JP4868494B2 - 樹脂体の溶着方法および溶着装置 - Google Patents
樹脂体の溶着方法および溶着装置 Download PDFInfo
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- JP4868494B2 JP4868494B2 JP2005316309A JP2005316309A JP4868494B2 JP 4868494 B2 JP4868494 B2 JP 4868494B2 JP 2005316309 A JP2005316309 A JP 2005316309A JP 2005316309 A JP2005316309 A JP 2005316309A JP 4868494 B2 JP4868494 B2 JP 4868494B2
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- resin body
- laser beam
- laser light
- evaluation
- unit
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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
- 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
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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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- 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
- B29C65/1629—Laser beams characterised by the way of heating the interface
- B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
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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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- 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
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- B29C65/16—Laser beams
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- B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
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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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- 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
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- B29C65/1677—Laser beams making use of an absorber or impact modifier
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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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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B29C65/16—Laser beams
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C65/1683—Laser beams making use of an absorber or impact modifier coated on the article
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- 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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
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- 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
- B29C66/50—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
- B29C66/65—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 with a relative motion between the article and the welding tool
- B29C66/652—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 with a relative motion between the article and the welding tool moving the welding tool around the fixed article
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- 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
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- B29C66/72321—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 being multi-layered comprising a non-plastics layer consisting of metals or their alloys
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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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- B29C66/80—General aspects of machine operations or constructions and parts thereof
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- B29C66/8161—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 mounting of the pressing elements, e.g. of the welding jaws or clamps said pressing elements being supported or backed-up by springs or by resilient material
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- 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
- B29C66/90—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
- B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
- B29C66/939—Measuring or controlling the joining process by measuring or controlling the speed characterised by specific speed values or ranges
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/96—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process
- B29C66/967—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving special data inputs or special data outputs, e.g. for monitoring purposes
- B29C66/9672—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving special data inputs or special data outputs, e.g. for monitoring purposes involving special data inputs, e.g. involving barcodes, RFID tags
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Description
本発明の第1態様について図1〜5に基づき説明する。図1は第1態様の溶着装置の概略構成図、図2は図1の溶着装置が照射するレーザ光のエネルギー量の監視状態および樹脂体の溶着部の大きさと強度との関係を説明する図、図3は樹脂体の溶着部の大きさと強度との相関の関係を説明する図、図4は樹脂体同士の間に隙間が生じている場合に形成された溶着部を示す図、図5は図1の溶着装置の変形例の概略構成図である。
第1樹脂体51は、上記したようにレーザ光透過性を有する樹脂、例えばナイロン6やナイロン66等のポリアミド、ポリエチレン、ポリプロピレン、スチレン−アクリロニトリル共重合体、ポリエステル、ポリアセタール、ポリカーボネート、アクリル、ポリスチレン、アクリロニトリル−ブタジエン−スチレン共重合体(ABS)などを平板状に成形してなるものであり、例えば波長が808nmの半導体レーザに対して60〜90%程度のレーザ光透過率を有している。なお、第1樹脂体51としては、必要に応じ、上記樹脂にガラス繊維やカーボンファイバ等を添加して強化したもの、または上記樹脂にレーザ光吸収性のない染料等で着色したものを用いてもよい。また、第1態様においては、レーザ光吸収部53を第2樹脂体52に配置しているが、第1樹脂体51の下面(すなわち第2樹脂体52との当接面)に例えば膜状または層状にレーザ光吸収部を配設してもよい。
第2樹脂体52は、上記したレーザ光吸収部53を設けるためレーザ光吸収性を有する樹脂、次述する顔料または色素が添加されたナイロン6やナイロン66等のポリアミド、ポリエチレン、ポリプロピレン、スチレン−アクリロニトリル共重合体、ポリエステル、ポリアセタール、ポリカーボネート、アクリル、ポリスチレン、アクリロニトリル−ブタジエン−スチレン共重合体(ABS)などを平板状に成形してなるものであり、例えば波長が808nmの半導体レーザに対して70〜90%程度のレーザ光吸収率を有している。
