CN1723116A - 含氟聚合物的红外线焊接 - Google Patents

含氟聚合物的红外线焊接 Download PDF

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Publication number
CN1723116A
CN1723116A CNA018125727A CN01812572A CN1723116A CN 1723116 A CN1723116 A CN 1723116A CN A018125727 A CNA018125727 A CN A018125727A CN 01812572 A CN01812572 A CN 01812572A CN 1723116 A CN1723116 A CN 1723116A
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CN
China
Prior art keywords
workpiece
heating element
temperature
heater
welding
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Pending
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CNA018125727A
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English (en)
Inventor
G·A·埃文斯
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Swagelok Co
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Swagelok Co
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Publication date
Application filed by Swagelok Co filed Critical Swagelok Co
Publication of CN1723116A publication Critical patent/CN1723116A/zh
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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
    • B29C65/14—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
    • B29C65/1429—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 characterised by the way of heating the interface
    • B29C65/1464—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 characterised by the way of heating the interface making use of several radiators
    • B29C65/1467—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 characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous 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
    • B29C65/02—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
    • 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
    • B29C65/14—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
    • B29C65/1429—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 characterised by the way of heating the interface
    • B29C65/1432—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 characterised by the way of heating the interface direct heating of the surfaces 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
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5344—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends
    • 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
    • B29C66/71—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
    • B29C66/712—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 the composition of one of the parts to be joined being different from the composition of the other part
    • 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
