CN101384394A - 激光焊接方法 - Google Patents

激光焊接方法 Download PDF

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CN101384394A
CN101384394A CNA200780002544XA CN200780002544A CN101384394A CN 101384394 A CN101384394 A CN 101384394A CN A200780002544X A CNA200780002544X A CN A200780002544XA CN 200780002544 A CN200780002544 A CN 200780002544A CN 101384394 A CN101384394 A CN 101384394A
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laser beam
welding
focal length
laser
weld
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CN101384394B (zh
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A·詹森
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Shen Chi Automation Co., Ltd.
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Savcor Alfa Oy
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/0869—Devices involving movement of the laser head in at least one axial direction
    • B23K26/0876—Devices involving movement of the laser head in at least one axial direction in at least two axial directions
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
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    • 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
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明涉及一种快速、灵活和高质量激光焊接塑料工件的方法。在该方法中，激光束通过扫描反射镜被导向被焊接物体。根据本发明，在该方法中，控制和调整扫描反射镜的运动；并通过增大焦距至大于200mm而增大激光束的移动速率；且激光束的移动速率设置为大于10m/s；且激光束沿着预定的焊接路径移动多次。

Description

激光焊接方法
技术领域
本发明涉及一种如权利要求1前序部分所定义的一种用于快速、灵活、高质量的激光焊接工件的方法。
背景技术
现有技术有各种不同的激光焊接方法。而且，现有技术中有各种不同的应用于塑料的激光焊接应用。已知的用于塑料的激光焊应用的问题在于它们作为工业应用的引入受到这些方法的滞后性以及激光设备的高昂价格的限制，例如，在大规模生产应用中。
例如当今移动电话的部件主要依靠超声焊接彼此连接。该方法使得移动电话的各种尺寸部件的焊接时间少于0.5秒。当前的激光焊接方法仅用于例如照相机透镜这类较小部件时才能达到同样的焊接速率。例如，用于移动电话的显示窗口时，焊接时间可能在2至5秒之间，这在大规模生产应用中太长了。
超声焊接的问题在于其焊缝参差不齐的质量。而且，超声焊接是一种复杂的方法，且在生产线上从一个待焊接工件转移到另外一个需要大量的机械排列。而且，还存在达到给定类型的焊缝的各种局限的问题。
作为激光焊接方法在塑料的焊接中其可以使用连续搭焊或扫描型焊接。在搭焊中，激光束移动掠过待焊接的接头一次，就像在传统焊接中一样。在扫描型焊接中，激光束围绕接头移动扫描多次，从而在每次回转后使得焊缝变得越来越热，直到整个焊缝几乎在同时熔化。典型地，搭焊的速率为小于10m/min，传统地为1至3m/min。扫描型焊接的焊接速率典型地为0.5至5m/s。扫描型焊接具有的优势为在焊接点出现的空气间隙相比搭焊被更好地填充。相比采用搭焊，采用扫描型焊接可以焊接高达3至5倍的空气间隙。
