CN104275551B - 一种复杂曲面车灯的焊接方法及焊接装置 - Google Patents

一种复杂曲面车灯的焊接方法及焊接装置 Download PDF

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CN104275551B
CN104275551B CN201410476480.9A CN201410476480A CN104275551B CN 104275551 B CN104275551 B CN 104275551B CN 201410476480 A CN201410476480 A CN 201410476480A CN 104275551 B CN104275551 B CN 104275551B
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car light
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CN104275551A (zh
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忻国祥
邱王杰
吴杭
吴页欣
姜兆华
陈俊
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HASCO Vision Technology Co Ltd
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Shanghai Koito Automotive Lamp Co Ltd
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Abstract

本发明涉及一种复杂曲面车灯的焊接方法及焊接装置，所述的焊接方法根据待焊接车灯的材料以及车灯曲面的曲率，在激光发生器内设置待焊接复杂曲面车灯的焊接参数，由气缸驱动待焊接的灯体和配光镜与透明压膜接触，通过透明压膜将灯体和配光镜压紧，透明压膜与配光镜的形状一致，然后启动激光发生器，激光发生器按照设定的焊接参数，根据复杂曲面车灯的材料和待焊接车灯不同曲面位置的曲率，产生不同功率的激光光束，激光光束通过透明压膜聚光后，按设定的焊接速度沿焊接部位进行焊接。所述的焊接方法能耗非常低，没有环境污染，解决现有复杂曲面车灯的焊接方式能耗较高、焊接质量差且污染环境的问题。