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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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • 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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B29C66/73116—Melting point of different melting point, i.e. the melting point of one of the parts to be joined being different from the melting point of the other part
    • 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
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91211—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods
    • B29C66/91216—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods enabling contactless temperature measurements, e.g. using a pyrometer
    • 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
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91221—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
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    • B29C66/91231—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the joining tool
    • 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
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    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91421—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools
    • B29C66/91423—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools using joining tools having different temperature zones or using several joining tools with different temperatures
    • 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
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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
    • 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
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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
    • 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
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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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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/962—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process using proportional controllers, e.g. PID controllers [proportional–integral–derivative controllers]
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    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/12—Use of polyvinylhalogenides or derivatives thereof as moulding material containing fluorine
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)
  • Control Of Resistance Heating (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

一种用于将塑料工件焊接在一起的设备，该设备包括：具有第一和第二表面的加热器部件；用于从第一表面辐射热量的第一加热元件；用于从第二表面辐射热量的第二加热元件；其中第一和第二加热元件的温度被独立控制。提供用于检测焊接位置处的工件温度的温度传感器。最好以非平面的方式布置加热元件，该非平面的方式具有例如抛物线、凸面的或有角度的形状，以便于朝向工件上的焊接位置聚焦、定向或集中辐射热。本发明具体适用于使得由可熔化处理材料(诸如PFA)制成的零件焊接到由不可熔化处理材料(诸如改性的PTFE)制成的零件上。

Description

含氟聚合物的红外线焊接
相关申请
本申请是2000年5月10日提交的系列号为No.09/567,603标题为“含氟聚合物的红外线焊接”的共同未决的美国非临时专利申请的部分继续申请，并且本申请要求享有上述申请No.09/567,603的优先权，在此处作为参考结合其全部的内容。
技术领域
本发明涉及将非金属的含氟聚合物零件焊接或连接在一起。更具体地说，本发明涉及一种用于将两个工件辐射焊接在一起的方法和设备，其中在焊接操作期间可将两个工件加热到不同温度。
