CN1430543A - 激光焊接的距离模式控制 - Google Patents

激光焊接的距离模式控制 Download PDF

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Publication number
CN1430543A
CN1430543A CN01810169A CN01810169A CN1430543A CN 1430543 A CN1430543 A CN 1430543A CN 01810169 A CN01810169 A CN 01810169A CN 01810169 A CN01810169 A CN 01810169A CN 1430543 A CN1430543 A CN 1430543A
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Prior art keywords
laser
projection
reference position
irradiation
control signal
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CN01810169A
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CN1278845C (zh
Inventor
戴维·格雷维尔
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Branson Ultrasonics Corp
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Branson Ultrasonics Corp
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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
    • B29C65/72—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by combined operations or combined techniques, e.g. welding and stitching
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/03—Observing, e.g. monitoring, the workpiece
    • B23K26/034—Observing the temperature of the workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60—Riveting or staking
    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/43—Joining a relatively small portion of the surface of said articles
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
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    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
    • B29C66/81423—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being concave
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
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Abstract

本发明公开了一种激光连接***，基于工件的突起塌陷到预定位移变形工件的突起。所述激光连接***具有激光***，用于基于照射控制信号产生预定量的激光照射。激励***基于力控制信号把所述量的激光照射引导到部件并且用激光头接触所述部件。激励***还基于激光头的位置产生位置反馈，其中所述位置反馈包括激光头的基准位置。所述激光连接***还包括控制器，与激光***和激励***通信。所述控制器基于位置反馈产生照射控制信号和力控制信号。照射控制信号之一在突起相对于基准位置塌陷预定的位移时，引起激光***停止产生激光照射。基于塌陷距离，控制激光照射使之能够提高一致性和降低加工成本。