押圧部14は、第1樹脂体51と第2樹脂体52とが重ね合わされた状態で載置される平板状のテーブル143と、テーブル143に載置された第1樹脂体51の上面に当接可能に配設された平板状の押圧部材142と、押圧部材142の両端部に接続されたロッドを有するとともに該ロッド鉛直方向に押引するエアシリンダである押圧手段141と、で構成されている。なお押圧部材142は、レーザ光Lを十分透過する透明体により又は溶着部54に対応した位置に切欠を設ける等して構成することができる。この押圧部14によれば、押圧部材142が上方にある状態で、第1樹脂体51と第2樹脂体52をテーブル143の所定の位置に載置した後に、押圧手段141を作動させて押圧部材142を下降させ、押圧部材142によって第1樹脂体51の上面を所定の押圧力で押圧し、第1樹脂体51と第2樹脂体52とを密着させる。なお、押圧部材142は平板状に限らず種々の形状とすることができ、さらに、押圧手段141としては油圧シリンダ、電気的・機械的直動部材、クランプ冶具等を使用することができる。
レーザ光照射部12は、下方に向かいレーザ光Lを照射可能に取付部材(不図示)に取付けされたレーザ光照射手段121と、光ファイバを介してレーザ光照射手段121に接続されたレーザ光発振手段122とを備えており、レーザ光発振手段122には、レーザ光発振手段122に生じる電圧により発振されるレーザ光Lのエネルギー量をモニタする監視手段1221が組込まれている。なお、レーザ光照射手段121は、光ファイバを介さずレーザ光発振手段122と直接接続されていてもよい。
第1態様の溶着装置1は、レーザ光Lでレーザ光吸収部53近傍に形成された溶着部54の形状を計測する形状計測手段13を備えている。形状計測手段13は、前記レーザ光照射手段121が取付けられている取付部材に取付けられており、レーザ光照射手段121と一定の位置関係を保ちつつ前記移動手段で駆動されレーザ光照射手段121と同期して移動する。本態様においては、形状計測手段13として、所定の分解能および撮像範囲を有するCCDカメラを使用している。なお、CCDカメラには、溶着部54を照明するためのリング照明や適正な画像を得るための偏光フィルタ等が適宜取付けれらていてもよい。
上記したように演算部11は、第1〜第3評価手段111、112、113および判別手段114を主体として構成されており、第1評価手段111はレーザ光発振手段122に組込まれた監視手段1221と、第2評価手段112は形状計測手段13と、第3評価手段113は圧力計測手段15と、電気的に接続されている。また、第1〜第3評価手段111、112、113は、それぞれ判別手段114に電気的に接続されている。
第1評価手段111は、図2に示すように、監視手段1221でモニタされたレーザ光発振手段122の電圧が、予め設定された所定の電圧範囲から逸脱する場合には、照射されているレーザ光Lのエネルギー量が過大または過少と評価するとともに評価結果(異常・正常と問わない。)を判別手段114に伝送する。なお、必要に応じ、モニタされた電圧の状態を判断し、該電圧値の変動が大きい場合やノイズを含む場合には、該電圧値を時間軸方向に移動平均して電圧値の変動を抑制したり、該電圧値に周波数フィルタをかけてノイズを除去する機能を第1評価手段111に設けてもよい。
(1)レーザ照射速度:1m/min
(2)押圧力:10N/mm2
(3)ビームスポット面積:3mm2
(4)レーザ光発振時の出力:150W
(1)レーザ光照射工程
当接面であるレーザ光吸収部53を介し第1樹脂体51と第2樹脂体52をテーブル143上にて重ね合わせ、押圧部14にて所定の押圧力で第1樹脂体51を押圧し第1樹脂体51と第2樹脂体52を密着させる。次いで、レーザ光照射手段121で第1樹脂材51の側からレーザ光Lをレーザ光吸収部53に照射し該レーザ光吸収部53に溶着部54を形成する。
(2)第1評価工程
監視手段1221でモニタしているレーザ光発振手段122に生じる電圧に基づいてレーザ光照射手段121から照射されるレーザ光Lのエネルギー量を演算部11の第1評価手段111で評価する。
(3)第2評価工程
形状計測手段(CCDカメラ)13により計測された溶着部53の形状に基づき第2評価手段112にて溶着部54の剥離強度を評価する。
(4)第3評価工程
テーブル143に組込まれた圧力計測手段15で計測した押圧部14による溶着中の押圧力に基づいて押圧力を評価する。
(5)溶着部の溶着状態の良否を判別する工程
上記第1工程〜第3評価工程における評価に基づいて溶着部54の溶着状態の良否を判断する。
溶着装置2は、上記第1態様の溶着装置1に、レーザ光Lで溶着されている溶着部54の表面温度を計測する温度計測手段26を付加したものである。かかる温度計測手段26は特に限定されるものではないが、非接触で温度の計測が可能な例えば赤外線式温度センサ、放射線式温度センサなどを使用することが望ましい。この温度計測手段26によれば、該温度計測手段26で計測された溶着部54の表面温度に基づき、上記監視手段1221に替えて、第1評価手段111でレーザ光Lのエネルギー量を評価することができる。
本発明の溶着装置を樹脂被覆鋼管の接続部の被覆するために適用した第2態様について、図面に基づき説明する。図6、第2態様の被覆装置の概略構成を示す正面図、図7は図6において矢視aから見た矢視図、図8は図1で符号34で示す押圧部の部分拡大図、図9は図6の被覆装置の動作を説明するための図である。
回転部32は、樹脂被覆鋼管9の外周面を取り囲み周設される略円環状の案内手段321と、樹脂被覆鋼管9の軸心廻りに回転する方向のみに摺動可能に案内手段321に嵌着された支持部材323と、前記支持部材323に配設されるとともに前記案内手段321に係合して支持部材323を樹脂被覆鋼管9の軸心廻りに回転させる回転駆動手段322とから構成されている。なお、前記レーザ光照射手段311は、防食膜8の表面をレーザ光Lが照射できるようにレーザ光Lを照射する先端部が下方に向けられた状態で後述する水平駆動手段324、焦点調整手段325を介して支持部材323に取付けられている。
押圧部34について図8を参照し説明する。図8(a)は押圧部34の正面断面図、図8(b)は図8(a)の右側面図である。本態様の押圧部34は、一対のローラ状の押圧手段341と、押圧手段341を加圧して被覆層92の表面に押圧する加圧手段342とから構成され、図8(b)に示すように、レーザ光照射手段311から伸びた、平面視においてレーザ光Lが通過する部分が欠けている略コの字状の連結部材343の両椀にそれぞれ取付けられている。
