CN112743218A - 超声波焊接和具有压头的焊头 - Google Patents

超声波焊接和具有压头的焊头 Download PDF

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CN112743218A
CN112743218A CN202011190637.3A CN202011190637A CN112743218A CN 112743218 A CN112743218 A CN 112743218A CN 202011190637 A CN202011190637 A CN 202011190637A CN 112743218 A CN112743218 A CN 112743218A
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workpiece
welding
horn
weld
plan
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CN112743218B (zh
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P-C·王
B·J·布拉斯基
A·纳格什
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GM Global Technology Operations LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • 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
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/26—Auxiliary equipment
    • 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
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • 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
    • B29C66/45—Joining of substantially the whole surface of the 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
    • B29C66/71—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 composition of the plastics material of the parts to be joined
    • 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
    • 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
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72143—Fibres of discontinuous lengths
    • 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
    • B29C66/73—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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
    • B29C66/7315—Mechanical properties
    • B29C66/73151—Hardness
    • 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
    • B29C66/73—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
    • B29C66/739—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
    • 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
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
    • B29C66/81422—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being convex
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B29C66/81429—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • 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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    • B29C66/90—Measuring or controlling the joining process
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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
    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/967—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving special data inputs or special data outputs, e.g. for monitoring purposes
    • B29C66/9672—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving special data inputs or special data outputs, e.g. for monitoring purposes involving special data inputs, e.g. involving barcodes, RFID tags

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

一种接合方法，包括将第二工件布置成与第一工件相邻。该方法进一步包括识别在焊接位置处的第一和第二工件中的至少一者的确定的硬度参数。所确定的硬度参数通过估算、计算和测量中的至少一者来确定。该方法包括基于所确定的硬度参数来选择焊接计划，并且使用所选的焊接计划将第一工件和第二工件焊接在一起。焊头包括柄部和具有端面的尖端，该尖端布置在柄部的端部处并被构造成接触工件并将能量传递到工件。滚花布置在端面上，每个滚花具有远端。弯曲的压头从端面延伸到滚花的远端之外。

Description

超声波焊接和具有压头的焊头
技术领域
本公开大体上涉及焊接，并且更具体地涉及用于超声波焊接的技术，以及焊头，其特别用于接合聚合物复合部件。
背景技术
超声波焊接可用于接合聚合物和/或金属部件。在超声波焊接中，塑料或金属部件被夹在焊头和砧座之间。为了利用超声波能量进行焊接，通过焊头的高频振动将高频振动施加到待接合的部件。焊头或超声焊极为产生超声波振动的工具，该超声波振动施加到诸如用于焊接、机械加工或混合的工件或材料。在超声波焊接的情况下，由于施加的机械力和由于机械振动在部件之间的界面处产生的热量而导致部件接合。
使用超声波焊接传递一致的焊接质量需要克服许多挑战。必须精确设置包括夹紧载荷、振动幅度和焊接时间的过程变量，并且必须考虑堆叠高度和材料的变化。在进行塑料焊接时，夹紧力必须保持足够低，以避免部件变形，而较硬的材料则需要较高的夹紧载荷。如果夹紧力太低或如果发生不对准，可能会导致焊缝形成不足。
尝试接合聚合物复合材料时，还会出现其他复杂情况，并且这些材料的焊接接头可能会出现差异。因此，聚合物复合材料通常诸如通过铆固或铆接或通过粘合剂机械地接合，以避免焊接接头破裂的问题，但是这些方法可能增加时间和费用。
