接头。粘接剂置于第一和第二工件之间以限定接头。组件包括超声波焊接装置，其包括配置为将超声波能量输送到接头的超声波焊炬。控制器操作性地连接到超声波焊接装置。控制器包括处理器和实体的非瞬时存储器，在该存储器上记录有指令，所述指令用于执行检视和修理粘接剂连结的接头的方法。控制器被编程为经由超声波焊接装置将第一超声波脉冲(P1)输送到接头，且至少部分地基于第一超声波脉冲(P1)确定粘接剂覆盖度(AC)。
第一工件和第二工件可以由相同材料构成。第一工件和第二工件可以由不同的材料构成。至少一个传感器可以操作地连接到控制器且配置为测量超声波焊炬在接头中的位移深度。确定粘接剂覆盖度(AC)包括确定粘接剂是否固化。如果粘接剂未固化，则控制器被编程为在输送第一超声波脉冲(P1)之后经由至少一个传感器获得超声波焊炬在接头中的位移深度。如果粘接剂未固化，则控制器被编程为至少部分地基于位移深度和第一查找表获得用于接头的粘接剂覆盖度(AC)。如果粘接剂固化，则确定粘接剂覆盖度(AC)包括获得通过第一超声波脉冲(P1)输送到接头的能量和至少部分地基于通过接头输送的能量和第二查找表获得粘接剂覆盖度(AC)。
控制器可以进一步被编程为确定粘接剂覆盖度(AC)是否等于或低于预定临界覆盖度(TC)。如果粘接剂覆盖度(AC)等于或低于临界覆盖度(TC)，则控制器被编程为至少部分地基于粘接剂覆盖度(AC)和第三查找表确定第二超声波脉冲(P2)的能量。
如果粘接剂覆盖度(AC)等于或低于临界覆盖度(TC)，则控制器被编程为在挤压力下经由超声波焊接装置对接头输送第二超声波脉冲(P2)，以在接头处形成焊接部，由此修理接头。预定临界覆盖度(TC)可以被选择为使得处于临界覆盖度的未修理的连结接头接的头强度(SU，TC)小于或等于处于临界覆盖度的经修理焊接接头的接头强度(SR，TC)，[SU，TC≤SR，TC]。预定临界覆盖度可以为50％。
在下文结合附图进行的对实施本发明的较佳模式做出的详尽描述中能容易地理解上述的本发明的特征和优点以及其他的特征和优点。
附图说明
图1是接头组件的示意性部分视图，所述接头组件具有控制器、第一工件、第二工件和将第一和第二工件连结的粘接剂，其显示了第一超声波脉冲的施加；
图2是图1的粘接剂的示意性俯视图；
图3是图1的接头组件的示意性部分视图，其显示了第二超声波脉冲的施加；
图4是存储在图1的控制器上且通过其执行的方法的流程图；和
图5是针对给定接头构造在垂直轴线上显示接头强度(磅)和在水平轴线上显示粘接剂覆盖度百分比的示例示图。
具体实施方式
参见附图，其中相同的附图标记表示相同的部件，图1是组件10的示意图，其可以采取许多不同的形式且包括多个和/或替换的部件。参见图1，组件10包括第一工件12和第二工件14。第一工件12和第二工件14可以由相同材料构成。第一工件12和第二工件14可以由不同的材料构成。第一工件12可以由碳纤维尼龙复合材料构成且第二工件14可以由尼龙构成。在一个例子中，第一工件12和第二工件14两者由热塑性塑料构成。在另一例子中，第一工件12由热朔性塑料构成且第二工件14由金属构成。在另一例子中，第一工件12和第二工件14两者由金属构成。间隔件16(例如能量指示器(director)可以定位在第一工件12和第二工件14之间以形成间隙17。如图1所示，粘接剂18定位在第一工件12和第二工件14之间，以连结第一和第二工件12、14和限定粘接剂连结的部分20，在本文称为“接头20”。