まず、図9(a)、(b)に示すように、レーザ光照射手段311が頂部に固定された上部案内手段321aを樹脂被覆鋼管9の上側に置き、次に樹脂被覆鋼管9の下方から下部案内手段321bを上部案内手段321aと接続し、被覆装置3を組み上げるとともに防食膜8と被覆層92の一方の溶着部8aにレーザ光Lが照射されるように樹脂被覆鋼管9の軸心方向について被覆装置3の位置を調整し、被覆装置3を固定する。その後、焦点調整手段325によりレーザ光照射手段311の高さを変えてレーザ光Lの焦点位置を調整する。
11 :演算部
111 :第1評価手段
112 :第2評価手段
113 :第3評価手段
12 :レーザ光照射部
121 :レーザ光照射手段
122 :レーザ光発振手段
1221:監視手段
13 :形状計測手段
14 :押圧部
141 :押圧手段
142 :押圧部材
143 :テーブル
15 :圧力検出手段
3 :被覆装置
31 :レーザ照射部
311 :レーザ照射手段
312 :レーザ発信手段
313 :光ファイバ
32 :回転部
321 :案内手段
322 :回転駆動手段
323 :支持部材
324 :水平駆動手段
325 :焦点調整手段
33 :形状計測手段
34 :押圧部
341 :押圧手段
342 :加圧手段
343 :連結部材
35 :圧力検出手段
51 :第1樹脂体
52 :第2樹脂体
8 :防食膜
81 :重合部
82 :突合部
9 :樹脂被覆鋼管
91 :鋼管
92 :被覆層
93 :接合部
Claims (9)
- レーザ光透過性を有する第1樹脂体と、第2樹脂体とを、管の外周面上で重ね合わせ、レーザ光吸収性を有するレーザ光吸収部を介し、第1樹脂体と第2樹脂体とをレーザ光で溶着する樹脂体の溶着方法であって、レーザ光吸収部を介して重ね合わされた第1樹脂体と第2樹脂体のレーザ光が照射される領域を挟む、管の外周方向前後を所定の押圧力で押圧し、第1樹脂体の側からレーザ光をレーザ光吸収部に照射し該レーザ光吸収部に溶着部を形成するレーザ光照射工程と、前記レーザ光の熱量を評価する第1評価工程と、前記溶着部の形状を評価する第2評価工程と、前記押圧力を評価する第3評価工程を少なくとも含み、第1工程乃至第3評価工程における評価に基づいて溶着部の溶着状態の良否を判別する樹脂体の溶着方法。
- 前記第1樹脂体は伸縮性を有する膜状の樹脂体であり、前記第2の樹脂体は管の外周面上に被覆された樹脂体であることを特徴とする請求項1に記載の樹脂体の溶着方法。
- 前記第1評価工程において、レーザ光の発振状態に基づいて算出したレーザ光の熱量に基づいて溶着状態の良否を判別する請求項1または2に記載の樹脂体の溶着方法。
- 前記レーザ光照射工程において前記溶着部を筋状に形成するとともに、前記第2評価工程において計測した該溶着部の幅に基づいて溶着状態の良否を判別する請求項1または2に記載の樹脂体の溶着方法。
- レーザ光透過性を有する第1樹脂体と、第2樹脂体とを、管の外周面上で重ね合わせ、レーザ光吸収性を有するレーザ光吸収部を介し、第1樹脂体と第2樹脂体とをレーザ光で溶着する樹脂体の溶着装置であって、
(1)前記レーザ光吸収部を介して重ね合わされた前記第1樹脂体と前記第2樹脂体のレーザ光が照射される領域を挟む、管の外周方向前後を所定の押圧力で押圧する押圧部と、
(2)前記第1樹脂体の側からレーザ光を前記レーザ光吸収部に照射し該レーザ光吸収部に溶着部を形成するレーザ光照射部と、
(3)前記レーザ光照射部から照射されるレーザ光の熱量を評価する第1評価手段と、前記レーザ光照射部で形成された溶着部の形状を評価する第2評価手段と、前記押圧部の押圧力を評価する第3評価手段と、第1乃至第3評価手段の評価に基づいて溶着部の溶着状態の良否を判別する判別手段とを有する演算部と
を備えた樹脂体の溶着装置。 - 前記第1樹脂体は伸縮性を有する膜状の樹脂体であり、前記第2の樹脂体は管の外周面上に被覆された樹脂体であることを特徴とする請求項5に記載の樹脂体の溶着装置。
- 前記レーザ光の発振状態をモニタする監視手段を有し、前記第1評価手段は、前記監視手段によりモニタされたレーザ光の発振状態に基づいてレーザ光の熱量を評価する請求項5または6に記載の樹脂体の溶着装置。
- 前記レーザ光照射部から照射されるレーザ光を前記当接面に沿い移動させるレーザ光移動手段と前記レーザ光照射手段により形成された溶着部の形状を計測する形状計測手段とを有し、前記第2評価手段は、前記形状計測手段で計測された溶着部の形状に基づいて溶着部の形状を評価する請求項5または6に記載の溶着装置。
- 前記押圧部が発生する押圧力を計測する圧力計測手段を有し、前記第3評価手段は、前記圧力計測手段で計測された押圧力に基づいて押圧力を評価する請求項5または6に記載の樹脂体の溶着装置。
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JP4043859B2 (ja) * | 2002-06-18 | 2008-02-06 | 浜松ホトニクス株式会社 | 樹脂溶接装置及び樹脂溶接方法 |
JP2004168033A (ja) * | 2002-11-07 | 2004-06-17 | Aisan Ind Co Ltd | レーザ溶着における接合良否判定方法。 |
JP2004167840A (ja) * | 2002-11-20 | 2004-06-17 | Aisan Ind Co Ltd | レーザ溶着における接合良否判定方法 |
JP4577103B2 (ja) * | 2005-06-10 | 2010-11-10 | 株式会社デンソー | レーザ溶着良否判定方法及びその装置 |
JP2007054845A (ja) * | 2005-08-22 | 2007-03-08 | Ito Yoshihiko | 溶着装置における溶着データ表示装置及びコンピュータプログラム |
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