CN112399912B - 用于通过电磁焊接来接合模制部件的方法和设备 - Google Patents

用于通过电磁焊接来接合模制部件的方法和设备 Download PDF

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Publication number
CN112399912B
CN112399912B CN201980046862.9A CN201980046862A CN112399912B CN 112399912 B CN112399912 B CN 112399912B CN 201980046862 A CN201980046862 A CN 201980046862A CN 112399912 B CN112399912 B CN 112399912B
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inductor
molded parts
joining
sensing
field strength
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CN112399912A (zh
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马尔滕·拉伯杜斯
汤姆·约翰内斯·詹森
米歇尔·亨德里克·保罗·布鲁克斯
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Guo & Wan En Glenn Composite Structure Co ltd
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Guo & Wan En Glenn Composite Structure Co ltd
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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
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
    • B29C66/91651—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux by controlling or regulating the heat generated by Joule heating or induction heating
    • B29C66/91655—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux by controlling or regulating the heat generated by Joule heating or induction heating by controlling or regulating the current intensity
    • 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
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
    • B29C66/91651—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux by controlling or regulating the heat generated by Joule heating or induction heating
    • 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
    • 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
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • 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
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3604—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint
    • B29C65/364—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint being a woven or non-woven fabric or being a mesh
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/024—Thermal pre-treatments