背景技术
一种用于将塑料零件或工件焊接或连接在一起的已知技术是辐射加热，有时被称为红外线焊接或IR焊接。在已知方法中，将工件加热并将它们压在一起然后使之冷却。使用加热器以提供辐射热源，该加热器接近于该工件的待连接在一起的部分。
在已知的IR(红外线)焊接***中存在各种各样的缺陷。其中有：不良的可重复性、焊接的不一致性以及长的焊接周期。这可归因于多种因素，大多数因素与这个事实有关，即，焊工必须直观地(在视觉上)确定何时各个工件已被充分加热。例如对于诸如PFA(全氟烷氧基聚合物)的Teflon(聚四氟乙烯)TM类型材料来说，操作者检查工件中的不透明性的变化。这是非常主观的确定并且导致不一致的焊接。
已知***只用于焊接相同材料的两个工件，并且只用于可熔化处理的材料(诸如PFA)。可熔化处理是指材料可被熔化并被进一步加工，该加工例如为注塑或其它的使熔融材料在其中流动的处理技术。在此以前人们认为不可熔化处理的材料不能用已知的IR***进行IR焊接。已知***的另一个显著局限性在于，几乎不能控制将工件加热到的程度。对于一般焊接操作来说，通常只有工件的一小部分需要加热。然而已知***还加热了工件的除焊接位置以外的部分。这样的加热可不利地或不良地影响焊接位置外部的工件的材料特性。此外，在焊接和冷却期间，已知焊接***通常使用固定装置以固定工件。在冷却期间这些固定装置通常轴向地限制工件的移动，因此在焊接中产生残余应力。
仍然存在一种需要，即提供一种用于将塑料零件焊接在一起的辐射焊接方法和设备以形成高质量可重复性的焊接。这样的方法和设备将特别适用于但不仅仅适用于将具有不同熔化和分解温度的不同材料的两个工件焊接在一起。
发明内容
本发明在一个实施例中构想出一种用于将塑料工件焊接在一起的设备，其中该设备包括：具有第一和第二表面的加热器部件；用于从所述第一表面辐射热量的第一加热元件；用于从所述第二表面辐射热量的第二加热元件；其中所述第一和第二加热元件的温度可独立地控制。
加热器部件的另一个方面在于，加热元件和/或辐射表面可以构型成将辐射热定向或集中到焊接区域或焊接区的几何形状。在一个实施例中，以抛物面、凸面或其它非平面的方式布置加热元件。
依照本发明的另一个方面，焊接***独立地或联合地包括用于加热元件的温度传感器和用于检测焊接位置处的工件温度的温度传感器。
依照本发明的另一个方面，待焊接的工件被安装在固定装置上，该固定装置有助于合格的焊接的形成。依照本发明的这个方面，在后焊接期间，允许至少一个工件相对于另一个工件轴向地并自由地移动。该自由移动使得焊接位置可在焊接位置处不产生残余应力地冷却。在本发明的一个实施例中，使用一种固定装置，该固定装置在焊接操作的一部分期间保持该工件并且在焊接和冷却期间轴向地松释工件。
从以下结合附图所作的对本发明的详细描述中，可容易地理解本发明的这些和其它方面及优点。
附图说明
图1是本发明所涉及的焊接***的功能框图；
图2A-2D分别是本发明所涉及的加热器部件组件的侧视图、正视图、顶视图和等距视图；
图3A-3G是本发明所涉及的标准焊接操作的简化的略图；
图4A和4B本发明所涉及的对于不同尺寸零件的加热器部件的加热效果的简化示意图；
图5A和5B是可用本发明执行的示范性焊接工序的软件流程图；
图6和图7是本发明所涉及的示范性工件加热曲线的温度vs.时间视图；
图8A-8C示出了本发明所涉及的固定装置概念的第一实施例；以及
图9A-9D示出了本发明所涉及的固定装置概念的第二实施例。
具体实施方式
图1的示范性功能框图中示出了用于含氟聚合物零件的非接触辐射加热和焊接的焊接***10。虽然在文中是具体参考PFA零件与改性的PTFE零件的焊接(也就是，可熔化处理的材料与不可熔化处理的材料之间的焊接)而描述本发明的，但是它们只不过是可用体现本发明各个方面中一个或多个方面的设备和方法来焊接的含氟聚合物的两个例子。本发明还可用于将相同材料焊接在一起(例如，可熔化处理的材料例如PFA制成的零件与可熔化处理的零件之间的焊接，或不可熔化处理的材料例如改性的PTFE制成的零件与不可熔化处理的零件之间的焊接)。
本发明考虑了多种具体表现在焊接***10的方法和设备中的显著特征，每个特征都既可独立使用又可以与本发明的其它特征任意结合的方式使用。通常，这些特征具体表现在(但又不局限于)新型加热器单元和基于以下一种或多种条件而控制焊接操作的控制***：加热元件的温度、焊接位置的工件温度、以及工件的位置控制。新型加热器单元包含两个截然不同的方面或特征，该方面或特征通常为：1)至少两种加热元件的分开的和独立的温度控制；2)聚焦的或定向的辐射加热。控制***的另一个方面是对于每个工件可使用可选择的加热曲线。虽然在文中是用焊接不同材料的两种工件的示范性实施例来描述本发明的，但是本领域普通技术人员应该容易地理解，本发明的各个方面都可用于将相同材料的工件焊接在一起。
另外，虽然文中具有多个备选实施例或例子，但是没有打算(并且也不能)将这样的例子看作是详细的列示。不管文中是否明示，本领域普通技术人员都应该容易地理解对于所述实施例的各种不同的与电有关的、机械的和材料的改变，而且在没有脱离本发明的精神和保护范围的情况下可作这样的改变。
接着参考图1，图1示出了体现本发明各个方面的辐射焊接***。应在其最广的意义上理解文中所涉及的“焊接”，也就是，通过施热来连接或结合两个工件。本发明是指在不使得工件与热辐射表面直接接触的情况下，通过从辐射表面将热传输到工件的辐射或IR加热技术。这确保了清洁的焊接。
***10包括控制电路12、加热器部件组件14和固定平台或框架16(未示出)。可以以许多形式获得控制电路12，如本领域普通技术人员所公知的，该形式包括：分立电路、集成电路、模拟和/或数字电路等等。在图1的示范性实施例中，控制电路12包括数字控制器18，该数字控制器18可为任何适合的微控制器或其它数字控制器装置或电路。在焊接操作期间控制器18执行多种控制功能。这些功能包括：1)控制工件W1和W2相对于彼此的相对位置；2)控制加热器部件组件14相对于工件的位置；3)控制供应到加热器部件组件14中的加热元件20、22的功率；4)接收并处理各种涉及工件和加热器的位置的反馈信号以及温度反馈信号；以及5)依照一个或多个存储程序、控制参数、加热曲线和操作者输入而执行焊接操作。
可用常规伺服控制器执行工件W1和W2以及加热器部件14的位置控制，然而，也可使用其它任何适合的位置控制技术。控制电路12可通过第一和第二工件位置伺服机构24、26使得工件W1和W2移动和定位。例如可使用从IDS得到的诸如零件B8001等适合的伺服控制器。第三位置控制器25用于使得加热器部件14移动和定位。例如，可将加热器部件14安装在由气缸25控制的可移动的臂上，以使得加热器部件14可在工件W1和W2附近的缩进位置或初始位置与延伸位置或焊接位置之间移动。或者，可将加热器部件14固定在适当位置上。对加热器部件14的位置控制的考虑可使得当不在使用中时，可以以远离人员的方式安全地缩进加热器。另外，通过具有可移动的加热器部件14，多个加热器部件14可用于不同的零件尺寸或焊接参数。此外，如下文中将进一步描述的，具有由电子控制的加热器部件14大大增加了焊接***10执行可重复性高质量焊接的灵活性。