发明内容
本文的发明人已经发现，在焊接的聚合物复合材料中焊接失效的主要原因在于，材料本身在单个工件上的硬度或局部材料特性发生变化。因此，由于使用仅针对工件的一部分的硬度或局部材料特性进行调整的焊接计划，对工件堆叠中的所有焊接位置应用相同的焊接计划很可能会产生良好的焊缝和差异焊缝。因此，本文提供一种方法，该方法包括基于各个单独焊接位置处的硬度或硬度参数来改变焊接计划。硬度或硬度参数可以例如通过压头的位移深度的相关性或通过初始力施加的动力的相关性在每个单独的焊接位置处确定。还提供了包括压头的焊头。
在可以与本文提供的其他形式或示例组合或分开的一个形式中，本公开提供了一种接合方法。该方法包括提供第一工件和将第二工件布置在第一工件附近。该方法包括在焊接位置处识别第二工件和/或第一工件的所确定的硬度参数，其中所确定的硬度参数通过估算、计算和/或测量来确定。该方法还包括基于所确定的硬度参数选择焊接计划以识别所选的焊接计划，并且使用所选的焊接计划将第一工件和第二工件焊接在一起。
在可以与本文提供的其他形式或示例组合或分开的另一个形式中，提供了用于将多个工件超声波焊接在一起的焊头。焊头包括柄部和具有端面的尖端。尖端布置在柄部的端部处，并构造成接触第一工件并将能量传递到第一工件。多个滚花布置在端面上，每个滚花具有远端。弯曲的压头从端面延伸到滚花的远端之外。
可以可选地提供其他细节，包括但不限于以下：其中，第一工件和第二工件均由聚合物复合材料形成；其中，聚合物复合材料包括热塑性聚合物基体和布置在热塑性聚合物基体内的多根增强短切纤维；其中，聚合物复合材料为碳增强的尼龙，该碳增强的尼龙具有布置在尼龙内的多根短切碳纤维；多根短切碳纤维的平均纤维长度不大于50毫米，并且平均直径不大于一微米；其中，焊接步骤包括将第一工件和第二工件超声波焊接在一起；其中，识别所确定的硬度参数的步骤包括：以预定的力将压头压入第一工件的表面中，以及在将压头压入第一工件的表面中之后确定压头的位移深度；将压头设置在焊头的表面上；该焊接步骤包括通过包括焊头和配合砧座的工具套件应用所选的焊接计划；提供具有设置在焊头的表面上的多个滚花的焊头；该表面为弯曲的并且限定了尖端的曲率半径；压头限定压头曲率半径；尖端的曲率半径大于压头曲率半径；柄部在柄部的端部处限定端部柄部半径；尖端曲率半径至少为端部柄部半径的四倍；柄部在柄部的端部处限定端部柄部的直径；压头曲率半径小于端部柄部直径；端部柄部直径不大于压头曲率半径的四倍；压头在垂直于端面的方向上延伸超过滚花的远端不多于2.0毫米；多个滚花限定相邻滚花之间的滚花间距；每个滚花由从滚花基部延伸到向外延伸的滚花边缘的滚花角限定；滚花角在40至60度的范围内；并且滚花间距与端部柄部直径的比率至少为0.045且不大于0.065。
所选的焊接计划可以包括以下一项或多项：预定的焊头幅度，预定总焊接时间，初始的焊头触发力，焊头向第一工件的总位移距离，通过焊头施加到第一工件的总能量，将焊头移入第一工件的速度，由焊头施加到第一工件的最大力以及在将焊头移入第一工件之前从焊头初次施加能量后第一工件的熔化材料的量。
可以提供其他附加的可选细节，包括但不限于以下：其中，识别所确定的硬度参数的步骤包括以预定的力和预定的幅度将工具压入第一和第二工件中的一者的表面中，并确定当以预定的力和预定的幅度将工具压入表面时，通过工具施加的动力；其中，该工具为包括焊头和配合砧座的工具套件的焊头；并且其中，超声波焊接的步骤包括通过工具套件应用所选的焊接计划。
另外，该方法可以包括：识别在多个附加焊接位置处的第一工件和第二工件中的至少一者的多个附加确定的硬度参数；基于多个附加确定的硬度参数为多个附加焊接位置中的每个附加焊接位置选择焊接计划以识别多个附加所选的焊接计划，每个附加所选的焊接计划与多个附加焊接位置中的附加焊接位置相关；并使用多个附加所选的焊接计划在每个附加焊接位置将第一工件和第二工件焊接在一起。
本发明还包括以下方案：
方案1. 一种接合方法，所述方法包括：
提供第一工件；
在所述第一工件附近布置第二工件；
识别在焊接位置处的所述第一工件和所述第二工件中的至少一者的确定的硬度参数，所述确定的硬度参数由估算、计算和测量中的至少一者来确定；
基于所述确定的硬度参数选择焊接计划，以识别所选的焊接计划；以及
使用所选的焊接计划将所述第一工件和所述第二工件焊接在一起。
方案2. 根据方案1所述的方法，其中，所述第一工件和所述第二工件各自由聚合物复合材料形成。