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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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    • B29C66/00—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
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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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    • B29C66/00—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
    • B29C66/347—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients
    • 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
    • B29C66/349—Cooling the welding zone on the welding spot
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/349—Cooling the welding zone on the welding spot
    • B29C66/3494—Cooling the welding zone on the welding spot while keeping the welding zone under pressure
    • 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
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • 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
    • B29C66/70—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
    • B29C66/72—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
    • B29C66/721—Fibre-reinforced materials
    • 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
    • B29C66/70—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
    • B29C66/72—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
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • 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
    • B29C66/70—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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    • B29C66/73—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B29C66/7392—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • 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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    • B—PERFORMING OPERATIONS; TRANSPORTING
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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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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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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Abstract

描述了用于通过电磁焊接来接合模制部件的方法。使接合电感器沿着模制部件的接触表面移动，在一个或多个所述模制部件的感应敏感成分中产生电磁场，以将一个或多个模制部件的热激活联结装置加热至所述联结装置的熔融温度以上。适于接合的所述电磁场的强度通过以下步骤确定：预先沿着接触平面移动感测电感器，产生相对弱的电磁场以将热激活联结装置稍微加热至感测温度，测量所述感测电感器在一个或多个模制部件中产生的场强，确定由感应电感器的已测量的场强与适于接合的场强之间的差异，以及调整适于接合的场强以消除所述差异。还描述了用于执行所述方法的设备。

Description

用于通过电磁焊接来接合模制部件的方法和设备
技术领域
本发明涉及用于通过电磁焊接来接合模制部件的方法。本发明还涉及用于电磁焊接的设备，所述设备被配置成用于实施所述方法。
背景技术
存在有许多用于接合模制部件(例如接合纤维增强热塑性或热固性复合部件)的技术。传统上，使用机械紧固和胶接来接合模制部件的两个接触表面。然而，机械紧固和胶接都显得昂贵且耗时。例如，机械紧固需要昂贵的孔定位、钻孔、填隙以及紧固件安装，而胶接需要可能涉及化学物质的复杂表面预处理。
电磁焊接可以排除使用单独的紧固件，并且潜在地提供以相对高的速度和很少的预处理(如果有的话)来将模制复合材料部件的接触表面接合的能力。电磁焊接在一个或多个模制部件的感应敏感成分中产生电磁场，以将该模制部件的热激活的联结装置加热至该联结装置的熔融温度以上。该模制部件的接触表面通过熔融的联结装置彼此接合。联结装置例如可以是待接合的一个或多个部件中的热塑性树脂，或者可以是单独施加的热塑性树脂。为了将热塑性和热固性模制部件焊接在一起，感应敏感成分熔融的热塑性树脂可以起到例如热熔粘合剂的作用。
许多焊接方法可用于在模制部件(例如纤维增强复合材料模制部件)之间形成焊接连接。例如，在振动焊接中，增强纤维可能由于运动而受损，并且超声波焊接不太适合于连续焊接。已知的电磁焊接方法可能产生质量较差的接合产品，特别是在需要相对较高机械强度和承载能力的焊接连接的高级应用中，例如在航空业中。
特别地，已知的方法是基于确定焊接参数值(例如适于接合的电磁场的强度和产生这种场强所需的功率)，并且将这些焊接参数值应用于接合该模制部件或一系列的这种模制部件。该方法基于随后可以实现恒定的焊接质量的理念。焊接质量的概念是本领域技术人员已知的，并且例如可涉及到该模制部件的接触表面之间产生的接缝或连接的强度。
仅当成型的复合材料部件对施加的电磁感应场表现出一致的响应时，这种已知的方法才能工作。事实证明，对于许多模制部件而言，情况可能并非如此。例如，已经发现，基于半结晶聚合物和增强纤维(例如碳纤维)的成型复合材料部件对所施加的电磁感应场的响应显示出相对较大的变化。这种变化可能是例如由增强纤维结构等因素而引起的。例如，由单向纤维带制成的复合材料部件中的这种结构提供的可以产生涡电流的限定路径不如织物结构。这意味着该响应似乎与例如纤维体积含量、纤维取向、树脂和纤维的局部分布以及固结质量等因素有关。此外，半结晶聚合物可随结晶度变化程度显示熔点变化。因此，根据模制部件的温度历程，其熔点可能会变化。例如，增强纤维也会在刚度方面变化，这也影响了它们的导电性能。例如，局部地施加厚度，或者使用加强件，也会影响模制部件上的感应响应。例如，由于纤维体积含量的局部变化，或者由于增强纤维中的感应预应力，在接合之前模制这些部件也可能影响电磁感应响应。
成型复合材料部件中的上述变化会导致对施加的电磁感应场的响应沿待接合的接触表面不一致。这直接影响所产生的接缝的质量，并且接缝质量的变化可能是不期望的。
发明内容
本发明的目的是提供用于通过电磁焊接来接合模制部件的改进方法，特别地，提供可以在模制部件之间产生更一致的接缝质量的方法。另一目的涉及提供可实施所述方法的设备。
为此，本发明提供了一种用于通过电磁焊接来接合模制部件的方法。所述方法包括：将接合电感器沿着所述模制部件的接触表面的焊接线A移动，在一个或多个模制部件的感应敏感成分中产生电磁场，以将所述一个或多个模制部件的热激活热塑性塑料加热至所述热塑性塑料的熔融温度以上，并通过熔融的所述热塑性塑料将所述模制部件在所述接触表面彼此接合，其中，适于接合的所述电磁场的强度通过以下步骤确定：预先沿着接触表面的所述焊接线A移动感测电感器，产生相对弱的电磁场，沿着所述焊接线A测量所述感测电感器在所述一个或多个模制部件中产生感应的场强，沿着所述焊接线A确定所述感测电感器的已测量的所述场强与适于接合的场强之间的差异，以及调整适于沿着所述焊接线A接合所述接合电感器的感应线圈的场强以消除所述差异。
所述相对弱的电磁场可以将所述热激活联结装置稍微加热至感测温度。
在一个实施例中，其中，所述热激活联结装置包括热塑性树脂，所述感测温度可以远低于所述树脂的玻璃化转变温度Tg和/或再结晶温度。所述感测电感器所测量的场强可以预测适于接合所述模制部件的最合适的焊接参数，并且有助于获得一致的焊接接缝质量。
