WELDING METHOD AND RESPECTIVE WELDING DEVICE

Abstract

A welding method for welding a first component to a second component using a welding device including an upper tool mounted to an upper support for receiving the first component, a lower tool mounted to a lower support for receiving the second component as well as a preheating arrangement for preheating the first and/or the second component and a controller. A welding device in accordance with the welding method is further provided.

Claims

1. A welding method for welding a first component to a second component using a welding device comprising an upper tool mounted to an upper support for receiving the first component, a lower tool mounted to a lower support for receiving the second component, a preheating arrangement for preheating the first and/or the second component, and a controller, comprising the steps of: a. moving the upper and the lower tool relative to each other along a first axis by a first drive from an initial position to an adjacent position and moving the preheating arrangement by a second drive from a parking position to a preheating position at least partly at the same time, b. preheating the first and/or the second component by the preheating arrangement, thereafter c. moving the upper tool and the lower tool relative to each other along the first axis by the first drive from the adjacent position to a spaced position and moving the preheating arrangement by the second drive from the preheating position to the parking position at least partly at the same time, d. moving the upper tool and the lower tool relative to each other along the first axis by the first drive from the spaced position to a welding position, e. welding the first component and the second component to each other in the welding position of the upper tool and the lower tool, and f. moving the upper tool and the lower tool relative to each other along the first axis by the first drive from the welding position to the initial position.

2. The welding method according to claim 1, wherein the controller controls the first drive and the second drive such that they are energized at least partly at the same time.

3. The welding method according to claim 1, wherein the second drive moves the preheating arrangement along a second axis that is perpendicular to the first axis and a third drive is provided for moving the preheating arrangement along a third axis that is parallel to the first axis.

4. The welding method according to claim 3, wherein the controller controls the third drive with the first and the second drive and at least two of the first drive, the second drive and the third drive are energized at the same time.

5. The welding method according to claim 1, wherein the welding method is a vibration welding method or an infrared welding method.

6. The welding method according to claim 1, wherein the first component and the second component consist of a plastic material.

7. The welding method according to claim 1, wherein the first drive and the second drive are servo drives.

8. The welding method according to claim 1, wherein one drive acts as a master drive and the remaining drive or drives act as slave-drives.

9. The welding method according to claim 1, wherein in case of a failure of one drive, the remaining drive or drives which are energized at least partly at the same time are stopped by the controller.

10. A welding device for welding a first component to a second component using the welding method according to claim 1, comprising a. an upper tool mounted to an upper support for receiving the first component, b. a lower tool mounted to a lower support for receiving the second component as well as c. a preheating arrangement for preheating the first and/or the second component, wherein d. the upper support and the lower support are movable relative to each other along a first axis by a first drive between an initial position, an adjacent position, a spaced position, and a welding position and e. the preheating arrangement is movable by a second drive between a parking position and a preheating position, wherein f. the welding device comprises a controller controlling the first drive and the second drive such that they are energized at least partly at the same time.

11. The welding device according to claim 10, wherein the second drive moves the preheating arrangement along a second axis being perpendicular to the first axis and a third drive is provided for moving the preheating arrangement along a third axis being parallel to the first axis.

12. The welding device according to claim 11, wherein the controller controls the drives such that at least two of the first drive, the second drive and the third drive are energized at the same time.

13. The welding device according to claim 10, wherein the welding device is a vibration welding device or an infrared welding device.

14. The welding device according to claim 10, wherein the first component and the second component consist of a plastic material.

15. The welding device according to claim 10, wherein the first and the second drive are servo drives.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] In the following, the present invention will be described in detail based on the drawings. In the drawings, the same reference signs denote the same elements and/or components. It shows:

[0048] FIG. 1 depicts a welding device having a preheating arrangement in an initial position,

[0049] FIG. 2 shows the welding device according to FIG. 1 with the preheating arrangement being positioned in an intermediate position,

[0050] FIG. 3 shows the welding device according to FIG. 1 with the preheating arrangement being positioned in a preheating position,

[0051] FIG. 4 shows the welding device according to FIG. 1 with the preheating arrangement being positioned in the preheating position and the lower tool in an adjacent position,

[0052] FIG. 5 shows a diagram of the movement of the structural components of the welding device according to the prior art,

[0053] FIG. 6 shows a diagram of the movement of the structural components of the welding device according to an embodiment of the inventive welding method,

[0054] FIG. 7 shows a diagram of simplified electronic cam disks,

[0055] FIG. 8 shows the welding device at time T1/T1′ of an embodiment of the inventive welding method,

[0056] FIG. 9 shows the welding device at time T2/T2′ of an embodiment of the inventive welding method,

[0057] FIG. 10 shows the welding device at time T3/T3′ of an embodiment of the inventive welding method,

[0058] FIG. 11 shows the welding device at time T4/T4′ of an embodiment of the inventive welding method, and

[0059] FIG. 12 shows a flow chart of an embodiment of the inventive welding method.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0060] In the following, an embodiment of the inventive method is explained based on the functioning of a respective welding device. For increasing the understanding of the technical effects of the welding method, first the known procedure is illustrated based in figures Ito 5.