Description

一种复杂曲面车灯的焊接方法及焊接装置
技术领域
本发明涉及汽车车灯技术领域，具体是一种采用激光焊接复杂曲面车灯的焊接方法及焊接装置。
背景技术
目前对车灯的焊接一般采用摩擦焊和热板焊。摩擦焊在焊接时，旋转工件在电机驱动下开始高速旋转，移动工件在轴向力作用下逐步向旋转工件靠拢，两侧工件接触并压紧后，摩擦界面上一些微凸体首先发生粘接与剪切，并产生摩擦热。随着实际接触面积增大，摩擦扭矩迅速升高，摩擦界面处温度也随之上升，摩擦界面逐渐被一层高温粘塑性材料所覆盖。此时，两侧工件的相对运动实际上已发生在这层粘塑性材料内部，产热机制已由初期的摩擦产热转变为粘塑性材料层内的塑性变形产热。在热激活作用下，这层粘塑性材料发生动态再结晶，使变形抗力降低，故摩擦扭矩升高到一定程度后逐渐降低。随着摩擦热量向两侧工件的传导，焊接面两侧温度亦逐渐升高，在轴向压力作用下，焊合区材料发生径向塑性流动，从而形成飞边，轴向缩短量逐渐增大。随摩擦时间延长，摩擦界面温度与摩擦扭矩基本恒定，温度分布区逐渐变宽，飞边逐渐增大，此阶段称之为准稳定摩擦阶段。在此阶段，摩擦压力与震动速度保持恒定。当摩擦焊接区的温度分布、变形达到一定程度后，开始刹车制动并使轴向力迅速升高到所设定的顶端压力此时轴向缩短量急骤增大，并随着界面温度降低，摩擦压力增大，摩擦扭矩出现第二个峰值，即后峰值扭矩。在整个过程中，焊合区材料通过相互扩散与再结晶，使两侧材料牢固焊接在一起，从而完成整个焊接过程。
热板焊是通过一个由温度控制的加热板来焊接工件，焊接时，加热板置于两个待焊接的工件之间，当工件紧贴住加热板时，便开始熔化。在一段预先设置好的加热时间过去之后，工件表面将达到一定的熔化程度，此时工件向两边分开，加热板移开，随后在一定压力作用下两片工件快速并合在一起，当达到一定的焊接时间和焊接深度之后，整个焊接过程完成。
摩擦焊会有飞边焊渣现象，能耗较大，热板焊通常会有熔融后焦黑现象，能耗极大，而且两种焊接方式焊接的工件表面质量都不够好。
为了解决上述问题，可以采用激光焊接，激光焊接是利用高能量密度的激光束作为热源的一种高效精密焊接方法，通过激光辐射加热待加工表面，表面热量通过热传导向内部扩散，通过控制激光脉冲的宽度、能量、峰功率和重复频率等激光参数，使工件熔化，形成特定的熔池。激光束可由平面光学元件(如镜子)导引，随后再以反射聚焦元件或镜片将光束投射在焊缝上。但是目前的激光发生器主要用于平面板的焊接，对于复杂曲面车灯的焊接，目前还没有实现激光焊接技术。
发明内容
本发明的目的是提供一种复杂曲面车灯的焊接方法，该焊接方法采用激光焊接的方法实现复杂曲面车灯的焊接，能耗非常低，没有环境污染，用以解决现有复杂曲面车灯的焊接方式能耗较高、焊接质量差且污染环境的问题。
为实现上述目的，本发明的方案是：一种复杂曲面车灯的焊接方法，所述的焊接方法用于焊接汽车车灯的灯体与配光镜，所述的焊接方法采用激光焊接方式，具体包括如下步骤：
(1)将待焊接的灯体与配光镜放置在灯体定位座内，所述的灯体定位座安装在升降板上，所述升降板的底部安装气缸，所述的气缸安装在底部支架上；
(2)将激光发生器放置在顶板上，所述的顶板通过第三立柱和第四立柱固定在底部支架上；
(3)根据待焊接车灯的材料以及车灯曲面的曲率，在激光发生器内设置待焊接复杂曲面车灯的焊接参数，所述的焊接参数包括车灯材料的吸收值、激光功率、焊接速度以及焊接时间；
(4)气缸工作，将升降板顶起，使待焊接的灯体和配光镜与透明压膜接触，通过透明压膜将灯体和配光镜压紧，所述的透明压膜与配光镜的形状一致，所述的透明压膜固定在安装板上，所述的安装板通过第一立柱和第二立柱固定在底部支架上；
(5)启动激光发生器，激光发生器按照步骤(1)中设定的焊接参数，根据复杂曲面车灯的材料和待焊接车灯不同曲面位置的曲率，产生不同功率的激光光束，所述的激光光束通过透明压膜聚光后，按设定的焊接速度沿焊接部位进行焊接；
(6)达到设定的焊接时间后，完成焊接，激光发生器停止工作。
根据本发明所述的焊接方法，所述的激光发生器根据车灯材料的吸收值和车灯曲面的曲率，控制激光发生器产生相应功率的激光束，经过转动反射镜反射后的激光束对准焊接部位，对待焊接部位加热，使得配光镜和灯体焊接在一起，所述的激光发生器为光纤激光发生器。
根据本发明所述的焊接方法，所述的激光发生器在对配光镜和灯体进行焊接时，伺服电机根据焊接位置以及焊接速度，控制所述转动反射镜的旋转角度和转动速度，使得反射镜反射后的激光束对焊接部位加热，并使激光束按设定的焊接速度沿着待焊接部位扫描，直到达到设定的焊接时间后，停止工作。
本发明的目的还在于提供一种采用上述焊接方法的焊接装置，所述的焊接装置采用激光发生器对复杂曲面车灯进行焊接，能耗非常低，没有环境污染，用以解决现有复杂曲面车灯的焊接方式能耗较高、焊接质量差且污染环境的问题。