本发明的方法的实施例包括沿着所述接触表面连续确定所述差异。适于接合的所述场强可以沿着所述焊缝保持恒定，或者可以在需要的地方进行局部调整。当所述差异(值)在某一位置上为零或约为零时，该位置中的场强可以进行不调整或仅进行稍微地调整。
在根据本发明的方法的有效实施例中，调整适于接合的所述场强(以最小化所述差异)是沿着所述接触表面连续地执行的，并且更优选地，在沿着所述接触表面的若干移动位置处执行的，其中所述差异的值被确定为非零。
本发明的另一实施例涉及一种方法，其中，所述感测电感器在所述接合电感器之前沿着所述接触表面移动。在该实施例中，所述感测电感器和所述接合电感器是分开的电感器，并且从所述感测电感器获得的信息被用于控制所述接合电感器，特别是控制适于接合的所述电磁场的强度。
在根据本发明方法的另一个实施例中，所述感测电感器和所述接合电感器是同一个以及相同的电感器。在这样的实施例中，电感器首先被用作感测电感器以用于“感测”所述模制部件的待接合的所述接触表面，其中，该电感器沿着所述接触表面内的路径移动。然后将同一个电感器作为接合电感器以用于实际焊接，由此根据由所述感测电感器确定的所述差异来改变所述场强。
本发明的另一实施例涉及一种方法，其中所述感测电感器和所述接合电感器是分开的，并且沿着所述接触表面同时地移动。该实施例可以瞬时调节适于接合的所述场强，这意味着直接响应于由所述感测电感器测得的所述差异。
沿着所述焊接路径的所述感测电感器和所述接合电感器之间的距离可根据情况来选择。在所述接合电感器和所述感测感应器彼此相对接近的情况下，由这两个电感器产生的电磁场可能彼此影响。在一个优选实施例中，通过利用非负载基线测量量化该效果来校正所述接合电感器对所述感测电感器信号的影响，然后在实际接合焊接期间，从响应测量中减去在基线测量中获得的偏移值。这允许在任意位置量化感应响应，之后可以通过预定关系确定最佳焊接设置。
本发明的实施例提供了一种方法，其中，所述感测电感器包括发射电感器和接收电感器，所述发射电感器产生所述电磁场，所述接收电感器测量由所述感测电感器在一个或多个所述模制部件中产生的所述场强。所述发射电感器产生所述相对弱的电磁场，所述电磁场将在所述模制部件引起涡电流。另一方面，所述接收电感器量化在所述模制部件中产生的涡电流。所述发射电感器和所述接收电感器可分别安置或被安置在同一壳体中。在所述发射电感器和所述接收电感器彼此相对接近的情况下，由所述发射电感器产生的电磁场可能影响所述接收电感器的测量。在优选的实施例中，通过利用空载基线测量量化该作用来校正所述发射电感器对由所述接收电感器接收的信号的影响，然后在感测期间从所述接收发射器的响应测量中减去在基线测量中获得的偏移值。
本发明的方法包括，在利用相对弱的感应场对所述模制部件进行实际电磁焊接以沿接触表面使其接合之前来量化涡电流响应。借助于该响应，可以预测用于任何成型(复合材料)部件的正确焊接参数是什么，以潜在地获得良好的焊接质量。该方法通过在运行用于接合的实际焊接线圈之前运行感测电感器(例如感测线圈)来执行，从而所述感测线圈量化所述响应。
由所述感测电感器产生的场强可以被直接地测量或者可以通过其他参数来测量。例如，可以测量由施加的电磁场所引起的温度上升。所产生的温度可以直接在焊接中和/或在待焊接的部件的外部间接地确定。这种方法可能需要改进，因为通过定义所产生的温度上升滞后于焊接参数中的变化。
本发明方法的另一实施例包括，测量由所述感测电感器在一个或多个所述模制部件中产生的所述场强是通过测量在一个或多个所述模制部件的边缘处的短路所引起的电流来执行的。这种所谓的边缘效应本身是已知的，并且，在焊接期间，所产生的涡电流将通过测量该边缘效应而被直接量化。该边缘效应可通过在焊接区域周围或沿着焊接区域提供导电材料来最小化，可选地与感受器(susceptor，其本身是已知的)相结合。
测量以涡电流形式的所生成的电磁场的强度由所述感测电感器来执行。然而，另一实施例还包括，测量由所述接合电感器在一个或多个模制部件中产生的场强，并且确定所述接合电感器的所测得的场强与适于接合的所述场强度之间的差异。该实施例允许对已接合的部件进行质量控制，其中，所述接合电感器所测得的场强与适于接合的场强之间的差异高于某个预定的阈值，则接合部件被丢弃，或者允许在线调整场强，以确保适合接合的场强始终被保证。
对所产生的场强的所有测量优选也适用于产生这种场强所需的功率。
根据本发明的模制部件的电磁焊接可包括提供模具，将用于联结的至少两个模制部件放置于所述模具中，其中所述模制部件之间的接触表面包括热激活联结装置和感应敏感成分，借助于电感器加热所述感应敏感成分来激活所述联结装置，其中所述电感器可位于所述模具外部，以及在由所述模具限定的所述构造中将所述模制部件压在一起，其中所述模制部件通过所述热激活联结装置联结。