控制电路12还包括可从Grayhill获得的标准输入/输出(Input/Output)电路28，该电路28将控制器18与各种外部传感器、加热器部件14电源电路、以及操作者界面装置30进行界面连接，该操作者界面装置30诸如键盘、触摸屏、鼠标器等等。一种适用的界面装置是可从Eason获得的Model 400。操作者可输入例如所焊接的零件材料、零件尺寸、温度参数等等，并且操作者可选择储存在存储器中的合适的焊接程序，或者由控制器18选择合适的程序。可通过常规视频显示器或其它适合途径与菜单驱动程序等一起键入并监控焊接参数。出于历史性的目的、质量控制、趋势分析以及所需要的其它统计分析的目的，数据存储器可用于储存焊接参数和焊接数据。
应该注意的是，虽然文中所描述的本发明是以计算机化或自动化的焊接***10的方式而具体化的，但是本发明的许多方面可以以包括手动***的更简化的***的方式实现。例如，加热器部件14可容易地与手动焊接***结合使用，其中工件用任何适合的固定设备将工件相对于加热器部件14手动地定向。倘若希望的话，各种温度反馈还可由操作者监视并调节。然而，由于一旦已设定参数，可与操作员(与计算机的)交互作用无关地完成完整的焊接操作，所以认为在许多情况中自动***将是优选的。这大大增加了焊接质量、可重复性并减少了焊接时间。
与每个加热元件20、22相连接的是温度传感器32、34。在该例子中温度传感器32、34是标准热电偶，并最好(但非必须)将其定位于加热器部件14中的加热元件附近。可使用任何适合的温度传感器。每个传感器32、34被监控，以使得加热元件20、22的各自的温度彼此独立地被控制。各个加热元件20、22的独立精密的温度控制，以及精确的温度控制和可选择的加热曲线，是本发明的允许将不同材料的工件焊接在一起的一个显著特征。
提供辅助温度传感器36、38以检测焊接位置的工件温度。在该实施例中，诸如可从RAYTEK获得的型号为no.RAYTXSLTCF2的精密红外传感器检测每个工件W1和W2的焊接位置的温度。通过使用这种工件温度反馈，控制器18可精确地确定何时已将工件加热到用于焊接的预定温度。这消除了现有***的主要缺陷，即操作者必须通过零件的不透明性的变化直观地(在视觉上)确定零件已被充分加热。使用工件温度传感器36、38还允许控制器18调节供应给加热元件20、22的功率，以便于当例如在另一个工件完全加热之前一个工件已达到其焊接温度时防止加热过度。还可为控制器18编程序，以便于调节工件到加热器之间的距离，其作为工件温度控制功能的一部分。可与加热器功率调节器结合或利用加热器功率调节器代替实现这一点。
标准的功率接口电路40为加热元件20、22提供电压和电流。一种适合的电路为可从Watlow获得的Din-a-Mite电路。如果需要也可使用常规功率极限电路42、44。例如可从Watlow获得的系列146的控制电路。
在图1的示范性实施例中，控制电路12还包括加热器控制器33、35。每个加热器控制器33、35都独立地调节供给到其各个加热器的电压和电流，以达到***控制器18所设定的程序化加热器温度。每个加热器控制器33、35可为例如可从Watlow获得的系列988的控制器。每个加热器控制器监控各个加热器热电偶32、34并调节供给电源电路40的功率，以便于将加热器保持在所选择的温度。加热器控制器33、35还监控各个IR传感器信号。当相关的焊接位置达到预期的焊接温度时，加热器控制器向***控制器18发送一个合适的信号。当两个工件都达到预期的焊接温度时，***控制器18使得加热器部件以远离工件的方式移动，并将工件聚集在一起以进行焊接。
两个加热器的独立温度控制，以及工件的焊接位置的独立温度监控，有助于焊接不相似材料的两个工件。例如，一个工件可比另一个工件更快地达到其焊接温度。如果这样，相关的加热器控制功能可调节供给加热器的功率以便于在没有加热过度的情况下将工件保持在焊接温度，直到第二个工件达到其焊接温度。由于可在不同的程度加热零件，因此各个工件的焊接温度可为相同的或彼此不同，并且可在不同时间达到其焊接温度。
参照图2A、2B和2C，本发明构想出在该例子中加热器部件组件14包括单个外壳或壳体50。在外壳50之中的是热的或热量的辐射基体52。在示范性实施例中，基体52是用陶瓷材料(诸如例如可从WATLOW获得的陶瓷纤维隔热)制成的。这里具体的材料是可模制的陶瓷，然而，任何合适的材料都可用于加热器基体52，只要它能够如所期望的那样支撑加热元件并为焊接过程辐射出足够的热量。
壳体50包括用于使得电源引线与嵌入在基体52中的加热元件20、22相连接的端子板。以紧邻近于各个加热元件20、22的方式将加热器温度传感器32、34(图1)放置于基体52中。可使用连接器引线56、58以通过I/O(输入/输出)板使得传感器34、36与***控制器18连接。
在该实施例中，每个加热元件20、22都以常规电热丝(诸如铁铬铝金属丝)60、62的形式体现。每个金属丝60、62都以螺旋形式布置(图2B)，并沿着曲面或其它非平面的轮廓或形状布置(图2A)。该示范性例子中的非平面的轮廓通常是抛物线的或凹面的，因此对于辐射的热量来说具有聚焦或定向的作用。本发明的一个方面包括具有一个定向或集中的辐射热源的理念。如下文中所述的，通过使用抛物线的或凹面的加热元件轮廓可使得辐射的热量被“聚焦”，然而，不需要聚焦到一个特定的焦点。因此本发明的基本特征是，辐射的热量通常被定向或聚集在焊接位置的区域中。
非平面的轮廓可以是对于辐射的热量来说产生定向聚集或聚焦作用的任意的几何形状。然而，在一些焊接***中也有可能不需要聚焦的或集中的热量。在这样的情况中，可以以平面方式布置金属丝60、62。金属丝60、62在布置上也无需是螺旋形式的。取决于所需要的聚焦作用的程度可使用其它的非平面的轮廓。例如，可在有角度的平面(诸如V形结构)上布置金属丝60、62。可得到许多其它的选择，包括在加热器部件14中增加热聚焦元件或与加热器部件14结合使用热聚焦元件。
如图2A和2B所示的，陶瓷基体52形成有两个热辐射表面64、66。还可使这些表面64、66以几何学的方式构造成以便于参与所辐射热量的聚焦作用。在示范性实施例中，每个表面64、66都包括通常为抛物线的或凹面的凹面部分68、70，凹面部分68、70通常符合金属丝60、62的几何形状，或者可用不同的几何轮廓构造成凹面部分68、70。为了获得期望的聚焦作用，任何形状都可使用。