已知的扫描设备通常用于激光标记，其中，由于标记所要求的精度，通常小于20μm，激光束的移动速度为几百mm/s。一般情况下，用于连接目的的塑料焊接并不需要激光束以如此高的精度移动，由此希望更高的速度。然而，在已知设备中，激光束的最大移动速度通常为5至小于10m/s的范围内，这对所有的焦距来说通常为最大速度。
如果想消除或者大大减轻待焊接工件的测量误差或者想获得足够坚固的接头，尤其是用于大工件时，已知的扫描型激光焊接应用需要大约20至50个扫描回转。已知的焊接速率太慢。因此，工业上还没有广泛的激光焊接应用。
而且，已知的非激光焊接方法具有缺少灵活性的劣势，例如，当改变待焊接工件或其尺寸时。
发明目的
本发明的目的在于消除上述提到的不足。
本发明的另一个目的在于公开一种改进的方法用于工件的灵活、快速且高质量的激光焊接。本发明的一个特殊的目的在于公开一种用于焊接大型焊接区域并缩短焊接时间的方法。
发明内容
本发明的方法的特征在于权利要求中的所呈现的内容。
本发明是基于一种用于快速、灵活且高质量的激光焊接工件的方法。根据本发明，在该方法中，激光束经过扫描反射镜被引导至待焊接物体上；控制并调整该扫描反射镜的运动；激光束的运动速率设定为大于10m/s；且激光束沿着预定的焊接路径运动多次。
这里，激光焊接通常指任何类型的激光焊接。
本发明具体基于一种焊接方法，其中焊接速率很高，因此，在焊接各种各样和各种尺寸的工件时能够达到短的焊接时间。
在本发明的方法中，激光束最好是掠过焊接接头多次，甚至是50次。通过移动激光束掠过焊接接头数十次能够达到更大的熔化，得到更紧固的接头。
在本发明的一个实施例中，激光束沿着焊接路径的移动次数，即，扫描次数被优选以获得最佳结果。主要通过增加扫描次数的数量，在焊接接头中的测量误差可以被弥补。
在本发明的一个实施例中，生成用于控制扫描反射镜运动的程序。
在本发明的一个实施例中，提供适当的透镜用来达到想要的光学聚焦距离使得激光束穿过透镜且焦距用于调整激光束的移动速率。优选地，激光束的移动速率通过增加焦距而被增加。最佳移动速率随着应用的不同而变化。
在本发明的一个实施例中，该方法采用的焦距大于100mm。在一个实施例中，该方法采用的焦距为100至5000mm。
在一个实施例中，该方法采用的焦距为大于200mm。在一个实施例中，该方法采用的焦距小于1000mm。
优选地，本发明的方法采用两个长焦距，大于100mm。但是，太长的焦距导致不准确的焊接结果。因此，焦距应当根据各种具体情况被优选。
而且，本发明是基于利用本发明的方法激光焊接塑料工件，其中两个塑料零件被焊接在一起。以前，更大的，即，那些具有手掌尺寸大小的塑料工件的激光焊接是很慢的，并且没有达到适于工业应用。本发明得到了一种工业可应用的用于具有各种尺寸的塑料工件快速激光焊接方法。
相比于在先技术，采用本发明的方法获得了可观的进步。
依靠本发明，获得了一种快速且灵活的焊接方法。依靠本发明，能够将具有不同尺寸和材料的工件彼此连接。也可以缩短更大工件的焊接时间。采用该方法达到的焊接时间可以比已知焊接方法快10倍。这种情况下，每个工件采用激光设备是有利的替代选择。而且，根据本发明中的方法一件激光设备可以替代许多超声设备。
而且，本发明具有这样的优势：当采用具有大于10m/s的移动速率的激光束时，焊接的参数范围增大。更进一步，本发明能够优化激光束运动即扫描周期的次数，从而得到最好的效果。在这种情况下，由塑料的注入成型导致的在塑料表面的误差可以通过激光束沿着焊接路径数十次的扫描和通过在焊接过程中挤压待焊接工件而被补偿，因而测量误差变得均匀。
而且，根据本发明，由于高焊接速度和几乎同步的焊接，紧密、可靠和高质量的焊缝被获得。而且，焊缝的质量容易监测。
而且，根据本发明的激光焊接方法，只需要通过改变程序，在生产线上就可以很简单地从一个产品转换到另一个产品。作为一条主要标准，我们不需要对本发明的方法中的设备做任何改变。因此，生产线上新产品的引入变得更快。
而且，本发明的方法能够同时焊接多个工件。
本发明的方法适用于在工业化范畴内的各种材料的焊接，例如，在移动电话工业中焊接塑料工件，该方法可用于可使用激光的任何产品的生产和标记。
附图说明
下面，本发明将参照附图详细描述，其中
图1表示扫描型焊接的原理；和