Description

激光焊接的距离模式控制
技术领域
本发明通常涉及激光铆接(laser staking)和激光焊接。更具体地，本发明涉及在热塑突起塌陷到对基准位置的预定位移时停止对热塑突起施加的激光照射。
背景技术
在许多工业领域内，固定或者铆接工序的一部分需要有把工件的热塑突起变形和成型。例如在汽车工业中通常用于把标志铆接到售出的方向盘的中心。进行这种铆接工作的早期方法包括使用超声波和热空气，但是超声波典型地产生部件痕迹，而热空气往往由于过量喷出热空气而造成损坏。
由于上述与超声波和热空气相关的局限性，在许多工业部门中开展了激光铆接。在现有技术的激光铆接方法中，通过施加预定量的激光照射使工件的突起变形，并且用特定的对所述突起施加预定的焊接力。预定焊接力和预定量的激光照射引起突起熔融塌陷成的形状。在预定的时间期间之后，停止激光照射和焊接力，让突起固化。在固化后铆接工序即完成，并且把所述工作固定到相邻的部件上。
对上述激光铆接工序有可能改进的特殊领域涉及在停止激光照射和焊接力时确定什么参数。特别是，上面讨论的焊接时间控制策略没有考虑铆接在一起的部件的模制和环境历史变量。例如对于给定的焊接力、激光照射和铆接时间下的各种突起将表现不同的塌陷量。由于塌陷不一致，最终组件会有不同的总体物理尺寸。本发明认识到突起的塌陷距离是最有关的参数并且在很大程度上决定部件连接强度和质量。因此特别地希望提供把最相关的铆接参数，也就是塌陷距离考虑在内的控制激光铆接工序的机构。这种机构应当提供降低的重复工作的成本和改善了的质量。
为了确定什么时间停止激光照射和焊接力而确定要监测什么参数所相关的困难对于其它的激光焊接领域也起作用。例如，在通过透射红外线(TTlr)焊接中，把对激光照射透明的第一部分焊接到吸收此照射的第二部分上。激光照射把激光吸收材料的温度提高到临界熔融温度，然后施加压力把部件压在一起。随着熔融冷却焊接或者结合把部件连接在一起。由于其相对快速形成焊接以及接缝的强度和均匀性，TTlr焊接有广泛的应用。从而，在TTlr焊接中，焊接区内的塌陷距离可以是最对部件连接的强度和质量有代表性。因此非常希望提供把最相关的焊接参数也就是塌陷距离考虑在内的用于控制TTlr焊接的机构。
发明内容
根据本发明的***和方法提供了上述目的和其它目的用于变形工件的突起或者说在工件内产生焊接以连接部件的组件。所述的方法包括：向组件施加预定的焊接力的步骤，和对组件施加预定量的激光照射的步骤。预定焊接力和预定量的激光照射引起组件塌陷。所述方法还在对于参照位置塌陷预定的位移时，提供停止施加激光照射。在本发明的一个实施例中，是在照射停止后在预定时间期间到期时，停止焊接力的施加，以允许组件的固化。
还有，根据本发明，公开了当突起对于参照位置塌陷到预定的位移时，停止对热塑突起施加激光照射的方法。所述方法包括确定基准位置的步骤，还有跟踪突起的塌陷位置的步骤。计算基准位置和塌陷位置之间的差值并且把该距离与预定的位移加以比较。
本发明还提供用于变形工件突起的激光铆接***和用于连接部件的组件的激光连接***。每个***都有激光***、激励***、和控制器。所述激光***基于照射控制信号产生预定量的激光照射。激励***基于力控制信号把所述预定量的照射引导到部件并且用激光头接触所述部件。激励***还基于激光头的位置产生位置反馈，其中位置反馈包括基准位置。控制器与激光***和激励***通信，并且基于激励***发出的位置反馈信号产生照射控制信号和力控制信号。照射控制信号之一在部件相对于基准位置塌陷到预定的位移时，引起激光停止产生激光照射。
附图说明
通过阅读下面参照附图所作的说明及所附权利要求书，领域内普通技术人员会清楚本发明的各种优点，其中：
图1是根据本发明的激光铆接***的方框图；
图2是根据本发明的控制器的方框图；
图3是根据本发明的控制器激励控制模块的方框图；
图4是根据本发明的控制器激光器控制模块的方框图；
图5是根据本发明的激光***电路示意图；
图6是根据本发明的激光头处于绝对初始位置的侧视截面图；
图7是根据本发明的激光头处于初始突起位置的侧视截面图；
图8是所述激光头处于突起对于基准位置塌陷预定的位移的位置的侧视截面图；
图9是根据本发明用于变形工件突起的计算机化方法的流程图；
图10是根据本发明，在突起对于基准位置塌陷预定的位置时，对热塑突起停止施加激光照射的工序流程图；
图11是根据本发明激光头对于TTIr焊接操作的激光头侧视截面图。
具体实施方式
参见图1，图中示出优选的激光连接***20，用于结合部件的组件，或者在一个实施例中，用于变形工件的热塑突起22。应当理解尽管对于施加于突起22说明***20，但是可以容易地把本发明用于施加在任意热塑部件的组装的非铆接工序。
因此，下面说明的在铆接***中突起的变形和突起塌陷的测量，应当理解为同样适用于在整个把对激光照射透明的第一部件焊接到吸收该照射的第二热塑部件的传送焊接过程中发生的位移或者塌陷。连接***20包括激光***40、激励***60和控制器80。激光***40基于照射控制信号产生预定量的激光照射。对于本发明的目的，激光照射可以是足以诱发热塑突起22的所需要的熔融和温度控制的任何频率或者波长。对于诸如本文所述的使用热塑突起的铆接应用，虽然本发明的一般应用覆盖各种频率和波长，激光照射的波长还是优选地在约600到约1000nm的范围内。激励***60基于力控制信号把激光照射导向突起22并且用激光头接触突起22。用激光头接触突起22得到预定的焊接力。预定的焊接力和预定量的激光照射的组合引起突起22塌陷从而把工件24铆接到部件26上(图8)。
激励***60基于激光头的位置产生位置反馈，其中位置反馈包括激光头的基准位置。可以看出控制器80与激光***40和激励***60通信。控制器80基于激励***60发出的位置反馈产生照射控制信号和力控制信号。当突起22相对基准位置塌陷到预定的位移时，从控制器80发出的照射控制信号之一引起激光***40停止激光照射的发生。基于位置反馈控制激光照射代表对基于时间的激光连接方法的显著改进。