图2是粘接剂18的示意性俯视图。在施加时，粘接剂18在图2的示为“TA”的“总区域”上铺展。尽管总区域TA在所示的例子中是长方形的，但是其可以按照需要具有任何形状或尺寸。出于各种原因，粘接剂18的一些部分会随着时间而损失，如图2所示的，成为消失部分22。总区域TA中消失部分22的尺寸、形状和位置可以基于当前应用来选择。总区域TA的仍然具有粘接剂18的其余部分被标记为粘接剂覆盖度(adhesive coverage:AC)(用浅阴影示出)。
参见图1，组件10包括超声波焊接装置24。超声波焊接装置24配置为对接头20施加超声波振动。超声波焊接装置24可以包括超声波焊炬26、换能器28和放大器30。电源32可以操作地连接到超声波焊接装置24。超声波焊接装置24可以包括适用于超声波焊接装置24的其他电子部件或声部件。
参见图1，换能器28可以配置为将电源32的输出电压转换为机械振动或振幅。该振动可以通过放大器30发送，所述放大器可增加或减少从换能器28而来的机械振动。超声波焊炬26配置为有效地将声能量从换能器28(经由放大器30)传输到接头20。
参见图1，超声波焊接装置24配置为输送第一超声波脉冲P1到接头20。超声波焊炬26接触第一工件12，且超声波焊接装置24被赋能并经过预定时间段。第一超声波脉冲P1使得第一和第二工件12、14局部熔化，且由于在相接界面处产生的热量而分解(或降解)粘接剂18。取决于粘接剂18的状态，通过超声波振动产生的热量会使得超声波焊炬26移位或“下沉”到接头20中。组件10可以包括深度传感器34，其操作性地连接到控制器40且配置为测量超声波焊炬26在接头20中的位移深度(图1中标记为“D”)。
图3是将第二超声波脉冲P2施加到接头20的示意性部分视图。超声波焊炬26接触第一工件12。随后，超声波焊接装置24被赋能并经过预定时间段，以使得超声波能量向接头20传输且最终造成局部熔化。第一和第二工件12、14在挤压力F下被保持在超声波焊炬26和固定砧36之间并经过短暂停留时段，由此允许软化的局部材料变得刚性且形成焊接部38。
参见图1，控制器40操作性地连接到超声波焊接装置24。控制器40包括处理器42和实体的非瞬时的存储器44，在该存储器上记录有用于执行检视和修理(粘接剂连结的)接头20的方法100的指令，在下文参考图4描述该方法。方法100可以包括基于检视结果修理有缺陷的接头。有缺陷的接头被限定为与目标构造或覆盖度有不期望的差异或不满足目标机械性能(例如强度或疲劳寿命)的接头20。
图1的控制器40可以包括其他驱动器电路(未示出)和用于控制超声波焊接装置24的其他部件。超声波焊炬26可以形成有适于当前应用的形状、截面和长度。超声波焊炬26的长度被选择为使得在期望的超声波操作频率下存在机械共振。通过换能器28产生的超声的具体频率可以基于应用而改变。超声振动的频率可以是15到300kHz。
现在参见图4，显示了存储在通过图1的控制器40上且被所述控制器执行的方法100的流程图。方法100的开始和结束分别通过“S”和“E”表示。方法100不需要按照本文所述的顺序执行，且应理解可以消除一些步骤。方法100的执行以多种方式改善组件10的功能。
方法100可以在图块102开始。在图块102，控制器40被编程为经由超声波焊接装置24输送第一超声波脉冲(P1)到接头20。如图2A所示，第一超声波脉冲(P1)使得第一和第二工件12、14局部熔化，且由于超声波振动能量的吸收而使得粘接剂18分解(或降解)。第一超声波脉冲(P1)配置为使得例如在强度不足时不在接头20处形成焊接部。