图2描述焦距的增加对焊接区域和焊接速度的影响。
具体实施方式
本发明的方法在塑料焊接中采用从激光标记中已知的扫描器(图1)进行测试。在该技术中，激光束通过金属烟雾热反射镜的方式以高速扫描掠过焊接位置。由于塑料的低的热导率，待形成的焊接接头逐渐变得越来越热且相对一致使得整个焊接接头几乎在同时熔化。在该方法中，焊接时间由焊接速率决定，即采用的扫描速率、采用的焊接周期的次数以及工件的尺寸。形成焊接接头的焊接路径可以基于例如CAD图像而被形成。
扫描型焊接采用的扫描器的速率和工作区域由采用的透镜决定。例如，在一个测试中，当采用160mm的焦距时，使用的一种已知的二极管激光设备达到100mm×100mm的工作区域，在该工作区域中焦点的尺寸，即焊接的宽度为1.1mm。当焦距被拉长时，工作区域的尺寸和焦点的尺寸都线性增大。例如，焦距为430mm，工作区域为大约300mm×300mm且焦点尺寸为2.7mm。由于大的焦点，塑料的二极管激光焊接在此之前还没有使用大工作区域。一个测试采用新型纤维激光达到了小焦点尺寸也适用于大的工作区域；例如，具有300mm的焦距，工作区域为200mm×200mm，且焦点的尺寸为0.15mm。
扫描反射镜的角度可根据待焊接目标的形态、焊接区域和焊缝的宽度等进行自动调整。
在该连接中，具有大于10m/s的焊接速率被测试，而且基于这些得到的结果将与采用典型的2至5m/s的速率得到的结果进行比较。对于扫描周期的次数，采用每道焊缝扫描30至50次。每次扫描焊缝加大。
该测试采用不同焦距来增加焊接速率。例如，测试焦距为100mm、200mm和500mm。
在进行的测试中发现焦距越长，相比具有更短的焦距，激光束可以以越高的速率移动。激光束的移动速率受扫描反射镜的速率的影响。具有100mm的焦距，最大速率为Vm/s，具有500mm的焦距，则最大速率为5倍的Vm/s(图2)。因此，不论采用短的还是长的焦距，激光束在相同的时间内从A点运行到B点，但是采用长焦距时被拉得更长。
在所作的测试中发现通过增加焦距激光束的移动速率可以增加至甚至达到50至100m/s。但是，与焦距的增加相联系的移动速率的增加应当被优化，因为采用的扫描器的焊接精度成了限制因素。作为通用规律，扫描器的精度随着焦距的增加而变差。焦距为500mm时，精度则比焦距为100mm时差5倍。
在所作的测试中，例如，采用本发明的扫描型焊接当采用10m/s的焊接速率且焊缝被扫描50次时，具有150mm长的焊缝可以在0.75秒内被焊接。相似地，当焊接速率为25m/s且扫描次数为50时，同样的焊缝能够在0.3秒内被焊接。先前已知方法的相应焊接时间为在采用2.5m/s和5m/s时分别为3和1.5秒。
为了提升焊接速率到大于10m/s、为了使用更长的焦距和为了控制扫描反射镜的运动，在使用已知的扫描器中需要在扫描器中生成新的程序。在一个实施例中，实现程序的变化以致激光束的最大移动速率依靠采用的扫描反射镜和焦距。在这种情况下，采用500mm的焦距获得大约50m/s的移动速率。
设计用于激光焊接扫描装置即扫描器在机构和功能本身是已知的，因此在这里不再详细描述。所述激光焊接本质也是以已知的方式进行，因此在这里不再进行详细描述。
在各种实施例的形式下，本发明的方法适于多种类的工件的激光焊接。
本发明不仅仅局限于上面涉及的实施例，但是在权利要求限定的发明构思的范围内任何改进都是可能的。

Claims (7)

1、一种用于激光焊接塑料工件的方法，其中，激光束经扫描反射镜导向被焊接物体，其特征在于，在该方法中，控制和调节扫描反射镜的运动，并通过增大焦距至大于200mm而增大激光束的移动速率；且激光束的移动速率设置为大于10m/s；且激光束沿着预定的焊接路径移动多次。
2、根据权利要求1所述的方法，其特征在于，优化激光束沿着焊接路径移动的次数。
3、根据权利要求1或2所述的方法，其特征在于，生成用于控制扫描反射镜的运动和使用较长焦距的程序。
4、根据权利要求1至3中任意一项所述的方法，其特征在于，激光束的最大移动速率取决于所使用的扫描反射镜和焦距。
5、根据权利要求1至4中任意一项所述的方法，其特征在于，提供适用的透镜以获得所需的最佳焦距以便激光束穿过该透镜，且该焦距用于调节激光束的运动速率。
6、根据权利要求1至5中任意一项所述的方法，其特征在于，该方法采用小于5000mm的焦距。
7、根据权利要求1至6中任意一项所述的方法，其特征在于，该方法采用小于1000mm的焦距。
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