电感器通常包括导电体，其中，所述导电体在交流电压下产生电磁场。所述电磁场的形状可以是任何已知的形状，例如螺旋形，或在焊接方向上大致为圆柱形。使用在焊接方向上大致圆柱形的电磁场使得加热能够严格受控、均匀和有针对性的加热，从而尽可能地防止过热。过热可能导致材料的劣化，从而导致不期望的结构弱化。其它电感器包括多个绕组，绕组产生环形电磁场。通过使用与所述电感器成直角的方向作为感应方向的这种已知的电感器，产生加热模式，在该加热模式中，在中心处出现相对冷的区域。另一方面，圆柱形电磁场产生更有利的发热分布，该发热分布能够均匀加热。此外，可以使圆柱形电磁场形成非常窄，宽度最多为10mm至20mm。在环形场中，这样的宽度无法结合所需的发热功率和穿透性来实现。
所述电感器的电磁场可直接地穿过模制部件的区段和/或穿过所述模具的壁到达所述模制部件之间的接触表面。本发明的方法使得能够以快速且有效的方式实现所述模制部件之间的良好质量的焊接连接或接合，所获得的接合产品具有特别好的机械承载能力。
一个或多个模制部件优选地由热塑性材料制造，所述热塑性材料可以通过熔合来焊接，尽管也可以设想是，仅在所述模制部件之间的接触表面上设置热塑性材料或热激活粘合剂作为热接合装置。
感应敏感成分通常包括导电成分，例如金属和/或碳纤维。所述模具和所述电感器附近的其它成分不需要被加热，优选地它们基本上不含感应敏感成分，或者利用合适的屏蔽材料从感应场中屏蔽，其中，推荐电绝缘但导热的成分，例如陶瓷材料，用于在焊接期间从相邻模制部件的接触表面提取热量。在这样的模具中，电磁场穿过可以所述模具的壁而施加在期望的位置处。
在该方法中，优选地，热塑性模制部件通常设置有导电成分，例如金属网，或者将该成分布置在所述模制部件之间。通过波动电磁场，在所述导电成分中感应出傅科电流或涡电流，该波动电磁场由发电机提供交流电的电感器产生。由于类似于焦耳效应、纤维结加热以及介电滞后几种加热机构，这些傅科(Foucault)电流产生熔化所述热塑性材料和/或激活所述联结装置所需的热量。通过沿着所述接触表面移动所述电感器，所述热塑性模制部件在它们的接触表面上相互连接。所述电感器可以例如借助于机器人臂或线性引导器在所述接触表面上被引导，以便实现所述连接。
为了加热，所述感应敏感成分必须与所述热激活联结装置热接触。例如，可以混合所述感应敏感元件和所述联结装置。
在一个实施例中，其中所述接合电感器位于所述模具外部，且所述电感器的电磁场穿过所述模具的壁到达所述模制部件之间的所述接触表面，该实施例允许焊接期间在所述模具的压力下使所述模制部件靠在一起。其它实施例中，可以在用于联接的模制部件的感应加热已经发生之后，施加压力。
压紧所述模制部件可以使用现有技术中已知的装置来进行，例如气动或液压机和压辊。所述压力优选地施加在所述模具的非电感器侧上的模具上，换言之，位于所述模具的未设置所述电感器的那一侧上。所述模具的壁优选地在所述接触表面的位置处设置有凹槽，换言之，位于所述焊接位置上方。这样的凹槽能够使所述电感器更靠近所述接触表面移动，从而能够以更高的精度进行加热，并且由此需要的功率也更少。为了使所述模制部件上用于接合的压力在所述焊接位置处尽可能高，凹槽的宽度尽可能小是有利的，并且优选地，使其几乎不超过所述电感器的宽度。为了能够获得最高的可能压力，该壁在所述凹槽位置由具有高刚度的材料制成。
根据所使用的材料，特别是所述感应敏感成分和所述电感器距离所述成分的距离，作为所述感应电感器响应的结果，可以确定合适的功率和频率。该频率尤其确定所述电磁场的穿透力；所述电感器的电功率确定所述波动电磁场强度，从而确定所述感应敏感成分中产生的发热程度。
如果热激活联结装置包括热塑性塑料则是有利的。热塑性塑料可以通过熔融以简单的方式联接。此外，将热塑性塑料与诸如金属网或碳纤维等的感应敏感成分混合是很容易的。虽然该方法原则上适用于任何热塑性塑料，特别合适的热塑性塑料的示例为：聚丙烯(polypropylene)、聚酰胺(polyamide)、聚醚酰亚胺(polyetherimide)、聚醚酮酮(polyetherketoneketone)、聚醚醚酮(polyetheretherketone)和聚苯硫醚(polyphenylene sulfide)。
可通过感应来加热的成分优选地包括碳纤维和/或金属。这些材料可以很容易地通过感应加热，并且除了导电之外还具有良好的导热性，从而产生的热量可以很好地分散。推荐在热塑性塑料中包含碳纤维，因为所述碳纤维也提高了材料强度。在所述方法的另一优选实施例中，所述通过感应可加热的成分包括：铁磁性或碳纳米颗粒。
根据本发明的方法，所述模具和所述电感器都是固定的。这例如可适用于所述模制部件的相对较小部分的接触表面的联接。在优选实施例中，所述电感器相对于所述接触表面沿着路径移动，使得所述联结装置在所述接触表面的预定部分中被激活。还可以保持所述电感器静止，使所述模具与所述模制部件一起移动。
对于根据本发明的方法中的应用，所述电感器连接到交流发电机，其中所述交流发电机电连接到所述电感器的所述电连接装置。可用频率通常在0.1MHz至10MHz之间。
在另一优选实施例中，所述感应部件设置有至少一个适于冷却介质通过的进料通道。所述感应部件的温度在使用过程中可以保持恒定，这对所述电感器的电阻也是有利的。所述冷却介质优选为具有高热容量的液体，例如水。所述感应部件例如可以是弯曲成所需形式的金属管，在利用交流电压产生经过管子本身的金属的电磁场时，所述冷却介质被泵送通过所述金属管。