在图块104，控制器40被编程为至少部分地基于第一超声波脉冲(P1)确定接头20的粘接剂覆盖度(AC)。图块104包括下文所述的子图块106、108、110、112和114。在子图块106中，控制器40被编程为确定粘接剂18是否固化。固化被限定为一过程，例如化学反应或物理动作，其形成更强的粘接剂连结。粘接剂连结可以经由烘烤步骤固化，其中粘接剂18经历升高的温度并经过预定量的时间。控制器40可以确定粘接剂18是否通过本领域技术人员可用的方法固化。例如，用户通过视觉检视或对接头20历史的得知而确定这一点，且将该信息经由用户界面52(见图1)传输到控制器40。还有，可以使用本领域技术人员可用的物理测试来确定粘接剂18的状态，包括但不限于接头强度或超声波焊炬26的位移深度D。
如果粘接剂18未固化，则方法100从子图块106前进到子图块108，其中控制器40被编程为获得在第一超声波脉冲(P1)输送之后超声波焊炬26在接头20中的位移深度D。位移深度D的测量经由深度传感器34做出。如上所述超声波焊炬26的位移深度(图1中的D)的测量还可以用于在子图块106中识别粘接剂18的状态。对于给定的超声波脉冲能量，固化的粘接剂18的深度位移D将小于不固化的粘接剂18。
方法100随后前进到子图块110，其中控制器40被编程为至少部分地基于位移深度D(来自图块108)和第一查找表而获得用于接头20的粘接剂覆盖度(AC)。第一查找表(和下文所述的第二和第三查找表)的值可以经由校准或在测试单元或实验室中获得。第一、第二和第三查找表可以是数据资源库或存储介质的类型。插补法可以用于确定相应查找表中数据点之间的值。第一查找表的非限制性例子显示在以下表格1中：
表格1
位移深度(mm) 粘接剂覆盖度(AC)(％)
0.14 0
0.20 42
0.26 85
0.33 95
0.42 100
如果粘接剂18固化，则方法100从子图块106前进到子图块112，控制器40被编程为获得通过第一超声波脉冲(P1)对接头20的能量输送(ED)。到接头20的能量输送(ED)可以至少部分地基于输送到接头20的功率(例如经由随时间对输送的功率进行积分)来获得。电源32可以以其可输送的峰值功率为额定，其可以从数百瓦特变化到数千瓦特。基于恒定的功率输出，从1.5-kW超声波焊接装置而来的0.5秒的脉冲将输送750焦耳的能量。组件10可以包括电压传感器48和电流传感器50，以分别估定输送到超声波焊接装置24的电压和电流。组件10可以包括其他传感器或采用其他方法或本领域技术人员可用的模型来获得通过第一超声波脉冲(P1)对接头20的能量输送(ED)。
方法100前进到子图块114，其中控制器40被编程为至少部分地基于对接头20的能量输送(ED)和第二查找表来获得粘接剂覆盖度(AC)。第二查找表的值可经由校准或在测试单元或实验室中获得。第二查找表的例子显示在如下的表格2中：
表格2
输送的能量 粘接剂覆盖度(AC)％
ED1 0
ED2 25
ED3 50
ED4 75
ED5 100
在图块116中，控制器40被编程为确定粘接剂覆盖度(AC)是否等于或低于预定临界覆盖度(TC)。预定临界覆盖度(TC)可以针对当前应用选择。预定临界覆盖度(TC)可以被选择为使得，处于临界覆盖度的未修理的连结接头的接头强度(SU，TC)小于或等于处于临界覆盖度的经修理焊接接头的接头强度(SR，TC)，[SU，TC≤SR，TC]。图5是示例性视图，其在垂直轴线上显示了接头强度“JS”(以磅计)和在水平轴线上显示了粘接剂覆盖度百分比。图5是出于展示的目的而显示的，且目的是作为非限制性例子。参见图5，在25％、50％、75％和100％的粘接剂覆盖度下未修理的连结接头的接头强度分别为约1100、1700、1900和2200磅。参见图5，在25％、50％、75％和100％的粘接剂覆盖度下经修理焊接(之前连结且随后经由超声波脉冲焊接修理)接头的接头强度分别为约1700、1700、1800和1700磅。在该例子中，预定临界覆盖度(TC)可以被设定为50％。