[0061] The welding device 1 comprises an upper tool 12 mounted to an upper support 10 and a lower tool 16 mounted to a lower support 14. The upper tool 12 and the lower tool 16 are movable relative to each other by a first drive 30 along a first axis 32. In the present example, the upper support 10 to which the upper tool 12 is rigidly mounted is an upper tool plate and the lower support 14 to which the lower tool 16 is mounted is a lifting table. As a result, in such an exemplary arrangement, only the lifting table as the lower support 14 will be moved along the first axis 32.

[0062] Further, the welding device 1 comprises a preheating arrangement 18 having a first preheating device 20 and a second preheating device 22. The first preheating device 20 is arranged on an upper side facing in a preheating position the upper tool 12 and the second preheating device 22 is arranged on a lower side facing in the preheating position the lower tool 16. Further, the preheating arrangement 18 comprises a second drive 40 for movement along a second axis 42. The second axis 42 is perpendicular to the first axis 32. Further, a third drive 50 is provided for a movement of the preheating arrangement 18 along a third axis 52. The third axis 52 is parallel to the first axis 32.

[0063] In FIG. 1, the upper tool 12 and the lower tool 16 of the respective welding device 1 are arranged in an initial position, i.e., a starting position. The preheating arrangement 18 is arranged in a parking position.

[0064] Due to the shape of the components to be welded, which is reflected by the shape of the upper tool 12 and the lower tool 16, an undercut is present. An undercut is an element, which protrudes from the respective component such that it covers an area of the component depending on the orientation of the component in the space. In the example, the upper tool 12 is formed like a roof having a gable or, in other words, it provides a reversed V-shape. The lower tool 16 has a complementary shape. The first component and the second component are formed such that they match the form provided by the upper tool 12 and the lower tool 16. Further, the first preheating device 20 and the second preheating device 22 have also a shape matching the form provided by the respective tools 12, 16.

[0065] If the reverse V-shaped upper tool 12 is viewed from below, i.e., from the lower tool 16 along the first axis 32, it does not contain an undercut since all areas are freely accessible. However, if the upper tool 12 is viewed from the side, then one side, namely the left side, covers respectively the other side, namely the right side. One side thus covers the other side depending on the orientation in the space. The respective left side thus represents an undercut in terms of the present disclosure. For clarification, the undercut is thus assumed to be an imaginary point or a curve, which represents the undercut and must be circumnavigated. Only after this circumnavigation can the preheating arrangement 18 be arranged next to the surface of the first component to be heated. Further, it also follows from the above explanation that a movement of the preheating arrangement 18 towards a surface covered by the undercut, for example a surface to be heated, may not be possible with a single straight-line movement.

[0066] The operation is such that in a first step a user places the second component on the lower tool 16. Subsequently, the user positions the first component on the second component in the lower tool 16. Then, the lower support 14 with the lower tool 16 and the components arranged thereon moves from an initial position in the direction of the upper tool 12 until the first component abuts the upper tool 12. This movement takes place along the first axis 32 by means of the first drive 30. The first axis 32 is vertical with respect to the floor or ground on which the welding device 1 is arranged. Then, the lower support 14 moves along this vertical first axis 32 back into a position in which the preheating arrangement 18 can be arranged between the components, here the initial position. For example, the lifting table moves back into the initial position.

[0067] For circumnavigating the undercut, the preheating arrangement 18 is moved in a second step by the second drive 40 along the second axis 42 perpendicular to the first axis 32, i.e., horizontal with respect to the floor or ground, from a parking position into an aligning position between the components to be welded. This position is shown in FIG. 2. The respective movement curve realized by the second drive 40 over time is indicated in FIG. 5 by reference sign 44.

[0068] After the preheating arrangement 18 has been arranged between the two components in the aligning position, the preheating arrangement 18 is moved in a third step by the third drive 50 along the third axis 52 into the preheating position. This position is indicated in FIG. 3. The corresponding movement curve realized by the third drive 50 over time is indicated in FIG. 5 by reference sign 54.

[0069] In a fourth step and after the preheating arrangement 18 has reached the preheating position, the lower tool 16 is moved along the first axis 32 into a position adjacent to the preheating arrangement 18. This position is also called the adjacent position and is indicated in FIG. 4. The movement curve realized by the first drive 30 over time is indicated in FIG. 5 by reference sign 34.