方案3. 根据方案2所述的方法，其中，所述聚合物复合材料包括热塑性聚合物基体和布置在所述热塑性聚合物基体内的多根增强短切纤维。
方案4. 根据方案3所述的方法，其中，所述聚合物复合材料为碳增强尼龙，所述碳增强尼龙具有布置在所述尼龙内的多根短切碳纤维，所述多根短切碳纤维的平均纤维长度不大于50毫米，并且平均直径大于一微米。
方案5. 根据方案2所述的方法，其中，所述焊接步骤包括将所述第一工件和所述第二工件超声波焊接在一起。
方案6. 根据方案5所述的方法，其中，识别所述确定的硬度参数的步骤包括：以预定的力将压头压入所述第一工件的表面中；以及在将所述压头压入所述第一工件的所述表面中之后确定所述压头的位移深度。
方案7. 根据方案6所述的方法，进一步包括在焊头的表面上提供所述压头，所述焊接步骤包括通过包括所述焊头和配合砧座的工具套件来应用所选的焊接计划。
方案8. 根据方案7所述的方法，进一步包括提供具有布置在所述焊头的所述表面上的多个滚花的所述焊头。
方案9. 根据方案6所述的方法，其中，所选的焊接计划包括预定的焊头幅度。
方案10. 根据方案9所述的方法，所选的焊接计划进一步包括以下至少一项：预定总焊接时间，初始的焊头触发力，所述焊头到所述第一工件中的总位移距离，通过所述焊头施加到所述第一工件的总能量，将所述焊头移入所述第一工件的速度，由所述焊头施加到所述第一工件的最大力的量以及在将所述焊头移入所述第一工件之前从所述焊头初次施加能量后所述第一工件的熔化材料的量。
方案11. 根据方案2所述的方法，其中，所述识别所确定的硬度参数的步骤包括：以预定的力和预定的幅度将工具压入所述第一工件和所述第二工件中的一者的表面中；以及在以所述预定的力和所述预定的幅度将所述工具压入所述表面时确定通过所述工具施加的动力。
方案12. 根据方案11所述的方法，其中，所述工具为包括所述焊头和配合砧座的工具套件的焊头，并且所述焊接步骤包括通过所述工具套件应用所选的焊接计划。
方案13. 根据方案12所述的方法，进一步包括提供具有多个滚花的所述焊头，所述多个滚花布置在所述焊头的所述表面上，并且所述表面限定了曲率半径。
方案14. 根据方案1所述的方法，所述焊接位置为第一焊接位置，所述确定的硬度参数为第一确定的硬度参数，并且所选的焊接计划为第一所选的焊接计划，所述方法进一步包括：识别在多个附加焊接位置处的所述第一工件和所述第二工件中的至少一者的多个附加确定的硬度参数；基于所述多个附加确定的硬度参数为所述多个附加焊接位置中的每个附加焊接位置选择焊接计划以识别多个附加所选的焊接计划，每个附加所选的焊接计划与所述多个附加焊接位置中的附加焊接位置相关；并使用所述多个附加所选的焊接计划在每个所述附加焊接位置将所述第一工件和所述第二工件焊接在一起。
方案15. 一种用于将多个工件超声波焊接在一起的焊头，所述焊头包括：
柄部；
具有端面的尖端，所述尖端布置在所述柄部的端部处，并构造成接触所述多个工件中的第一工件并将能量传递到所述第一工件；
布置在所述端面上的多个滚花，每个滚花具有远端；以及
从所述端面延伸到所述滚花的所述远端之外的弯曲的压头。
方案16. 根据方案15所述的焊头，所述表面为弯曲的并且限定了尖端曲率半径，所述压头限定了压头曲率半径，所述尖端曲率半径大于所述压头曲率半径。
方案17. 根据方案16所述的焊头，所述柄部在所述柄部的所述端部处限定端部柄部半径，所述尖端曲率半径为所述端部柄部半径的至少四倍。
方案18. 根据方案16所述的焊头，所述柄部在所述柄部的端部处限定端部柄部直径，所述压头曲率半径小于所述端部柄部直径。
方案19. 根据方案18所述的焊头，所述端部柄部直径不大于所述压头曲率半径的四倍，所述压头延伸超过所述滚花的所述远端不多于2.0毫米。
方案20. 根据方案19所述的焊头，所述多个滚花限定了在每个相邻的滚花之间没有被所述压头中断的滚花间距，每个滚花由从滚花基部延伸到向外延伸的滚花边缘的滚花角限定，所述滚花角在40度至60度的范围内，并且滚花间距与所述端部柄部直径的比率至少为0.045且不大于0.065。
从本文提供的描述，其他方面、优点和适用领域将变得明显。应当理解，描述和具体示例仅用于说明的目的，并不旨在限制本公开的范围。
附图说明
本文描述的附图仅用于说明目的，并不旨在以任何方式限制本公开的范围。
本文中的附图本质上为示意性的，并且不一定按比例绘制或代表所示元件之间的距离或关系。