如果粘接剂覆盖度(AC)高于临界覆盖度(TC)，则方法结束。如果粘接剂覆盖度(AC)等于或低于临界覆盖度(TC)，方法前进到图块118，其中控制器40被编程为至少部分地基于粘接剂覆盖度(AC)和第三查找表来确定第二超声波脉冲(P2)的能量。第二超声波脉冲(P2)的能量需要具有足够的强度，以在接头20处形成焊接部38。第三查找表的例子显示在如下的表格3中：
表格3
粘接剂覆盖度(AC)％ 第二脉冲的能量(P2)(焦耳)
0 E1
25 E2
50 E3
75 E4
在图块118，控制器40被编程为在挤压力F下经由超声波焊接装置24输送第二超声波脉冲(P2)到接头20。第二超声波脉冲(P2)的施加将第一和第二工件12、14和粘接剂18之间的接合界面处的一些位置熔化，由此修复接头20，以达到期望的接头强度。
图1的控制器40可以包括用于控制超声波焊接装置24的驱动电路(未示出)。参见图1-2，控制器40可包括相应的计算机可读介质(也称为处理器可读介质)，包括非瞬时(例如实体的)介质，其实施为提供可以被计算机(例如被计算机的处理器)读取的数据(例如指令)。这种介质可以采取许多形成，包括但不限于，非易失介质和易失介质。非易失介质可以包括例如光盘或磁盘和其他永久存储器。易失介质可以包括例如动态随机存储器(DRAM)，其可以构成主存储器。这种指令可以通过一个或多个传递介质传递，包括同轴线缆、铜导线和光学纤维，其包括含有联接到计算机处理器的***总线的导线。一些形式的计算机可读介质包括例如软盘、柔性盘、硬盘、磁带、其他介质、CD-ROM、DVD、其他光学介质、打孔卡、纸带、具有孔样式的其他物理介质、RAM、PROM、EPROM、FLASH-EEPROM、其他存储芯片或卡带、或计算机可读的其他介质。
本文所述的查找表、数据库、数据存储库或其他类型的数据存储形式包括各种用于存储、访问和获取各类数据的机制，包括分层的数据库、文件***中的一组文件、专用格式的应用数据库、相关的数据库管理***(RDBMS)，等。每一个这样的数据存储可以包括在采用计算机操作***的计算装置中，例如如上所述的那些中的一个，且可以以各类方式中一个或多个经由网络访问。文件***可以从计算机操作***访问，且可以包括存储为各种格式的文件。除了用于形成、存储、编辑、和执行存储程序的语言外，RDBMS可以使用结构化查询语言(SQL)，例如上述PL/SQL语言。
附图中的详细的描述和显示是对本发明的支持和描述，而本发明的范围仅通过权利要求限定。尽管已经对执行本发明的较佳模式进行了详尽的描述但是本领域技术人员可得知在所附的权利要求的范围内的用来实施本发明的许多替换设计和实施例。进而，附图所示的实施例或本发明说明书提到的各种实施例的特点不应被理解为是彼此独立的实施例。相反，实施例的一个例子中所述的每一个特点可以与其他实施例的一个或多个其他期望特点组合，形成并未参考附图所述的其他实施例因而，这种其他实施例落入所附权利要求的范围。
相关申请的交叉引用
本申请要求2016年6月8日提交的美国临时专利申请No.62/347,371的权益，其公开内容通过引用合并于此。

Claims (10)

1.一种配置为检视和修理接头的组件，所述接头通过第一工件、第二工件、和置于第一和第二工件之间以限定接头的粘接剂形成，所述组件包括：
超声波焊接装置，包括超声波焊炬，所述超声波焊炬配置为将超声波能量输送到接头；
控制器，操作性地连接到所述超声波焊接装置；
其中，所述控制器包括处理器和实体的非瞬时存储器，在所述存储器上记录有用于执行检视和修理粘接剂连结的接头的方法的指令；
其中，所述控制器被编程为：
将第一超声波脉冲(P1)经由所述超声波焊接装置输送到接头；和