现在转向图2，图中较详细地示出控制器80的一个实施例。特别地，控制器80可以包括确定头46的基准位置的基准模块82，和动态塌陷模块82用于通过监测头位置跟踪突起22的塌陷位置(图1)。从而，位置反馈还包括突起22的动态塌陷位置。求和模块计算基准位置和塌陷位置之间的差值，而比较模块86把所述的差值与对特定应用规定的预定位移加以比较。优选地位移数据库88含有比较模块86比较所需要的预定的位移信息。位移数据库88中的信息可以相关于要由连接***20连接的所有可能的部件和组件。在基准位置与塌陷位置之间的差值等于预定的位移时，比较元件86向激光器控制模块96发出信号以停止照射。
应当理解本发明还提供各种确定基准位置的方式。从而控制器包括模式选择器89用于提供在模式之间转换的机构。例如，基准模块82可以把初始突起位置记录成基准位置，或者把绝对初始位置记录成基准位置。下文将较详细地讨论各种确定基准位置的各种模式。
还应当理解，控制器80还可以包括激励控制模块90用于与激励***60传递恒定的焊接力数据或者可变焊接力数据。结果，尽管本文中所指的照射和焊接力基于“预定”的量，在整个焊接工序中这些数值的大小可以是恒定的也可以是可变的。举例来说，图3示出控制器80的激励控制模块90可以有恒定的激励子模块92，用于产生恒定的焊接力数据，和可变的激励子模块94，用于产生可变的焊接力数据。同样地，图4示出控制器80的激光器控制模块96可以有恒定的照射子模块98，用于产生恒定的照射数据，和可变的照射子模块99，用于产生可变的照射数据。
图5示出激光***40的一个实施例。特别地，可以看到激光***40使用二极管阵列42以产生激光照射。可以把二极管阵列42发出的激光照射经由光纤或者其它适当的光传输机制运送到激光头46(图6-8)。激光子***44起“黑盒子”的作用并且响应控制器80发出的照射控制(驱动)信号向二极管阵列42提供电流。
如下文所述，激光头46的激光头有压力换能器用于向激励***60(图1)提供力反馈。这使激励***60能够确定什么时候接触了突起22，以及施加了多大的力。当力反馈指出已经接触了突起22并且连接***20用塌陷模式(在下文说明)工作，激励***60向控制器80返回初始位置的报告。在这种情况下，把初始的突起位置确定为基准位置。激励***60用作为编码器(未示出)，所述编码器也安装在激光头46中，以向控制器80提供所需要的位置数据。不论是换能器还是编码器都是市售的“现成”部件，并且是领域内公知的。
现在转向图6-8，图中较详细地示出本发明的连接和铆接工序。特别参看图6，可以看到工件24有要与相邻的部件26连接的突起22。激光头46有模具48和压力检测装置，譬如换能器49。如前已述，可以基于绝对初始位置50确定基准位置，也可以基于初始突起位置52确定基准位置。如果是基于绝对初始位置50确定基准位置，可以把连接***20说成以“绝对模式”工作。
图7示出激光头46向突起22运动直到在初始的突起位置52发生接触，当***以“塌陷模式”工作时此初始位置52可以确定为基准位置。在所述的塌陷位置，换能器49向激励***60返回接触力的报告。当接触力达到预定的触发力时，激光头的位置储存为初始的突起位置52。还应当理解，触发力可以起启动激光照射41的机构的作用。
在焊接的过程中，激光头46向突起22施加预定量的激光照射直到突起22塌陷到预定的位置，如图8所示。如果把绝对初始位置50用作基准位置(即绝对模式)，预定位移54将用作停止施加激光照射41的距离(图7)。另一方面，如果用初始突起位置52作为基准位置(即塌陷模式)，预定位移56将用作停止施加激光照射41的距离。应当理解，在突起22塌陷的同时，激光头46还在施加焊接力，就是说激光头46从其初始突起位置向其预定位移运动。在终止了激光照射后，还可以把激光头46保持在其预定的位移位置一段时间，从而让突起在受模具结构制约的情况下固化。在此固化的期间一般地降低焊接力以保持突起的位置，固化时间可以由使用者编程。
现在转向图9，图中示出用于连接部件组件的计算机化的方法100，用作编程的目的。应当理解，本发明可以使用领域内公知的技术用硬件也可以用软件实施，也可以两者兼用之。特别地，图中可以看到在步骤110确定基准位置110，在步骤120对组件施加预定的焊接力，而在步骤130对组件施加预定量的激光照射。如已经讨论的，预定的焊接力和预定量的激光照射引起组件塌陷。在步骤140确定组件是否已经相对基准位置塌陷到了预定的位移。如果是，在步骤150停止激光照射的施加。如果没有达到预定的位移，就继续施加预定的焊接力和激光照射。本发明的一个实施例还包括步骤160，用于确定在步骤170对于停止施加预定的焊接力，预定的时间周期是否已经到期。这让组件能够固化。
图10详细地示出确定是否已经达到预定的位移的步骤140。特别地，在步骤142跟踪组件的塌陷位置。这可以仅通过记录激励***编码器所提供的位置数据实现。在步骤1 44计算基准位置与塌陷位置的差值。然后，在步骤146将该差值与预定的位移相比较。在所述的差值大于或者等于预定的位移时，终止激光照射并且停止所述的力。可以应用冷却时间进行固化。
重要的是注意到尽管一般地对热塑材料说明了本发明，任何激光照射具有可以在其中足以诱发材料熔融的频率的材料都可以被使用。而且如以上一般地说明，停止激光照射和压力时，控制的距离模式可以用于各种其它的应用包括TTlr焊接。为了完整性，代表性TTl焊接应用的开始一般地示于图11。在此应用中，对于透明的第一部件70激光照射接近于百分之百的透明，但是对于吸收的第二部件72是吸收的。在多数TTlr应用中，吸收的第二部件在颜色上是黑色的。一系列二极管一般地以并列的关系布置在二极管阵列中以产生与所需要的焊线轮廓相配合的照射线。激光照射穿过透明的第一部件70然后作用在优选地是吸收光的聚合物的第二部件72上。随着把第二部件72加热到临界的熔融温度，移动激光头46以把两个部件压在一起。这时头46的位移距离又是测量来停止照射和压力的参数。在焊接或者说连接冷却以形成接缝时可以保持压力。应当理解上述的控制技术对TTlr应用同样适用，也适用于其它的激光焊接技术。
领域内普通技术人员从上述的说明可以理解本发明的广义的技术可以由各种形式实施。因此，尽管结合其具体实施例说明了本发明，本发明的实际范围不应当受到限制，因为在学习附图、说明书和随后的权利要求书后，领域内普通技术人员会清楚其它的改进。