图1为根据本公开的原理的具有多个滚花和从端面延伸的压头的焊头的示意性侧视图；
图2为根据本公开原理的图1的焊头的示意性端视图；
图3为根据本公开原理的图1和2的焊头的多个滚花的一部分的示意性侧视图；
图4A为示意性地示出根据本公开的原理的接合方法的框图；
图4B为示意性地示出根据本公开的原理的图4A的方法的步骤的附加细节的框图；
图5A为根据本公开的原理的焊接组件的示意性截面视图，该焊接组件包括与工件堆叠接触的图1-3的焊头并且具有与工件堆叠相邻布置的相应的砧座，使得工件堆叠被夹在焊头和砧座之间，该焊头在不施加热量的情况下接触工件堆叠，以执行图4的方法的步骤；
图5B为根据本公开的原理的图5A的焊接组件的示意性截面视图，其中焊头在与图5A中所示的工件堆叠接触后，从与工件堆叠的接触移开；
图5C为根据本公开的原理的图5A-5B的焊接组件的示意性截面视图，其中焊头接触工件堆叠并向工件堆叠施加初始力和焊头幅度；
图5D为根据本公开的原理的图5A-5C的焊接组件的示意性截面视图，其中在向图5C中所示的工件堆叠施加初始力和感应热之后，焊头接触工件堆叠并向工件堆叠施加附加的焊头幅度；以及
图6为根据本公开的原理的具有由压头、诸如图1-3和5A-5D中所示的焊头的压头形成的凹陷部分的工件的透视图。
具体实施方式
以下详细描述本质上仅为示例性的，并不旨在限制应用和使用。
现在参考图1-2，示出了用于在振动或超声波焊接，诸如常规的超声波焊接或超声波扭焊中使用以将多个工件焊接在一起的焊头或超声焊极，并且该焊头或超声焊极通常以10表示。焊头10包括柄部12和布置在柄部12的端部16处的尖端14。尖端14具有端面18，该端面可以稍微弯曲以限定相对较大的曲率半径R1。尖端14被构造成接触工件并将能量传递到工件以执行焊接操作，这将在下面更详细地描述。
参考图1-3，多个滚花20可布置在端面18上。滚花20可以彼此相邻布置并且均匀地分布在端面18上，除非被压头22中断之处。在示出的示例中，每个滚花20被成形为菱形角锥或四棱锥，其具有基部24和倾斜的侧面26，该倾斜的侧面26终止于滚花20的远端28中。因此，每个远端28为滚花20的尖头，并且远端28被滚花20之间的凹槽30隔开。尽管滚花20被示为以直线的图案并排布置，但是作为示例，滚花20可以可替代地以其他图案，诸如交错或环形图案示出。此外，尽管滚花20被示为四棱锥，但是它们可以为其他形状，诸如三棱锥、圆锥形或其他形状。
除了将压头22布置在端面18上的滚花20之间之外，滚花20以均匀的滚花间距d彼此分开。滚花间距d可以被定义为从一个滚花20的尖的远端28（或中心）到相邻滚花20的尖的远端28（或中心）的距离。每个滚花还定义了滚花角θ。滚花角θ可以被定义为滚花20的每个侧面26与滚花20的基部24之间的角度，或者被定义为滚花20的侧面26与在整个表面18上切向延伸的切面P之间的角度，在表面18处，基部24与滚花20的侧面26相交。滚花间距d和滚花角θ确定每个滚花20的尺寸，包括高度h。高度h可以定义为沿着垂直于基部24的线从基部24到滚花20的远端28的距离，或从基部24到在远端28的正下方的点处沿着滚花20的基部24切向延伸的平面的距离，使得该平面垂直于焊头10的中心轴线X延伸。
取决于应用，可能需要各种滚花间距d、滚花角θ和尖端半径R1。仅作为示例，可以在0.75至1.25毫米的范围内提供滚花间距d，可以在30至60度或40至60度的范围内提供滚花角θ，并且可以在32至41毫米的范围内提供尖端半径R1。
压头22为弯曲的并且从尖端14的端面18延伸超过滚花20的远端28。压头22可以位于表面18上的中心，关于焊头10的中心轴线X对称，但是也可以位于表面18的另一部分上，或者可以将压头设置在单独的工具上。在一些示例中，压头22可以被成形为球形的一部分并且可以限定曲率半径R2。如图1可见，尖端曲率半径R1大于压头曲率半径R2。柄部12在连接至尖端14的柄部12的端部32处限定端部柄部半径R3和端部柄部直径E。尖端曲率半径R1优选至少为端部柄部半径R3的四倍。压头曲率半径R2小于端部柄部直径E。在一些示例中，端部柄部直径E不大于压头曲率半径R2的四倍。在一个优选的示例中，端部柄部直径E和压头曲率半径R2之间的关系可以定义如下：
0.78*E≥R2≥0.29*E （1）.