为实现上述目的，本发明的本发明的方案是：一种复杂曲面车灯的焊接装置，所述的焊接装置包括激光发生器、灯体定位座、透明压膜、气缸、安装板、升降板和和底部支架，待焊接的灯体和配光镜安装在灯体定位座内，所述的灯体定位座安装在升降板上，所述升降板的底部安装气缸，所述的气缸安装在底部支架上，所述气缸的活塞杆作用于升降板；所述的透明压膜与配光镜的形状一致，所述的透明压膜固定在安装板上，所述安装板的两侧通过第一立柱和第二立柱固定在底部支架上；所述激光发生器固定在顶板上，所述的顶板通过第三立柱和第四立柱固定在底部支架上。
所述的激光发生器为光纤激光发生器。
本发明达到的有益效果：本发明采用激光焊接方法对复杂曲面的车灯进行焊接，焊接部位几乎没有变形，焊接速度快，而且不需要焊后热处理，采用激光焊接的车灯焊缝漂亮，没有焊渣，且能耗非常低，没有环境污染，而且采用本发明的焊接方法，焊接完成后，灯体与配光镜之间的间隙小于0.5mm,，更加美观。
附图说明
图1是本发明的焊接方法流程图；
图2是激光焊接原理；
图3是本发明的焊接装置结构原理图。
图中：1为激光发生器，2为顶板，3为第三立柱，4为透明压膜，5为配光镜，6为灯体，7为安装板，8为灯体定位座，9为升降板，10为第一立柱，11为气缸，12为底板，13为底部支架，14为第四立柱，15为第二立柱。
具体实施方式
下面结合附图和实施例对本发明作进一步详细的说明。
本发明的焊接方法实施例：
本发明所述的焊接方法用于焊接具有复杂曲面车灯的灯体与配光镜，目前对灯体与配光镜的焊接一般采用摩擦焊和热板焊，这两种焊接方法的能耗较大，焊接质量不高，而且焊接表面不够美观，为解决现有焊接方法存在的问题，本发明所述的焊接方法采用的是激光焊接方式，如图1所示，本发明的焊接方法具体包括如下步骤：
步骤1，将待焊接的灯体与配光镜放置在灯体定位座内，所述的灯体定位座安装在升降板上，所述升降板的底部安装气缸，所述的气缸安装在底部支架上，气缸作用于升降板，用于将灯体和配光镜升到合适的位置。
步骤2，将激光发生器放置在顶板上，所述的顶板通过第三立柱和第四立柱固定在底部支架上，激光发生器用于发出激光束对待焊接部位进行加热。
步骤3，根据待焊接车灯的材料以及车灯曲面的曲率，在激光发生器内设置待焊接复杂曲面车灯的焊接参数，所述的焊接参数包括车灯材料的吸收值、激光功率、焊接速度以及焊接时间。由于激光束发射到待焊接部位后，不同的材料对激光有不同的吸收率，曲面不同的曲率也会对发射过来的激光产生不同程度的反射，所以，需要根据待焊接车灯的材料和曲率，确定激光束的功率。
步骤4，气缸工作，将升降板顶起，使待焊接的灯体和配光镜与透明压膜接触，通过透明压膜将灯体和配光镜压紧，所述的透明压膜与配光镜的形状一致，所述的透明压膜固定在安装板上，所述的安装板通过第一立柱和第二立柱固定在底部支架上。
步骤5，启动激光发生器，激光发生器按照步骤(1)中设定的焊接参数，根据复杂曲面车灯的材料和待焊接车灯不同曲面位置的曲率，沿着焊接部位产生不同功率的激光光束，所述的激光光束通过透明压膜聚光后，按设定的焊接速度沿焊接部位进行焊接。
步骤6，达到设定的焊接时间后，完成焊接，激光发生器停止工作。
激光焊接的原理如图2所示，激光发生器在进行工作时，根据车灯材料的吸收值和车灯曲面的曲率，控制激光发生器产生相应功率的激光束，经过转动反射镜反射后的激光束对准焊接部位，对待焊接部位加热，使得配光镜和灯体焊接在一起，所述的激光发生器为光纤激光发生器。
本发明的激光发生器在对配光镜和灯体进行焊接时，伺服电机根据焊接位置以及焊接速度，控制所述转动反射镜的旋转角度和转动速度，使得反射镜反射后的激光束对焊接部位加热，并使激光束按设定的焊接速度沿着待焊接部位扫描，直到达到设定的焊接时间后，停止工作。
本发明的焊接装置实施例：
如图3所示，本发明的焊接装置包括激光发生器1、灯体定位座8、透明压膜4、气缸11、安装板7、升降板9和和底部支架13，待焊接的灯体6和配光镜5安装在灯体定位座8内，所述的灯体定位座8安装在升降板9上，所述升降板9的底部安装气缸11，所述的气缸11安装在底部支架13上，所述气缸9的活塞杆作用于升降板9；所述的透明压膜4与配光镜5的形状一致，所述的透明压膜4固定在安装板7上，所述安装板7的两侧通过第一立柱10和第二立柱15固定在底部支架13上；所述激光发生器1固定在顶板2上，所述的顶板2通过第三立柱3和第四立柱14固定在底部支架13上。本实施例采用的激光发生器为光纤激光发生器。
采用本发明的焊接装置进行焊接时，先把灯体6和配光镜5分别放入灯体定位座8里，气缸11顶起升降板9使得待焊接的灯体6和配光镜5与透明压模4接触，激光发生器1通过转动反射镜发出一束激光沿焊接部位扫描，直到达到设定的焊接时间后，完成焊接。采用激光焊接的车灯具有焊缝漂亮，没有焊渣，并且能耗非常低，没有环境污染的特点。而且焊接速度快，不需要焊后热处理。