[0070] The preheating then takes place in a fifth step, in which all structural elements of the welding device are held in their position. This can be seen in FIG. 5 from the respective movement curves.

[0071] Subsequently to the pre-heating, the above movements are performed in a reversed order. Thus, the lower support 14 is moved in a sixth step along the first axis 32 back into a position allowing the preheating arrangement 18 to be moved into the parking position. According to the movement curve 34, the lower support 14 is moved back to the initial position as indicated in FIG. 3.

[0072] Next and in a seventh step, the preheating arrangement 18 is moved along the third axis 52 by the third drive 50 back into the aligning position shown in FIG. 2. In an eighth step, the preheating arrangement 18 is moved along the second axis 42 by the second drive 40 into the parking position with reference to FIG. 1. The respective movements and their sequence order are also indicated in FIG. 5.

[0073] For welding the first component to the second component, the lower support 14 is now moved in a ninth step along the first axis 32 into the welding position. The welding of the first component to the second component takes place in a tenth step.

[0074] After finishing the welding, the lower support 14 moves in step eleven with the lower tool 16 and the compound of first and second component arranged thereon along the first axis 32 from the welding position back into the initial position. As soon as the lower support 14 has reached the initial position, the user may remove the compound of first and second component.

[0075] From the above and with respect to FIG. 5, the actuation of each drive occurs only one at a time for avoiding collisions in particular in case of highly complex components to be welded. This applies for all types of drives, i.e., servo drives, pneumatic drives, or hydraulic drives.

[0076] Now referring to FIGS. 6 to 12, an embodiment of the inventive welding method is explained in comparison to the above discussed welding method.

[0077] The welding device 100 used here comprises an upper tool 112 mounted to an upper support 110 and a lower tool 116 mounted to a lower support 114. The upper 112 and the lower tool 116 are movable relative to each other by a first drive 130 along a first axis 132. Here, the upper support 110 to which the upper tool 112 is rigidly mounted is an upper tool plate and the lower support 114 to which the lower tool 116 is mounted is a lifting table. As a result, in such an exemplary arrangement, only the lifting table as lower support 114 will be moved along the first axis 132.

[0078] This arrangement is particularly preferred in case of a vibration welding device. Nevertheless, and in case an infrared welding method is used, a movability of the upper support 110 may also be provided. For the sake of completeness, it is pointed out that the first axis 132 is preferably a vertical axis, i.e., perpendicular to the floor on which the welding device 100 is arranged. Further, the first component and the second component to be welded to each other preferably consist of a plastic material.

[0079] The welding device 100 comprises also a preheating arrangement 118 having a first preheating device 120 and a second preheating device 122. The first preheating device 120 is arranged on an upper side facing in a preheating position the upper tool 112 and the second preheating device 122 is arranged on a lower side facing in the preheating position the lower tool 116. Further, the preheating arrangement 118 comprises a second drive 140 for movement along a second axis 142. The second axis 142 is perpendicular to the first axis 132. Further, a third drive 150 is provided for a movement of the preheating arrangement 118 along a third axis 152. The third axis 152 is parallel to the first axis 132.

[0080] Additionally, the welding device 100 comprises a controller for controlling, preferably electronically coupling or synchronizing, the first drive 130, the second drive 140 and the third drive 150. The controller may be the controller of one of the drives 130, 140, 150 which acts as master or host controller or a separate master or host controller. Using one of the controllers already present realizes a cost-effective embodiment. On the other hand, the usage of a separate controller as master or host controller ensures sufficient processing power and a higher variability in view of different applications.

[0081] Further, and with respect to the drives 130, 140 and 150, they are realized as servo drives. The use of such servo drives ensures a reliable control of the movements and due to the controller, a fast interruption of the movement of the drives, in particular all drives, in case of failure of one drive can be achieved, as discussed in the following. Further, servo drives have the advantage of providing fast movements compared to pneumatic or hydraulic drives while at the same time producing less noise and consuming less energy.

[0082] In FIG. 8, the upper tool 112 and the lower tool 116 of the respective welding device 100 are arranged in an initial position, i.e., a starting position. The preheating arrangement 118 is arranged in a parking position.

[0083] The first step S1 is identical to the above described first step for arranging the first component and the second component in the upper tool 112 and the lower tool 116. At the end of the first step S1, the welding device 100 has the positions as indicated in FIG. 8 and by reference sign T1 in FIGS. 6 and 7. In this regard, FIG. 7 illustrates simplified electronic cam disks used by the controller for controlling the movement of the drives 130, 140 and 150.

[0084] Now, and in a second step S2, the moving of the preheating arrangement 18 from the parking position to the preheating position by the second drive 140 and the third drive 150 occurs without intermediate position. For achieving this, the second drive 140 and the third drive 150 are controlled by the controller such that they are at least partly energized or actuated at the same time.