Claims (20)

1.连接部件的组件的方法，所述方法包括：
向组件施加预定的焊接力的步骤；向组件施加预定量的激光照射的步骤，预定的焊接力和预定量的激光照射引起组件塌陷；以及
在对于参照位置组件塌陷预定的位移时，停止施加激光照射的步骤。
2.如权利要求1所述的方法，其特征在于，还包括：
确定基准位置的步骤；
跟踪组件的塌陷位置的步骤；以及
把基准位置和塌陷位置之间的差值与预定的位移加以比较的步骤。
3.如权利要求2所述的方法，其特征在于，还包括记录初始组件位置和把基准位置限定为所述初始组件位置的步骤。
4如权利要求2所述的方法，其特征在于，还包括记录绝对初始位置和把基准位置限定为所述绝对初始突起位置的步骤。
5.如权利要求1所述的方法，其特征在于，预定的焊接力是可变的。
6.如权利要求1所述的方法，其特征在于，所述组件包括热塑材料，所述激光照射具有足以诱发热塑组件熔融的频率。
7.如权利要求6所述的方法，其特征在于，所述预定量的激光照射是恒定的。
8.如权利要求6所述的方法，其特征在于，所述预定量的激光照射是可变的。
9.如权利要求1所述的方法，其特征在于，还包括在预定的时间周期到期时停止施加焊接力的步骤。
10.一种在热塑突起相对基准位置塌陷到预定的位移时，对热塑突起施加激光照射的方法，所述方法包括：
确定基准位置的步骤；
跟踪突起的塌陷位置的步骤；以及
把基准位置和塌陷位置之间的差值与预定的位移加以比较的步骤。
11.如权利要求10所述的方法，其特征在于，还包括记录初始突起位置和把基准位置限定为所述初始突起位置的步骤。
12.如权利要求10所述的方法，其特征在于，还包括记录绝对初始位置和把基准位置限定为所述初始位置的步骤。
13.激光连接***，用于连接部件的组件，所述的激光连接***包括：
激光***，用于基于照射控制信号产生预定量的激光照射；
激励***，用于基于力控制信号把所述激光照射引导到部件并且用激光头接触所述部件，激励***基于激光头的位置产生位置反馈，所述位置反馈包括激光头基准位置；和
控制器，与激光***和激励***通信，所述控制器基于位置反馈产生照射控制信号和力控制信号，照射控制信号之一在部件相对于基准位置塌陷预定的位移时，引起激光***停止产生激光***照射。
14.如权利要求13所述的连接***，其特征在于，位置反馈还包括部件的塌陷位置，所述控制器包括：
基准模块，用于确定基准位置；
塌陷模块，用于跟踪塌陷位置；和
比较模块，用于把基准位置和塌陷位置之间的差值与预定的位移加以比较。
15.如权利要求14所述的连接***，其特征在于，所述基准模块把初始部件位置记录为基准位置。
16.如权利要求14所述的连接***，其特征在于，所述基准模块把绝对初始位置记录为基准位置。
17.如权利要求14所述的连接***，其特征在于，所述控制器还包括激励控制模块，用于产生激励控制信号，激励控制信号包括恒定的焊接力信号。
18.如权利要求14所述的连接***，其特征在于，所述控制器还包括激励控制模块，用于产生激励控制信号，激励控制信号包括可变的焊接力信号。
19.如权利要求14所述的连接***，其特征在于，所述控制器在预定的时间周期到期时，用激励控制信号之一停止接触部件。
20.如权利要求19所述的连接***，其特征在于，所述的预定时间周期允许部件能够固化。
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