本发明还提供了一种通过电磁焊接来接合模制部件的设备。本发明的设备包括：用于使接合电感器沿着所述模制部件的接触表面移动的装置、用于在一个或多个模制部件的感应敏感成分中产生电磁场以将所述一个或多个模制部件的热激活联结装置加热至所述联结装置的熔融温度以上的装置、以及用于通过熔融的所述联结装置在所述接触表面上将所述模制部件彼此接合的装置，还包括感测电感器，其被配置为确定适于接合的所述电磁场的强度、并且包括用于产生相对弱的电磁场以将所述热激活联结装置稍微加热至感测温度的装置、用于测量由所述感测电感器在所述一个或多个模制部件中产生的所述场强的装置、用于确定所述感测电感器的已测量的场强与适于接合的所述场强之间的差异的装置、以及用于调整适于接合的所述场强以消除差异的装置。这种设备可以以有利的方式实施根据本发明的所述方法。
本专利申请中描述的本发明的实施例可以在这些实施例的任何可能的组合中进行组合，并且每个实施例可以单独地形成分案专利申请的主题。
附图说明
现在将参考以下附图来解释本发明，但本发明并不限于此。在附图中：
图1示意性地示出了根据现有技术通过电磁焊接来接合两个模制部件的方法；
图2示意性地示出了根据本发明的一个实施例的焊接设备；
图3示意性地图示了根据本发明的实施例的用于通过电磁焊接来接合两个模制部件的方法；
图4示意性地图示了根据本发明的另一实施例的用于通过电磁焊接来接合两个模制部件的方法；以及
图5和图6示意性地图示了根据本发明的其它实施例的用于通过电磁焊接来接合两个模制部件的方法。
具体实施方式
图1示出了线性电感器1，该线性电感器1通过以合适的功率施加适于电磁焊接的频率的交流电来产生环形电磁场2。在该电磁场中的第一模制部件3和第二模制部件4沿着接触表面相互接触。模制部件是由利用碳纤维增强的热塑性树脂来制成的。碳纤维在电磁场2的影响下局部地发热，从而该热塑性树脂被加热到其熔融温度以上。通过利用压紧装置(未示出)压紧，可以因此将热激活的热塑性模制部件3、4在接触表面5处联结，其中，在模制部件3、4冷却之后，在接触表面5处的联接变成永久性的。该图还示出了在加热期间接触表面处的温度示意图，其中相对温度T是针对接触表面5上的位置来绘制的。第三方向6限定了在焊接期间感应线圈1被移动的方向。该温度示意图示出了恒定强度的电磁场2将引起接触表面5上的不规则加热，其中，在接触表面5中观察到大体上为抛物线的温度变化。所示的变化也可能是由模制部件(3，4)中的特性的变化引起的。更重要的是，该温度示意图还显示出了方向6的变化，其对应于感应线圈1的运动方向，即焊接方向A。由于对模制部件(3，4)的这种相对不均匀的加热，这两个部件的接合也可能经历变化，这可能意味着部件3、4的粘合或接合的组合件的机械承载能力降低。该加热变化可导致模制部件部分由于模制部件(3，4)局部过热和/或局部不完全相互粘合而热降解。通常这是不期望的，而根据本发明的方法提供了该问题的解决方案。
参照图3，示出了根据本发明的方法的实施例。通过该方法，模制部件(3，4)可以通过电磁焊接接合。在图3所示的实施例中，感测电感器10沿着两个模制部件(3，4)之间的接触表面移动，所述两个模制部件通过压力16彼此压紧。请注意，这些附图是分解图。可以设置散热器17以避免过热。感测电感器10包括发射电感器11，感测电感器10的感应线圈12产生相对弱的电磁场13。该磁场13使得在模制部件(3，4)中，尤其是在它们的接触表面5中产生涡电流14。感测电感器10的接收电感器15以非零电压读数150的形式测量发射电感器11在模制部件(3、4)中产生的场强。针对沿着焊接方向或焊接线A的每个位置，确定由感测电感器10的接收电感器15测量的场强与适于接合的场强之间的差异。该适于接合的场强是在待接合的模制部件(3、4)的接触表面5中感应最佳温度曲线的场强。最佳温度曲线是在期望的恒定焊接温度附近最小变化的曲线。该期望的恒定焊接温度取决于涉及该模制部件材料的特性的多个变量。
图4图示了这样的实施例，其中用于接合的实际焊接是单独进行的，即，在感测电感器已经执行了其适当的动作之后进行的。所示方法包括：沿着模制部件(3，4)的接触表面5并且沿着与感测电感器10先前移动的焊接方向A相同的路径移动接合电感器20。模制部件(3，4)通过压力16彼此压紧。接合电感器20具有产生电磁场23的感应线圈22。该磁场23使得在模制部件(3，4)中，尤其是在它们的接触表面5中产生涡电流24。涡电流24引起存在于模制部件(3，4)中(至少是在接触表面5中及其周围)的热塑性树脂的加热。该加热引起模制部件(3，4)中(至少在接触表面5中及其周围)的温度升高至接合温度，该接合温度高于一个或多个模制部件的热塑性树脂的熔融温度。针对沿焊接线或方向A的每个位置，调整适于接合的场强以消除先前确定的由感测电感器10的接收电感器15测量的场强与适于接合的场强之间的差异。这可以通过对施加至接合电感器20的线圈22的功率或电压25进行适配来完成。这种对接合电感器20沿着焊接路径产生的电磁波的场强的恒定的调整使模制部件(3，4)中(至少在它们的接触表面5中及其周围)更恒定的温度上升。这使焊缝质量更好且更一致。