[0085] For example, and with respect to FIGS. 6 and 7, after the second drive 140 has moved the preheating arrangement 18 along the second axis 142 for a predetermined distance (see reference sign T2 in FIGS. 6 and 7 and the position shown in FIG. 9), the third drive 150 is additionally energized or actuated so that additionally a movement along the third axis 152 results. The movement is thus continuous, and the combined movement is diagonal. Continuous movement defines in this regard a movement without intermediate stops or intermediate positions.

[0086] Also starting at reference sign T2, the first drive 130 is energized or actuated resulting in a movement of the lower support 114 along the first axis 132 (see FIGS. 6 and 7).

[0087] For an easier understanding, FIG. 10 shows the position at reference sign T3 in FIGS. 6 and 7. At the end of the second step S2, the welding device 100 shows the configuration of FIG. 11, which corresponds to reference sign T4.

[0088] A result of this course of procedure is that the path of the preheating arrangement 118 is shortened compared to the above welding method which moves the preheating arrangement 18 along each of the axis separately. A further reduction of the time required before the preheating of the components to be welded can take place in step S3 is achieved by the movement of the lower support 114 from the initial position to the adjacent position at the same time as the third drive 150 of the preheating arrangement 118 is energized or actuated by the controller.

[0089] As mentioned above and for realizing such movements at the same time, the drives 130, 140 and 150 are controlled together by for example electronic cam disks. Thus, the drives 130, 140 and 150 are preferably coupled to or synchronized with each other. This is realized by the controller. Due to this, the respective movements depend on each other so that in case of a failure of one drive 130, 140, 150 the remaining drives are stopped, preferably automatically, due to the common control. Accordingly, a damaging of the first component, the second component, and/or the welding device 100 is avoidable.

[0090] Further, the second drive 140 acts in this example as a master drive and the remaining drives 130, 150 act as slave-drives. This is due to the fact that the second drive 140 is initially energized or actuated without the remaining drives being energized or actuated. Accordingly, and only after the second drive 140 has realized the predetermined distance indicated by reference sign T2, the remaining drives are energized or actuated by the controller.

[0091] Next, the preheating takes place in step S3. To this end, and depending on the application, the preheating arrangement is preferably an infrared preheating arrangement.

[0092] Thereafter, the above movements are performed in the reverse order in step S4, which is indicated by the reference signs T3′, T2′ and T1′ in FIG. 6. Thus, the lower tool 116 is moved along the first axis 132 from the adjacent position to a spaced position, which may be the initial position or any intermediate position allowing a movement of the preheating arrangement 118 into the parking position. Accordingly, and at least partly at the same time, the preheating arrangement 118 is moved from the preheating position to the parking position, preferably in a continuous manner, as explained above. At the end of step S4, the welding device 100 is arranged in the position shown in FIG. 8.

[0093] Next, and in steps S5 to S7, the above explained steps nine to eleven are performed. Thus, the lower tool 116 is moved into the welding position, the components are welded to each other and the lower tool 116 is moved back to the initial position so that a user may remove the produced compound of first and second component.

PARTS LIST FOR FIGS. 1-12

[0094] 1 welding device [0095] 10 upper support [0096] 12 upper tool [0097] 14 lower support [0098] 16 lower tool [0099] 18 preheating arrangement [0100] 20 first preheating device [0101] 22 second preheating device [0102] 30 first drive [0103] 32 first axis [0104] 34 movement sequences realized by the first drive 30 along the first axis 32 [0105] 40 second drive [0106] 42 second axis [0107] 44 movement sequences realized by the second drive 40 along the second axis 42 [0108] 50 third drive [0109] 52 third axis [0110] 54 movement sequences realized by the third drive 50 along the third axis 52 [0111] 100 welding device [0112] 110 upper support [0113] 112 upper tool [0114] 114 lower support [0115] 116 lower tool [0116] 118 preheating arrangement [0117] 120 first preheating device [0118] 122 second preheating device [0119] 130 first drive [0120] 132 first axis [0121] 134 movement sequences realized by the first drive 130 along the first axis 132 [0122] 136 simplified electronic cam disk for the movement to be realized by the first drive 130 along the first axis 132 [0123] 140 second drive [0124] 142 second axis [0125] 144 movement sequences realized by the second drive 40 along the second axis 42 [0126] 146 simplified electronic cam disk for the movement to be realized by the second drive 140 along the second axis 142 [0127] 150 third drive [0128] 152 third axis [0129] 154 movement sequences realized by the third drive 150 along the third axis 152 [0130] 156 simplified electronic cam disk for the movement to be realized by the third drive 150 along the third axis 152

[0131] It should be noted that various modifications are possible that employ one or more aspects of the invention as described herein, including the following appended claims.