在一些示例中，压头曲率半径R2可以为柄部半径R3的约一半，或者压头曲率半径R2可以在柄部半径R3的1/4到3/4的范围内。在用于本文所述的工件材料的优选示例中，压头22在垂直于端面18的方向上或在垂直于在焊头10的中心轴线X处与端面18相切的平面的方向上延伸超过滚花20的远端28不超过2.0毫米。在一些示例中，滚花间距d与端部柄部直径E的比率为至少0.045且不大于0.065。
现在参考图4，在该框图中示出了一种接合方法，并且该接合方法通常以100表示。参考图5A，并且继续参考图4，方法100包括提供第一工件36的步骤102和与第一工件36相邻地布置第二工件38使得第一工件36和第二工件38形成工件堆叠40的步骤104。焊接组件42包括布置在第一工件36的外侧44上的焊头10和布置在第二工件38的外侧48上的相应的砧座46。
第一工件36和第二工件38均可以由相同或不同的聚合物复合材料形成。例如，聚合物复合材料可包括热塑性聚合物基体和布置在热塑性聚合物基体内的多根增强短切纤维。在一种形式中，聚合物复合材料为碳增强的尼龙，诸如尼龙6，其具有布置在尼龙内的多根短切碳纤维。多根短切碳纤维可以为短纤维，并且可以具有不大于50毫米的平均纤维长度和不大于1微米的平均直径。
材料中使用的热塑性塑料的其他示例包括：聚酰胺树脂，聚苯乙烯树脂，丙烯腈苯乙烯树脂，丙烯腈-丁二烯-苯乙烯树脂，聚乙烯醇树脂，氯乙烯树脂，偏二氯乙烯树脂，乙酸乙烯树脂，丙烯酸树脂，聚丙烯酸酯树脂，甲基丙烯酸酯树脂，聚丙烯树脂，聚乙烯树脂，聚碳酸酯树脂，聚缩醛树脂，聚乳酸树脂，聚对苯二甲酸乙二醇酯树脂，聚萘二甲酸乙二醇酯树脂，聚对苯二甲酸丁二醇酯树脂，聚苯醚树脂，聚苯硫醚树脂，聚砜树脂，聚醚砜树脂，聚醚醚酮树脂，共聚物及其组合。增强材料的一些示例包括但不限于：碳纤维，玻璃纤维，炭黑颗粒及其组合。
如图5A中所示，焊头10首先以初始力压靠在第一工件36的外侧44上，优选不施加能量或热量，以将压头22压入第一工件36中。在焊头10已经从与第一工件36的接触移开和移出后，将压头22压靠在第一工件36的外侧44上，在第一工件36的外侧44产生凹陷部分50，如在图5B中可见。
方法100包括在焊接位置60处识别第一工件和第二工件中的至少一者的确定的硬度参数的步骤106。如本文中所用，硬度参数指示给定位置处的局部硬度或其他局部材料性质。所确定的硬度参数可以通过估算、计算和/或测量来确定。在所示出的示例中，确定的第一工件36的硬度参数包括凹陷部分50的深度F。深度F基于第一工件36在焊接位置处的硬度而变化。对于由复合热塑性纤维材料形成的工件，硬度可沿工件36的外侧44变化，因为纤维以随机不同的方式布置在材料的整个热塑性基体中。在由焊头10施加预定力以将压头22压入第一工件中时，凹陷部分50的深度F可以与一组预定硬度值或范围（诸如在查找表或经过校准的程序）相关。因此，深度F可以为确定的硬度参数，其可以用于确定焊接位置60处的硬度，或者深度F可以输入到程序中并直接用于选择焊接计划，这将在下文中进一步详细描述。
代替使用焊头10，凹陷部分50可以可替代地由单独的压头工具形成以确定每个焊接位置处的位移，而不会超出本公开的精神和范围。
在又一示例中，识别所确定的硬度参数的步骤106可以包括以预定的力和预定的幅度将诸如焊头10或没有压头的焊头的工具压入外表面44中。可以确定在以预定的力和预定的幅度将工具压入表面44中时通过工具施加的动力，并将其识别为确定的硬度参数。当施加预定的力和幅度时，施加的动力量将基于材料的局部硬度而变化。根据需要，可以将施加的动力与一组预定的硬度值相关联，以最终选择计划，或者可以将施加的动力本身用于选择焊接计划，而无需将动力与硬度值相关联的中间步骤。
方法100然后包括基于所确定的硬度参数选择焊接计划的步骤108。焊接计划可以具有各种参数。例如，焊接计划可以包括以下参数中的一个或多个参数：预定的初始焊头幅度；预定总焊接时间；初始的焊头触发力；焊头进入工件的总位移距离；通过焊头施加到工件的总能量；将焊头移入工件的速度；由焊头施加到工件上的最大力；在将焊头移入工件之前从焊头初次施加能量后工件的熔化材料的量；和/或任何其他期望的参数。因此，焊接控制器（未示出）可以被校准以基于所确定的硬度参数来选择预定的焊接计划，并且焊接计划的参数可以根据基于所确定的硬度参数进行选择的所选焊接计划而不同。因此，对于具有第一确定的硬度参数的工件36上的第一焊接位置，可以选择第一焊接计划，并且对于具有第二确定的硬度参数的相同工件36上的第二焊接位置，可以选择第二焊接计划，其中第二确定的硬度参数不同于第一确定的硬度参数。在那种情况下，由于不同的硬度参数，第一和第二计划可能彼此不同，具有不同的焊接计划参数值。