Claims (5)

1.一种复杂曲面车灯的焊接方法，所述的焊接方法用于焊接汽车车灯的灯体与配光镜，其特征在于：
所述的焊接方法采用激光焊接方式，具体包括如下步骤：
(1)将待焊接的灯体与配光镜放置在灯体定位座内，所述的灯体定位座安装在升降板上，所述升降板的底部安装气缸，所述的气缸安装在底部支架上；
(2)将激光发生器固定在顶板上，所述的顶板通过第三立柱和第四立柱固定在底部支架上；
(3)根据待焊接车灯的材料以及车灯曲面的曲率，在激光发生器内设置待焊接复杂曲面车灯的焊接参数，所述的焊接参数包括车灯材料的吸收值、激光功率、焊接速度以及焊接时间；
(4)气缸工作，将升降板顶起，使待焊接的灯体和配光镜与透明压膜接触，通过透明压膜将灯体和配光镜压紧，所述的透明压膜与配光镜的形状一致，所述的透明压膜固定在安装板上，所述的安装板通过第一立柱和第二立柱固定在底部支架上；
(5)启动激光发生器，激光发生器按照步骤(1)中设定的焊接参数，根据复杂曲面车灯的材料和待焊接车灯不同曲面位置的曲率，产生不同功率的激光光束；
(6)所述的激光光束首先照射到透明压膜上，所述的透明压膜具有外侧曲面与内侧曲面，所述的内侧曲面与配光镜贴合，激光光束从透明压模的外侧曲面，穿过透明压模照射到内侧曲面，激光光束在穿过透明压模时发生一次折射，然后再照射到配光镜，经过配光镜发生第二次折射，最后照射到灯体上，并按设定的焊接速度沿焊接部位进行焊接；
(7)达到设定的焊接时间后，激光发生器停止工作，完成焊接，焊接完成后的灯体与配光镜之间的间隙小于0.5mm。
2.根据权利要求1所述的焊接方法，其特征在于所述的激光发生器根据车灯材料的吸收值和车灯曲面的曲率，控制激光发生器产生相应功率的激光束，经过转动反射镜反射后的激光束对准焊接部位，对待焊接部位加热，使得配光镜和灯体焊接在一起，所述的激光发生器为光纤激光发生器。
3.根据权利要求2所述的焊接方法，其特征在于所述的激光发生器在对配光镜和灯体进行焊接时，伺服电机根据焊接位置以及焊接速度，控制所述转动反射镜的旋转角度和转动速度，使得反射镜反射后的激光束对焊接部位加热，并使激光束按设定的焊接速度沿着待焊接部位扫描，直到达到设定的焊接时间后，停止工作。
4.一种采用如权利要求1所述焊接方法的焊接装置，其特征在于：所述的焊接装置包括激光发生器、灯体定位座、透明压膜、气缸、安装板、升降板和和底部支架，待焊接的灯体和配光镜安装在灯体定位座内，所述的灯体定位座安装在升降板上，所述升降板的底部安装气缸，所述的气缸安装在底部支架上，所述气缸的活塞杆作用于升降板；所述的透明压膜与配光镜的形状一致，所述的透明压膜固定在安装板上，所述安装板的两侧通过第一立柱和第二立柱固定在底部支架上；所述激光发生器固定在顶板上，所述的顶板通过第三立柱和第四立柱固定在底部支架上。
5.根据权利要求4所述的焊接装置，其特征在于所述的激光发生器为光纤激光发生器。
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