图4的实施例还包括在焊接模制部件(3，4)期间测量边缘效应。可以由测量模制部件4边缘处的电流的传感器18来执行测量边缘效应。这允许在接合电感器20沿着焊接线A移动时微调由接合电感器20产生的电磁场强度，以便进一步消除该差异并且避免场强和温度的变化。
图5示出了本发明方法的另一实施例，其中感测电感器10再次在已通过电磁焊接接合(例如如上所述)的模制部件(3，4)的上方移动。感测电感器10优选地沿着焊接路径(即，沿着焊接线A)移动。感测电感器10的接收电感器15再次以非零电压读数151的形式测量由发射电感器11在已接合的模制部件(3，4)组合件中产生的场强。该读数151很可能与未接合的模制部件(3，4)中获得的读数150不同。该系列读数151可以用作附加的质量控制的手段。
如图6所示，另一实施例涉及使感测电感器10同时与接合电感器20但在接合电感器20稍微靠前处沿焊接线A移动。两个电感器(10、20)均按照箭头(100、200)沿焊接线A移动，但彼此之间有距离40。请注意，焊接线A并不限于直线，并且焊接线可包括任何路径，甚至是曲折的或间断的路径。
最后，图2示出了具有接合电感器20的焊接装置30。可以借助工业六轴机器人32沿着焊接线(其可以是预编程路径)来引导电感器20，以便实现期望的焊接。在这种情况下，用于焊接的模制部件(如图3至图6中所示)可以在为此目的而制造的模具33中固定并压在一起。模具33可以设置有凹槽34，电感器20可以移动穿过该凹槽34靠近模制部件以进行焊接。为了产生电磁场，电感器20可以连接到交流发电机35，交流发电机35布置在机器人32上。该电磁场强度沿着焊接线变化，以至少部分地补偿沿着焊接线在模制部件的接触表面中可能发生的、并且由根据本申请中公开的任何实施例的感测电感器确定的任何温度变化。

Claims (12)

1.一种用于通过电磁焊接来接合模制部件的方法，包括：使接合电感器沿着所述模制部件的接触表面的焊接线A移动，在一个或多个模制部件的感应敏感成分中产生电磁场，以将所述一个或多个模制部件的热塑性塑料加热至所述热塑性塑料的熔融温度以上，以及通过熔融的所述热塑性塑料将所述模制部件在所述接触表面彼此接合，其中，适于接合的所述电磁场的强度通过以下步骤确定：预先沿着所述接触表面的所述焊接线A移动感测电感器，产生相对弱的电磁场，沿着所述焊接线A测量所述感测电感器在所述一个或多个所述模制部件中产生的场强，沿着所述焊接线A确定所述感测电感器的已测量的所述场强与适于接合的场强之间的差异，以及通过对施加至所述接合电感器的感应线圈的功率或电压进行适配来调整适于沿着所述焊接线A接合所述接合电感器的感应线圈的场强以消除所述差异。
2.根据权利要求1所述的方法，其中，所述差异是在沿着所述接触表面的所述焊接线A的若干移动位置处确定的。
3.根据权利要求2所述的方法，其中，调整所述适于接合的所述场强以消除所述差异是沿着所述接触表面连续地执行的。
4.根据上述权利要求中任一项所述的方法，其中，所述感测电感器在所述接合电感器的前方沿着所述接触表面移动。
5.根据权利要求4所述的方法，其中，所述感测电感器和所述接合电感器是同一个以及相同的电感器。
6.根据权利要求4所述的方法，其中，所述感测电感器和所述接合电感器是分开的，并且沿着所述接触表面同时地移动。
7.根据权利要求1所述的方法，其中，所述感测电感器包括发射电感器和接收电感器，所述发射电感器产生所述电磁场，所述接收电感器测量由所述感测电感器在所述一个或多个模制部件中产生的所述场强。
8.根据权利要求7所述的方法，其中，考虑所述发射电感器对由所述感测电感器在所述一个或多个模制部件中产生的并且由所述接收电感器测量的场强的影响。
9.根据权利要求1所述的方法，其中，测量由所述感测电感器在所述一个或多个模制部件中产生的所述场强是通过测量在所述一个或多个模制部件的边缘处的短路所引起的电流来执行的。
10.根据权利要求1所述的方法，其中，所述电感器包括线性感应部分，所述线性感应部分产生大致圆柱形的电磁场。
11.根据权利要求1所述的方法，其中，所述感应敏感成分选自碳纤维、金属、或其组合。
12.一种用于通过电磁焊接来接合模制部件的设备，包括：用于使接合电感器沿着所述模制部件的接触表面的焊接线A移动的装置和接合电感器，所述接合电感器用于在一个或多个模制部件的感应敏感成分中产生电磁场以将所述一个或多个模制部件的热塑性塑料加热至所述热塑性塑料的熔融温度以上、以及用于通过熔融的所述热塑性塑料将所述模制部件在所述接触表面的所述焊接线A上彼此接合，所述设备还包括被配置成确定适于沿着所述焊接线A接合的所述电磁场的强度的感测电感器，并且所述感测电感器包括用于产生相对弱的电磁场以将所述热塑性塑料稍微加热至感测温度的发射电感器、用于沿着所述焊接线A测量由所述感测电感器在所述一个或多个模制部件中产生的场强的接收电感器，其中所述感测电感器用于沿着所述焊接线A确定所述感测电感器的已测量的场强与适于接合的场强之间的差异、以及用于通过对施加至所述接合电感器的感应线圈的功率或电压进行适配来调整适于沿着所述焊接线A接合所述接合电感器的感应线圈的场强以消除差异。
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