参考图4B，更详细地示出了选择焊接计划的步骤108。经由步骤106提供所确定的硬度参数，并且然后步骤108可以包括子步骤108A，其中方法100包括确定所确定的硬度参数所处的范围。在所示的示例中，如果可以选择三个预定的硬度参数范围，则步骤108A确定所确定的硬度参数107是处于第一范围、第二范围还是第三范围。如果所确定的硬度参数在第一范围内，则方法100进行到子步骤108B以选择第一预定焊接计划；如果所确定的硬度参数在第二范围内，则方法100进行到子步骤108C以选择第二预定焊接计划；并且如果所确定的硬度参数在第三范围内，则方法100进行到子步骤108D以选择第三预定焊接计划。尽管这里描述了三个范围和焊接计划，但是可以在不超出本公开的精神和范围的情况下使用任何数量的期望范围和相应的焊接计划。
然后将在步骤108中选择的所选的焊接计划提供给步骤110。然后在步骤110中，方法100包括使用所选的焊接计划将第一工件36和第二工件38焊接在一起。参考图5C，焊接步骤110可以包括首先使用初始触发力经由焊头10施加初始焊接幅度。因此，在步骤5C中，通过焊头10将初始能量施加到第一工件36的外侧44。这导致第一工件36的一些在焊头10与外侧44之间的界面52处熔化或软化，并且初始熔体54开始在第一工件36与第二工件38之间的接合界面56处形成。根据需要，在施加了初始焊接幅度和触发力之后，然后可以将焊头10从第一工件36的外侧44移开。
现在参考图5D，然后将焊头10移回成与第一工件36接触（如果已移开的话），并应用其余焊接计划以完成在接合界面56处的焊核54的形成。焊接步骤110包括例如通过包括焊头10和配合砧座46的工具套件来应用所选的焊接计划，以将工件36、38焊接在一起并形成焊接组件。尽管在堆叠40中示出了两个工件36、38，但是如果需要的话可以包括附加的工件。
焊接组件42可以为超声波类型的，其被配置为使用超声波焊接执行焊接步骤110。工件堆叠40被夹紧在焊头10和砧座46之间。焊头10可以电连接到转换器/升压器（未示出），该转换器/升压器将电信号转换成机械振动并产生焊头10的幅度。焊头10将振动施加到部件36、38。振动频率通常在20至40千赫的范围内。焊头面18处的振动运动被传递到两个部件36、38。振动通过第一工件36移动，并在第一工件36和第二工件38之间的接合界面56处产生摩擦和粘弹性变形。结果，在接合界面56处产生热量，该热量熔化材料，然后将其冷却以形成将部件36、38融合在一起的焊接接头。
现在参考图6，示出了第一工件36的一部分。在第一工件36上的焊接位置60处执行上述方法100。在第一焊接位置60处确定的硬度参数为第一确定的硬度参数，并且所选的焊接计划为第一所选的焊接计划。然而，许多需要接合的零件很大，并且可能需要许多焊接接头才能将它们充分地接合在一起。因此，方法100可以进一步包括在多个附加焊接位置62、64、66、68处识别第一和第二工件中的至少一者的（在这种情况下，第一工件36的）多个附加确定的硬度参数。在每个附加焊接位置62、64、66、68处，可以基于在每个焊接位置62、64、66、68处确定的硬度参数来选择焊接计划。然后，使用多个附加所选的焊接计划在每个附加焊接位置62、64、66、68处将第一工件36和第二工件38焊接在一起。
可以以任何合适的方式（诸如上述的那些）来确定在焊接位置62、64、66、68中的每者处的硬度参数。例如，压头，诸如压头22，可用于分别在每个焊接位置62、64、66、68处形成凹陷部分70、72、74、76。然后，与预定硬度参数相关的每个凹陷部分70、72、74、76的深度可以成为为每个焊接位置62、64、66、68选择焊接计划的基础。