通过使用本发明的定向热原理可获得多个优点。这些优点之一是，各个工件的更有效的加热。大范围地产生辐射热量的现有***必定在工件焊接位置处减少加热(在此处使用的焊接位置是指被加热到其熔化温度以便于执行焊接操作的工件的那个部分)，其中某些现有***的效率低甚至不对工件起作用。通过将辐射热量集中在焊接位置处和焊接位置附近，可更快速有效地加热工件。
使辐射热定向或集中的另一个优点是，它减少了工件的远离焊接位置的部分的热量。例如，假定阀体由改性的PTFE聚合物制成并包括管端部，接头将被焊接到该管端部上。理论上，只有管端部的外部端(例如，大约1/8英寸)将被加热。如果阀体被同时加热并且温度充分提升，改性的PTFE材料将被不利地影响。通过使辐射热集中或定向，可基本上减少工件的非焊接部分的外部热量。
在图2A-2C中加热器部件组件14是带有单个壳体50的集成装置。如果需要，可通过壁或其它热障或反射器72将两个加热元件20、22分隔在它们自己的区中。或者，可将加热元件20、22布置于独立的基体/壳体单元中，该独立的基体/壳体单元被一起固定到或安装到共同的移动装置上。另一个选择是，使各个加热元件20、22处于其自己的加热器部件组件中，以使得控制电路12可将每个加热器独立地定位在其相关的工件的位置附近。图2D是加热器部件14的实体模型等距视图，该加热器部件14包括热辐射表面64的凹面部分。
参照图3A-3G，其中图3A-3G以简化的形式示出了由控制电路12或手动地或别的方式执行的标准焊接操作。在这些视图中，出于清楚的目的省略了***10的固定装置和其它的电气和机械的零件。另外，图3A-3G的例子采用了可移动的加热器部件14和可独立移动的工件W1和W2。
在该例子中，第一工件W1是阀体100，阀体100具有管端部102，接头104将被焊接于管端部上。可用常规固定装置支撑第一工件W1，该常规固定装置例如由控制电路12通过第一工件位置伺服机构26定位的第一可移动平台上的夹子或其它适合的结构。在该例子中，第二工件W2是将被焊接到第一工件W1上的接头或其它零件的管端104。也可将第二工件W3安装在由控制电路12通过第二工件位置伺服机构24定位的可移动平台或其它适合的结构上。如图中所示的，为了焊接，优选(但非必须)的是，本发明涉及了用于焊接的工件的垂直对齐。这可获得更均匀的焊缝。或者，可通过水平校准或其它任何需要的定向来焊接工件。比较简单的***还可只使用一个可移动工件。
还可通过加热器伺服机构24将加热器部件14安装在由控制电路12控制的可移动平台或臂上。在示范性实施例中，加热器部件14可横截于工件W1和W3的移动轴平移(也就是说，水平或横截于图3A-3G的纸平面)。如果期望的话，加热器部件14可以以相对于工件W1和W2平移轴的不同角度移动，但是为了方便起见可在基本横截或非平行于可移动工件W1和W2的平移轴的平面中移动。
参照图3A，通过控制电路12将工件W1移动到加热器部件14所将要移动到的位置，以使得焊接程序被启动，为工件W1确定起始位置参考点。在图3A中所示的加热器14处在适当的位置，但是在实践中可由电容性的位置传感器指示出加热器14的位置。可将初始位置参考点设定成向上移动工件W1，直到电容传感器(未示出)指示出该工件处于加热器的位置。可使用电容传感器、接近传感器或其它适合的位置传感器以确定何时确定起始位置。
参照图3B，接着第一工件W1离开起始位置以收缩预定的距离或间隙。可根据在焊接操作过程中从加热器14辐射的热量以及工件将达到的期望温度，以及由于零件在焊接操作过程中暴露于热量中的生长，来经验地确定该距离。
参照图3C，为了找到第二工件相对于第一工件的起始位置，第二工件W2移动就位并抵靠第一工件W2。可使用测压仪或其它适合的接触传感器以确定何时定位起始位置。
在图3D中，第二工件远离开第一工件102移动预定的间隙距离，该预定的间隙距离根据由于焊接操作中加热导致的每个工件所期望的生长量以及在完成加热阶段以后被压在一起的两个零件所需要的重叠量而确定。因此通常可以根据经验地测定该间隙距离。该间隙距离还起到程序控制的制动器的作用。因此，在零件被加热以后，第二工件移动到其初始参考点或停止位置，但是由于在加热期间零件已“生长”或胀大，所以它们将重叠，并且根据所提供的重叠量，较软的可熔化加工的工件管端104将被镦粗以形成焊缝。因此，当零件移动相接触以完成焊接时，焊接过程是基于位置而非基于作用力的。
在图3E中，工件被进一步分开预定距离，以远离各自的加热器表面64、66。第一工件W1与相关的加热器表面66之间的实际距离可相同或不同于第二工件104与加热器部件组件14的第二加热器表面64之间的距离。此外，对给定的焊接操作，为了实现最有效的工件加热，这些距离将取决于各个工件的材料和最佳的或经验上由相关的加热器表面确定的距离。
在图3F中，已对加热器部件14供应电力，以使得将工件端部105、107加热到足以允许工件连接或焊接在一起的温度。
在图3G中，工件已被移动，从而彼此接合以完成焊接操作以形成焊缝106。
本发明的一个显著优点是，独立的两个加热器设计虑及了使用辐射焊接程序，以使得由不同材料制成的两个工件有效有力地焊接在一起。例如，管接头诸如第二工件104可由PFA的TeflonTM类型材料(也就是可熔化加工的材料并显示出第一温度范围内的熔化温度)制成。阀体例如可由不同的TeflonTM类型材料诸如改性的PTFE制成，该改性的PTFE不是可熔化加工的材料并显示出较高的熔点温度。通过对于两个加热元件20、22设置独立的温度控制以及对于焊接位置设置独立的温度传感器，从而使用辐射热焊接技术可将这样的工件便利地焊接在一起。注意到这一点是重要的，即这里所描述的用于工件的材料(也就是PFA和改性的PTFE)事实上只是用于例证而不应将其看作为对本发明范围的限制。本发明可便利地用于使相同材料的零件焊接在一起以及使得由显示出不同熔点特性的不同材料制成的零件焊接在一起，或者其中一种零件由非可熔化加工的材料制成，而另一种零件由可熔化加工的材料制成。最好(但非必须)使工件加热到处于或略高于材料熔点温度但低于材料分解温度的温度。
参照图4A和4B，示出了加热器部件14与工件W(诸如PFA管端部)之间关系的放大图。如图4A中所示的，加热元件20、22的非平面剖面(在该例子中通常为抛物线或背弧型面)有助于朝向局部的加热区或范围110聚焦或定向辐射热。在该例子中，以略微圆锥状的方式辐射热量。关于其位置，可以实验的方式测定该局部加热区，并且工件W的焊接位置端部移动到在焊接操作中用于加热的位置中，以使得待焊接的工件部分112(即，焊接位置)处于辐射热范围之内。然而工件的受热部分不必要必须刚好处于加热区110上，而是可位于沿着相对于加热器部件14热辐射表面的加热区110的其它位置上，以便于在焊接操作中实现期望的加热速率和工件的温升。在图4B中示出了一种不同尺寸的工件，以便于解释与图4A的较大的工件相比较，较小的零件将被定位成离加热器部件14更远(距离“Y”大于距离“X”)。然而，实际加热距离X和Y将取决于零件的材料、零件几何形状、期望的加热速率以及期望的温度等等。因此本发明提出了一种用于IR焊接程序的完全热学管理***，即，通过控制加热元件的温度、工件温度以及工件位置而控制焊接位置处的温度。