至少部分地基于所述第一超声波脉冲(P1)确定粘接剂覆盖度(AC)。
2.一种检视和修理组件中的接头的方法，所述组件具有超声焊接装置、第一工件、第二工件、和将第一和第二工件连结以限定接头的粘接剂，所述方法包括：
将第一超声波脉冲(P1)经由所述超声波焊接装置输送到接头；
至少部分地基于所述第一超声波脉冲(P1)确定接头的粘接剂覆盖度(AC)；
确定粘接剂覆盖度(AC)是否等于或低于预定临界覆盖度(TC)；
如果粘接剂覆盖度(AC)等于或低于临界覆盖度，则至少部分地基于粘接剂覆盖度(AC)确定第二超声波脉冲(P2)的能量；和
如果粘接剂覆盖度(AC)等于或低于临界覆盖度，则在挤压力下经由所述超声波焊接装置对接头施加第二超声波脉冲(P2)，以在接头处形成焊接部，由此修理接头。
3.如权利要求2所述的方法，其中，所述确定接头的粘接剂覆盖度(AC)包括：
确定粘接剂是否固化；
如果粘接剂未固化，则在输送所述第一超声波脉冲(P1)之后经由至少一个传感器获得超声波焊炬在接头中的位移深度；和
如果粘接剂未固化，则至少部分地基于位移深度和第一查找表获得用于接头的粘接剂覆盖度(AC)。
4.如权利要求2所述的方法，其中，所述确定粘接剂覆盖度(AC)包括：
确定粘接剂是否固化；
如果粘接剂固化，则获得通过所述第一超声波脉冲(P1)输送到接头的能量，且至少部分地基于通过接头输送的能量和第二查找表获得粘接剂覆盖度(AC)。
5.一种配置为检视和修理接头的组件，所述接头通过第一工件、第二工件、和置于第一和第二工件之间以限定接头的粘接剂形成，所述组件包括：
超声波焊接装置，包括超声波焊炬，所述超声波焊炬配置为将超声波能量输送到接头；
控制器，操作性地连接到所述超声波焊接装置；
至少一个传感器，操作性地连接到所述控制器且配置为测量超声波焊炬在接头中的位移深度；
其中，所述控制器包括处理器和实体的非瞬时存储器，在该存储器上记录有用于执行检视和修理粘接剂连结的接头的方法的指令；
其中，所述控制器被编程为：
将第一超声波脉冲(P1)经由所述超声波焊接装置输送到接头；和
至少部分地基于所述第一超声波脉冲(P1)确定粘接剂覆盖度(AC)，包括确定粘接剂是否固化。
6.如权利要求5所述的组件，其中，所述确定粘接剂覆盖度(AC)包括：
如果粘接剂未固化，则在输送第一超声波脉冲(P1)之后经由至少一个传感器获得超声波焊炬在接头中的位移深度；和
如果粘接剂未固化，则至少部分地基于位移深度和第一查找表获得用于接头的粘接剂覆盖度(AC)。
7.如权利要求6所述的组件，其中，所述确定粘接剂覆盖度(AC)包括：
如果粘接剂固化，则获得通过第一超声波脉冲(P1)输送到接头的能量，且至少部分地基于通过接头输送的能量和第二查找表获得粘接剂覆盖度(AC)。
8.如权利要求7所述的组件，其中，所述控制器进一步被编程为:
确定粘接剂覆盖度(AC)是否等于或低于预定临界覆盖度(TC)；
如果粘接剂覆盖度(AC)等于或低于临界覆盖度(TC)，则至少部分地基于粘接剂覆盖度(AC)和第三查找表确定第二超声波脉冲(P2)的能量。
9.如权利要求8所述的组件，其中，所述控制器被编程为：
如果粘接剂覆盖度(AC)等于或低于临界覆盖度(TC)，则在挤压力下经由超声波焊接装置输送第二超声波脉冲(P2)到接头，以在接头处形成焊接部，由此修理接头。
10.如权利要求9所述的组件，其中，预定临界覆盖度(TC)被选择为使得，处于临界覆盖度的未修理的连结接头的接头强度(SU，TC)小于或等于处于临界覆盖度的经修理焊接接头的接头强度(SR，TC)，[SU，TC≤SR，TC]。
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