在一些示例中，该方法的步骤由控制器执行，并且硬度本身可能永远不会被单独识别，使得控制器在其进行深度测量、计算或估算之后前进到选择焊接计划，因为确定硬度值然后选择焊接计划的中间步骤可能不需要显示给用户。因此，确定的硬度参数可以为与硬度相关的任何确定的值，诸如凹陷部分的深度或基于预定幅度和力的施加动力。因此，控制器然后将作为确定的硬度参数的深度或其他识别信息（例如，施加的动力）用作为其基于控制器中的校准或程序选择预定焊接计划的基础。可以执行任何数量的临时计算或估算，以基于所确定的硬度参数得出所选的焊接计划。此外，可以将多个确定的硬度参数一起使用以选择焊接计划；例如，可以基于施加的动力和凹陷部分的深度两者来选择焊接计划。应当理解，由于复合热塑性材料的变化，在每个焊接位置60、62、64、66、68处确定的硬度参数可能彼此不同。
通过本文公开的方法总体上改善了焊接质量，因为基于在局部焊接位置处计算、估算或测量的确定的硬度参数，应用了基于局部材料硬度的适当的焊接计划，并且可以对于进行的每道焊缝调整焊接计划，使得每道焊缝对于执行焊接操作的局部区域的硬度具有最有效的焊接计划。因此，基于确定的硬度参数选择将导致良好熔接接头的焊接计划，该硬度参数与局部焊接位置处材料的硬度相关。
举例来说，本文描述的方法100可以由控制器或一组控制器来执行。一个或多个控制器可以为专用集成电路（ASIC）；电子电路；组合逻辑电路；现场可编程门阵列（FPGA）；执行代码的处理器（共享，专用或组）的一部分或包括以上；提供上述功能的其他合适部件；或上述某些或全部的组合，诸如在片上系统中。一个或多个控制器可以包括存储由处理器执行的代码的存储器（共享，专用或组）。如上所使用的术语代码可以包括软件、固件和/或微代码，并且可以指代程序、例程、功能、类和/或对象。如上所使用的术语共享意指可以使用单个（共享）处理器来执行来自多个模块的一些或所有代码。另外，来自多个模块的一些或全部代码可以由单个（共享）存储器存储。如上所用，术语组是指来自单个模块的一些或所有代码可以使用一组处理器来执行。另外，可以使用一组存储器来存储来自单个模块的一些或全部代码。
因此，本文描述的装置和方法可以由一个或多个处理器执行的一个或多个计算机程序来实现。计算机程序包括存储在非暂时性有形计算机可读介质上的处理器可执行指令。计算机程序还可以包括存储的数据。非暂时性有形计算机可读介质的非限制性示例为非易失性存储器、磁存储器和光存储器。
该描述本质上仅为示例性的，并且各种变化均意图在本公开的范围内。在不超出本公开的精神和范围的情况下，本文所示的示例可以以各种方式组合。这样的变化不应被视为脱离本公开的精神和范围。

Claims (10)

1.一种接合方法，所述方法包括：
提供第一工件；
在所述第一工件附近布置第二工件；
识别在焊接位置处的所述第一工件和所述第二工件中的至少一者的确定的硬度参数，所述确定的硬度参数由估算、计算和测量中的至少一者来确定；
基于所述确定的硬度参数选择焊接计划，以识别所选的焊接计划；以及
使用所选的焊接计划将所述第一工件和所述第二工件焊接在一起。
2.根据权利要求1所述的方法，其中，所述第一工件和所述第二工件各自由聚合物复合材料形成。
3.根据权利要求2所述的方法，其中，所述聚合物复合材料包括热塑性聚合物基体和布置在所述热塑性聚合物基体内的多根增强短切纤维。
4.根据权利要求3所述的方法，其中，所述聚合物复合材料为碳增强尼龙，所述碳增强尼龙具有布置在所述尼龙内的多根短切碳纤维，所述多根短切碳纤维的平均纤维长度不大于50毫米，并且平均直径大于一微米。
5.根据权利要求2所述的方法，其中，所述焊接步骤包括将所述第一工件和所述第二工件超声波焊接在一起。
6.根据权利要求5所述的方法，其中，识别所述确定的硬度参数的步骤包括：以预定的力将压头压入所述第一工件的表面中；以及在将所述压头压入所述第一工件的所述表面中之后确定所述压头的位移深度。
7.根据权利要求6所述的方法，进一步包括在焊头的表面上提供所述压头，所述焊接步骤包括通过包括所述焊头和配合砧座的工具套件来应用所选的焊接计划。
8.根据权利要求7所述的方法，进一步包括提供具有布置在所述焊头的所述表面上的多个滚花的所述焊头。
9.根据权利要求6所述的方法，其中，所选的焊接计划包括预定的焊头幅度。
10.根据权利要求9所述的方法，所选的焊接计划进一步包括以下至少一项：预定总焊接时间，初始的焊头触发力，所述焊头到所述第一工件中的总位移距离，通过所述焊头施加到所述第一工件的总能量，将所述焊头移入所述第一工件的速度，由所述焊头施加到所述第一工件的最大力的量以及在将所述焊头移入所述第一工件之前从所述焊头初次施加能量后所述第一工件的熔化材料的量。
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