还是如图4A中所示的，使用工件温度传感器(在该例子中为红外线热传感器36的形式)，以在焊接操作中确定焊接位置112处的工件温度。传感器36可确定焊接位置处的表面温度，但是最好使其确定表面之下的温度，该表面之下的温度将表示已达到焊接温度并足以穿透零件。温度传感器36产生被反馈到***控制器18的电信号，由此控制器18可通过调节供应到相关加热元件20、22的电力和/或通过交替地调节工件W相对于热辐射表面66的位置从而在焊接期间精确地控制工件的温度。以这种方式，自动焊接***10可准确精密地确定何时工件W已被充分加热到可焊接于另一个工件上的程度。这消除了操作者作出主观的(在视觉上)工件已被充分加热的确定的任何需要。
参照图5A和5B，提供了可由控制***12执行的标准焊接工序的示范性软件流程图。在步骤200，操作者将第一工件安装在可移动平台或台板上，并且在步骤202到208，诸如可通过现有技术中公知的激光照准技术调整工件。在步骤210，第二工件被安装于其调节器(actuator)，在步骤212，操作者启动自动调整程序(set-up routine)。
在步骤214支撑第一工件的可移动平台被升高直到工件接触加热器部件14。这为第一工件设定了零参照点。当在步骤216时，可通过例如电容传感器和/或测压仪和其它任何适合的位置检测技术实现工件与加热器部件14的接触。在步骤218，根据来自于操作者的各种输入参数，工件被远离加热器14降低到预定的起始点，所述输入参数包括零件尺寸、材料等等。该起始间隙取决于加热期间零件的预期生长。在步骤220，第二工件W2被降低直到其接触加热器部件14，以便为第二工件建立在步骤222中的零参照点，利用例如电容传感器的合适的接触传感器对其进行再次确定。
在步骤224，第二工件被升高到预定起始点，再次根据加热期间预期的生长利用零件的尺寸和零件的材料对其进行确定。在步骤226，第二工件朝向第一工件移动，直到当在测压仪步骤228进行检测时它接触那个工件。这为两个工件之间的接触设立了零位置。在步骤230，再次基于零件尺寸和材料特性，第二工件被升高到预定间隙距离。在步骤232，第二工件完全收缩，以及在步骤234，操作者启动所选择的焊接程序。
在步骤236，加热器部件14从其原始位置向其在步骤238由限位开关所检测的焊接位置延伸。在步骤240，向加热器供应电力以开始加热器部件的温升。或者，在加热器位于原始缩回位置期间时已被预先加热。在这样一种情况中，在步骤240，接着增加加热器功率以使加热器温度提高到期望的焊接温度，所述焊接温度是为每个工件独立地选择和控制的。在步骤242，启动焊接计时器。通过精确控制加热元件20、22的温度以及焊接位置处的工件温度，工件可在步骤244开始被加热直到在步骤246工件温度传感器测定出工件已被加热到其适当的温度。在步骤248使用计时器以确保工件在预定的时窗范围内被加热，否则可能会显示加热器部件或相关线路的可能故障。当在步骤246工件温度传感器测定出工件已被适当地加热到焊接温度以后，在步骤249加热器部件重新返回到其原始位置或收缩位置。
在步骤250，工件调节器使工件移动接触以便于将两个工件连接在一起。在步骤252，在该例子中，使零件结合在一起大约十分钟(10分钟)。在步骤254，可提供可听见和/或可视的报警信号，以便于警告操作者已经完成了焊接程序，并且在步骤256，在步骤258操作者可从固定设备移除完成的结构。在步骤260，操作者确定在下一个循环期间是否将要焊接相同的零件或者由于零件改变是否需要新的调整(set-up)。在步骤262，将下一对工件放入设备中，并且焊接程序被重新启动返回到步骤234。如果在步骤264需要新的调整，程序循环返回到步骤200并且操作者输入焊接操作的各种参数。
参照图6，图6示出了本发明所涉及的加热元件20、22的标准加热曲线。在先前已知***中，加热器将被激活并简单加热到某个预定但非规定的温度。因此，焊接位置的工件加热是不受控制并且不一致的。根据本发明，由于加热元件温度传感器和工件温度传感器的使用，具有任何期望加热曲线的工件都可被加热。在图6的实施例中，最初加热元件20、22被加热到第一温度T1，所述第一温度T1最好(但非必须)低于工件材料的熔化温度T3。在实际焊接操作开始之前，工件必须在该温度下均热一段时间。我们已经发现，在一些应用中该预浸可导致更好和更一致的焊接。在选择的保温时期T1过后，加热元件20、22被加热以使得焊接位置处的工件温度被升高到温度T2，所述温度T2高于熔化温度T3但低于分解温度T4。然后如文中先前所述的，通过将零件压在一起而使得工件连接。在焊接时期T2过后，如果需要的话，焊接的零件可经受冷却曲线。
参照图7，示出了另一个加热曲线。在该图中，线A是加热器20、22中的一个的测定温度，而线B是另一个加热器的测定温度。在该实施例中，在温度上加热器逐渐升高到选择的温度T1，接着在工件加热时保持该温度。图表示出了控制电路12如何以常规方式操作以便于控制加热器温度。例如，控制电路12可执行常规PID控制算法。
在图7的实施例中，加热器20、22都升高到相同的温度，但这是不需要的，并将取决于相关工件的尺寸和材料。图7还用图表表示了相对于另一个加热器来说，各个加热器是如何被独立控制的。
图7的线C和D绘制了焊接位置处的工件W和W2的温度。工件温度逐渐上升直到达到选择的焊接温度，所述焊接温度在图7的实施例中出现在时间T1处。那时，加热器被移除并且工件如文中先前所述那样被连接。在图7中由于测量技术，线C逐渐下落。线C对应于可移动工件，因此当使其移动到与另一个工件相接触时，焊接位置从IR温度传感器的“窗口”位移。在实践中，线C将以与线D类似的方式显示出逐渐冷却。出现在T1的线D中的跳跃为当两个工件连接在一起时出现在焊接位置处的温升。
实际上图6和7的例子是示范性的。可为被焊接的各个具体零件或材料测定选择的加热曲线。
参照图8A-8C，本发明还包括通过减少焊接处施加的力和残余应力而提高最终焊接质量和强度的固定装置概念。依照本发明的这个方面，至少一个工件被安装在固定装置上，以便于当焊接冷却时，该工件可相对于固定装置轴向自由移动。这允许在没有轴向约束或残余应力的情况下焊缝冷却。
