Method for Welding a Ball onto a First Component, and Method for Connecting Two Components

Abstract

A method for welding a ball onto a first component includes the following steps: providing a first component; creating a physical mark in or on the first component; positioning the ball in the place where the physical mark has been created; and welding the ball in a non-contacting manner to the first component using a laser welding device that is positioned at a distance from the first component and the ball.

Claims

1. A method for welding a ball onto a first component, said method comprising the acts of: providing a first component; producing a physical mark in or on the first component; positioning the ball at a location at which the physical mark has been produced; contactlessly welding the ball to the first component via a laser welding device arranged at a distance from the first component and the ball.

2. The method according to claim 1, wherein the act of producing the physical mark is carried out by a forming tool by which the first component is formed.

3. The method according to claim 2, wherein the forming tool is a deep-drawing tool.

4. The method according to claim 1, wherein the physical mark is a trough-shaped depression.

5. The method according to claim 1, wherein the physical mark is an elevation of the first component having a central-trough-shaped depression.

6. The method according to claim 1, wherein the physical mark is a hole passing through the first component.

7. The method according to claim 1, wherein the physical mark is an elevation of the first component having a central through-hole.

8. The method according to claim 1, wherein the act of contactlessly welding the ball further comprises the acts of: generating a laser beam; and guiding the laser beam from one side in an undercut region, the undercut region being located between the ball and the first component in which the ball touches the first component.

9. The method according to claim 8, wherein an annular seam extending around the ball is generated with the laser beam.

10. The method according to claim 1, wherein the act of contactlessly welding the ball further comprises the acts of: generating a laser beam; and directing the laser beam from a side remote from the ball onto the first component such that the first component and/or the ball locally melts.

11. The method according to claim 1, wherein the act of contactlessly welding the ball further comprises the acts of: generating a laser beam; and directing the laser beam onto a side of the ball which is remote from the first component.

12. The method according to claim 11, wherein, in a first phase, material of the ball is evaporated via the laser beam such that a hole is formed in the ball extending in a direction toward the first component.

13. The method according to claim 12, wherein, in a second phase, the ball is welded to the first component from a base of the hole through a remaining ball material via the laser beam penetrating into the hole.

14. A method for connecting first and second components, the method comprising the acts of: first, welding a ball onto a first component according to the method of claim 1; and second, arranging a second component having a through-hole on the first component such that the ball welded onto the first component protrudes into the through-hole or through the through-hole of the second component.

15. The method according to claim 14, wherein the second component is clamped via the through-hole onto the ball of the first component.

16. The method according to claim 14, wherein a clip element is clipped onto the ball and projects beyond the through-hole in order to connect the second component to the first component.

17. The method according to claim 1, further comprising the act of: magnetically attracting together the ball and the first component at a location of the physical mark.

18. The method according to claim 17, wherein the ball is a magnetic ball.

19. A component having a welded-on ball produced by the method of claim 1.

20. A component connection produced by the method of claim 14.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIGS. 1 illustrates schematically a method for welding a ball onto a first component according to an exemplary embodiment of the invention.

[0028] FIG. 1A schematically illustrates various physical marks formed on a first component in accordance with embodiments of the invention

[0029] FIG. 2 illustrates schematically a further method for welding a ball onto a first component.

[0030] FIG. 3 illustrates another method for welding a ball onto a first component.

DETAILED DESCRIPTION OF THE DRAWINGS

[0031] FIG. 1 shows a first component 1, which may be, for example, a steel sheet or an aluminum sheet. A physical mark (not identifiable in FIG. 1, see FIG. 1A), e.g. in the form of an imprint in the style of crosshairs 10 or with a spherical segment shape 12, is produced at a predefined location from a top side la of the first component 1. As an alternative to such an imprint, an elevation like a volcanic crater having a central, trough-shaped depression and/or having a central through-hole 14 could also be produced.

[0032] After the production of the physical mark, a ball 2 is applied to the top side la of the first component 1. The ball 2 is positioned precisely at the location of the physical mark and is oriented precisely in relation to the first component 1 by the physical mark (self-centering).

[0033] If a magnetic force pulling the ball 2 and the first component 1 together is used, the first component can be arranged as desired in space, i.e. the ball 2 can also be applied to the first component from below, for example, without the need for a clamping apparatus or the like which presses the ball 2 against the first component.

[0034] In the exemplary embodiment shown in FIG. 1, a laser welding device (not shown specifically here) arranged at a distance from the ball 2 generates a laser beam 3 which is directed onto the ball 2 from a side of the ball 2 remote from the first component 1 and evaporates ball material, such that a hole 2a extending in the direction of the first component 1 is formed in the ball 2.

[0035] After the hole 2 has been produced, welding is carried out by means of the laser beam 3 from a base 2b of the hole 2a through the remaining ball material, i.e. the ball 2 and/or the first component 1 are locally melted in a region of contact 4 and are welded to one another.

[0036] FIG. 2 shows an exemplary embodiment in which a physical mark has been produced in a quite similar manner before the ball 2 was placed onto the component 1. A laser welding device (not shown specifically here) generates a laser beam 3 which is directed from a side remote from the ball 2 onto the first component 1. The laser beam 3 is therefore directed onto the first component 1 from the rear side of the first component. In this process, thermal energy is supplied through the first component 1 in the region of contact 4. This leads to local fusion of the ball 2 with the first component 1.

[0037] If the physical mark can also be identified from the rear side of the first component 1 remote from the ball 2 or can be detected by an optoelectronic device, the location or position of the physical mark can also be used for orienting the laser beam 3 with positional accuracy.

[0038] In the exemplary embodiment shown in FIG. 3, a physical mark is likewise produced, as described above, before the ball 2 is placed onto the first component 1. Then, a laser beam 3 is guided from one side into an undercut region located between the ball 2 and the first component 1, i.e. into the region of contact 4. By virtue of the fact that the laser beam 3 is guided around the ball, an annular seam extending around the ball 2 can be generated.

[0039] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.