在图8A-8C的示范性实施例中，第一工件W1(在该例子中为带螺纹的配件管端)将被焊接于第二工件W2(诸如一个阀)。出于清楚的目的简化了视图，并且只示出了工件和一个固定装置。在该例子中，阀W2为可移动工件。
图8A-8C中体现的概念涉及其中具有中心孔200的管状工件。工件W1的下端202(如图中所看到的)是将要被焊接于另一个工件上对应管端204的端部。这些端部202、204限定了焊接位置。在该例子中固定装置202为允许工件被连接的可移动固定装置(如之前参照图3A-3G所描述的)。
在该例子中，因为零件是模制的零件，因此中心孔200不是准确的圆柱体而是具有略微轴向逐渐缩减的锥形。然而还可将固定装置概念施加于非锥形或模制的工件。固定装置206包括被放置在适合的支撑物(未示出)上的基底208。如前面所述的适合的调节器使得基底208可移动。从基底208延伸的是固定架或销210。销210被适当地定尺寸，以致于在工件作为焊接操作的零件被加热之前，销210与工件孔200之间具有轻微的抵触或摩擦配合。
在图8A中，在加热之前工件W1被安装在固定装置210上并被紧密地支撑于销210上。在图8B中，工件已作为焊接操作的零件被加热。在加热期过程中，工件“生长”以致于在销210上具有基本减小的柄，但是具有足够的残余夹紧力以使得工件不会从销210上下落。工件与固定装置206之间的减小的摩擦干扰降低到在形成的焊接冷却期间配件可沿销210滑动的程度。在工件已达到其各自的焊接温度以后，零件连接在一起并将固定装置和销210保持在适当的位置中。在图8C中，在冷却期间(例如从约400℃到约270℃)，当焊接冷却时，固定装置206被保持在适当的位置中。由于已基本上除去了摩擦配合，由于焊接冷却而发生的收缩拉紧目前正自由地沿销210滑动的工件。本领域普通技术人员将明白的是，所描述的移动是相当小但却是重要的。如果工件没有自由地沿销210滑动，在焊接和将形成残余应力。在完全冷却之前将工件从销210上移除，否则工件将恢复其原尺寸并紧密地保留在销210上。然而当需要时可使用这种完全冷却。在图8C中为了清晰，工件沿销210的轻微轴向位移被放大为间隙212。在冷却期间依然使得工件W1径向对准，但是沿轴向不受限制，因此焊缝可带有一点点或没有残余应力地冷却。
参照图9A-9D，示出了固定装置概念的一个备选实施例。该实施例适用于诸如具有基本为圆柱形内孔的标准ISO管端配件250的零件。ISO配件是可移动工件并且在该例子中被焊接于阀体W2。
标准ISO配件的特征在于径向向外延伸的凸缘254。配置固定装置260以便于宽松地夹持配件250并通过销262保持其径向对齐，所述销262延伸到配件的中心孔252中。固定装置260包括轴环264，所述轴环264径向地夹持配件250并具有轴向抓持配件凸缘254的向内延伸的凸缘265。图9A示出了其中配件250被安置在固定装置260中的初始布置。如果需要可使用与销262的微小干涉配合。配件250沿轴向不受限制但被支撑在固定装置260中。在图9B中工件已被加热，并且在图9C中已将工件连接。当配件250被加热时，它与销262之间不再有干涉配合。如图9C中所示的，当制成焊接接头时，工件250已被上推到靠着固定装置260中的致动器266。当焊接270冷却时，配件250沿轴向自由后退并且沿轴向不受限制而同时还被径向对准。因此根据本发明的这个方面，在至少一个所连接的工件沿沿轴向不受限制的情况下，固定装置允许焊缝冷却。
图8A-8C和图9A-9D的示范性实施例由于具体配件设计或焊缝的几何形状而具有所使用的具体的结构特征。不应认为这些实施例是限制性的。其特点是，在加热步骤中至少一个工件被支撑，但是在焊后冷却步骤过程中沿轴向不受限制以消除残余应力。
已经参照优选实施例描述了本发明。在阅读并理解本说明书的基础上可出现其它的修正和变更。当这样的修正和变更在权利要求及其等效形式的保护范围之内时，本发明包括所有这样的修正和变更。

Claims (50)

1.一种用于将含氟聚合物工件焊接在一起的设备，其包括：
具有第一和第二表面的加热器部件；
用于从所述第一表面辐射热量的第一加热元件；
用于从所述第二表面辐射热量的第二加热元件；
所述第一和第二加热元件的温度被独立控制。
2.如权利要求1所述的设备，其特征在于，所述第一和第二加热元件布置在单个外壳中。
3.如权利要求1所述的设备，其特征在于，至少一个所述表面为非平面的。
4.如权利要求1所述的设备，其特征在于，两个所述表面都为非平面的。
5.如权利要求1所述的设备，其特征在于，至少一个所述加热元件是以非平面的形状布置的。
6.如权利要求5所述的设备，其特征在于，所述非平面加热元件是沿曲线轨迹布置的。
7.如权利要求5所述的设备，其特征在于，所述非平面加热元件使得从所述表面中的一个表面辐射的热量集中。
8.如权利要求1所述的设备，其特征在于，所述第一和第二加热元件使得从所述第一和第二表面辐射的热量定向。
9.如权利要求1所述的设备，包括控制电路，所述控制电路以相互独立的方式控制所述第一和第二加热元件各自的温度。
10.如权利要求9所述的设备，其特征在于，所述控制电路包括第一和第二温度传感器，所述第一和第二温度传感器中的每一个都独立地感测与之相连的一个加热元件的温度。
11.如权利要求9所述的设备，其特征在于，所述控制电路包括焊接温度传感器，所述焊接温度传感器用于检测由所述加热元件中的一个加热的工件的温度。
12.如权利要求11所述的设备，其特征在于，其包括第二焊接温度传感器，所述第二焊接温度传感器用于检测由另一个所述加热元件加热的第二工件的温度。
13.如权利要求12所述的设备，其特征在于，所述焊接温度传感器包括一红外线热传感器。
14.如权利要求1所述的设备，其包括用于支撑将被焊接在一起的第一和第二工件的第一和第二固定装置，至少一个所述固定装置被安装在可移动的平台上，其还包括用于在焊接操作中控制所述工件相对于彼此的位置的控制电路。
15.如权利要求14所述的设备，其特征在于，所述加热器部件在收缩位置和所述工件附近的焊接位置之间是可移动的。
16.如权利要求15所述的设备，其包括第一和第二加热元件温度传感器，所述加热元件温度传感器向所述控制电路提供对应于所述加热元件温度的信号。
17.如权利要求16所述的设备，其包括第一和第二焊接位置温度传感器，所述焊接位置温度传感器向所述控制电路提供对应于所述工件温度的信号。
18.如权利要求9所述的设备，其特征在于，所述控制电路根据预定的温度曲线控制所述加热元件的加热。
19.如权利要求18所述的设备，其特征在于，所述温度曲线包括一个加热期期间的阶式的斜面顺序。
20.一种用于焊接塑料工件的加热器，其包括：
加热器部件；
布置于所述加热器部件中的第一和第二加热元件，其中，每个加热元件的温度相对于另一个加热元件的温度被独立地控制。
21.如权利要求20所述的加热器，其特征在于，至少一个所述加热元件是以非平面的形状布置的。
22.如权利要求20所述的加热器，其特征在于，所述加热器部件包括从所述第一和第二加热元件辐射热量的第一和第二非平面表面。
23.如权利要求20所述的加热器，其特征在于，从所述加热器部件辐射的热量被聚焦。
24.一种将塑料工件焊接在一起的方法，所述方法包括以下步骤：
a)将各个工件加热到在预定温度范围内的一温度；
b)所述加热步骤包括使用两个加热元件，其中每个加热元件朝向相应的工件辐射热量；以及所述加热元件中的至少一个朝向相应的工件聚焦辐射热。
25.如权利要求24所述的方法，其特征在于，在焊接工序期间所述工件被加热到不同的温度。
26.如权利要求25所述的方法，其包括这个步骤：独立地检测所述加热元件的温度。
27.如权利要求25所述的方法，其包括这个步骤：独立地检测所述每个工件的温度。
28.如权利要求25所述的方法，其包括这个步骤：在两个工件都已达到其各自的预定温度以后，通过连接工件将两个工件焊接在一起。
29.如权利要求25所述的方法，其用于将全氟烷氧基聚合物(PFA)工件与改性的聚四氟乙烯(PTFE)工件焊接。
30.如权利要求25所述的方法，其特征在于，所述工件包括具有不同熔化温度的材料。
31.如权利要求30所述的方法，其特征在于，至少一个所述工件被加热到大约是其熔化温度或高于其熔化温度并低于其分解温度的一温度。
32.如权利要求25所述的方法，其特征在于，在所述加热步骤期间所述工件被竖直定向。
33.一种用于将含氟聚合物零件辐射焊接在一起的设备，包括：
第一和第二加热元件，可将所述第一和第二加热元件布置成以便加热第一和第二工件；
用于检测所述加热元件的温度的传感器；
用于检测焊接位置的工件温度的传感器；以及
控制电路，所述控制电路接收所述传感器的输出并根据基于所述传感器输出的加热曲线的控制工件的热量。
34.如权利要求33述设备，其特征在于，所述工件是用相同的材料制成的。
35.如权利要求33述设备，其特征在于，一个工件是用可熔化处理的材料制成的，而另一个工件是用不可熔化处理的材料制成的。
36.如权利要求33述设备，其特征在于，一个工件是用全氟烷氧基聚合物材料制成的，而另一个工件是用改性的聚四氟乙烯材料制成的。
37.如权利要求33述设备，其特征在于，所述加热元件使得辐射热集中在预定区域内，以便于主要加热焊接位置处的工件。
38.如权利要求33述设备，其特征在于，所述控制电路控制工件相对于彼此和所述加热元件之间的相对位置。
39.一种用于将含氟聚合物工件焊接在一起的设备，其包括：
加热器，所述加热器具有与之相连的第一和第二加热元件，其中，至少一个所述加热元件使得辐射热朝向工件的加热区域集中。
40.如权利要求39述设备，其特征在于，每个所述加热元件使得辐射热朝向相应的工件集中。
41.如权利要求39述设备，其特征在于，所述加热元件布置在基体中，所述基体被构成得使得辐射热集中。
42.如权利要求39述设备，其特征在于，以通常为抛物线的构形来布置所述加热元件。
43.如权利要求39述设备，其特征在于，以通常为非平面的构形来布置所述加热元件。
44.一种用于将含氟聚合物工件焊接在一起的方法，所述方法包括以下步骤：
a)将各个工件加热到在预定温度范围内的一温度；
b)所述加热步骤包括使用两个加热元件，其中每个加热元件朝向相应的工件辐射热量；以及
c)独立地控制每个加热元件的温度。
45.如权利要求44所述的方法，其包括这个步骤：检测每个所述加热元件的温度。
46.如权利要求45所述的方法，其包括这个步骤：检测工件的焊接位置处的每个工件的温度。
47.一种用于将含氟聚合物工件焊接在一起的方法，所述方法包括以下步骤：
a)选择将被焊接的第一和第二工件，其中，第一工件是用可熔化处理的材料制成的，而第二工件是用不可熔化处理的材料制成的；
b)将各个工件加热到在预定温度范围内的一温度；
c)所述加热步骤包括使用两个加热元件，其中每个加热元件朝向相应的工件辐射热量；
d)独立地控制每个加热元件的温度。
48.一种用于通过红外线热量被焊接的工件的固定装置，所述固定装置包括：
基底；
从所述基底延伸并适合于与所述工件接合的元件；在将热量施加于所述工件之前，所述元件与所述工件径向对准并轴向支撑所述工件；和
在该工件被加热以后，在所述元件上该工件沿轴向不受限制，该加热作为焊接操作的一部分。
49.如权利要求48所述的固定装置，其特征在于，所述元件包括一销，在工件被加热以前，所述销与工件之间具有干涉配合。
50.如权利要求48所述的固定装置，其特征在于，所述元件包括轴环，所述轴环夹持工件上的对应凸缘。
CNA018125727A 2000-05-10 2001-05-08 含氟聚合物的红外线焊接 Pending CN1723116A (zh)

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CN104626540A (zh) * 2015-01-16 2015-05-20 苏州凯尔博精密机械有限公司 一种用于分油管焊接机的红外加热装置
CN104669599A (zh) * 2013-10-25 2015-06-03 麦格纳外部有限责任公司 用于连接热塑性涂覆部件的方法以及塑料部件
CN110412964A (zh) * 2019-07-17 2019-11-05 广东科鉴检测工程技术有限公司 一种仪器电控***的步入式热测试方法及***
CN110678313A (zh) * 2017-05-23 2020-01-10 格拉夫协同有限公司 用于焊接型材件的机器

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CN102765192A (zh) * 2012-07-05 2012-11-07 无锡远翔物联科技有限公司 一种远红外热辐射焊接方法
CN104669599A (zh) * 2013-10-25 2015-06-03 麦格纳外部有限责任公司 用于连接热塑性涂覆部件的方法以及塑料部件
CN104626540A (zh) * 2015-01-16 2015-05-20 苏州凯尔博精密机械有限公司 一种用于分油管焊接机的红外加热装置
CN110678313A (zh) * 2017-05-23 2020-01-10 格拉夫协同有限公司 用于焊接型材件的机器
CN110678313B (zh) * 2017-05-23 2022-03-04 格拉夫协同有限公司 用于焊接型材件的机器
CN110412964A (zh) * 2019-07-17 2019-11-05 广东科鉴检测工程技术有限公司 一种仪器电控***的步入式热测试方法及***

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