CN113619125A - 一种热塑复合材料蒙皮桁条结构双线圈感应焊接的装置及方法 - Google Patents
一种热塑复合材料蒙皮桁条结构双线圈感应焊接的装置及方法 Download PDFInfo
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- CN113619125A CN113619125A CN202110821909.3A CN202110821909A CN113619125A CN 113619125 A CN113619125 A CN 113619125A CN 202110821909 A CN202110821909 A CN 202110821909A CN 113619125 A CN113619125 A CN 113619125A
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
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- Physics & Mathematics (AREA)
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- Lining Or Joining Of Plastics Or The Like (AREA)
Abstract
本发明公开了一种热塑复合材料蒙皮桁条结构双线圈感应焊接的装置及方法。本装置包括感应焊机、计算机控制系统、冷却装置、双线圈感应焊接装置,其中感应焊机用于对焊接过程的参数控制;计算机控制系统根据激光测距仪反馈的数据对两线圈之间的宽度进行调节;冷却装置用于对线圈进行冷却;双线圈感应焊接装置用于焊接热塑复合材料蒙皮桁条结构。该装置可适应不同桁条宽度的蒙皮桁条结构感应焊接,并且可实现桁条两侧的同步加压及焊接。本发明的优点在于能够有效地减小蒙皮桁条结构的焊后变形以及焊后应力,相比于现有技术,焊接成形质量以及效率均更佳。
Description
领域:
本发明涉及一种热塑复合材料蒙皮桁条结构双线圈感应焊接的装置及方法,属于复合材料感应焊接领域,具体应用于热塑性复合材料蒙皮桁条结构的感应焊接领域。
背景技术:
航空领域对于飞机结构轻量化的愈发重视,复合材料已成为飞机结构制造的重要材料之一,其中,热塑性复合材料因具有较好的韧性、可焊性、可修复性、可回收性和较短的加工时间等优点已逐渐受到人们的广泛关注。蒙皮桁条结构在航空航天等重大装备制造过程中十分常见,针对蒙皮桁条结构的连接,常规方法有胶接和机械连接,但这两种方法均存在不可避免的缺陷使得蒙皮桁条结构的连接效率、质量都无法进一步突破。
相比于胶接技术以及机械连接技术,感应焊接具有非接触、不损伤材料基体、高效率等优点已引起了技术人员的广泛关注。感应焊接是通过产生高频磁场,使置于磁场之内的材料基体感应生热,从而使连接层之间的树脂发生熔化再通过冷却凝固使材料连接。但针对于热塑性复合材料蒙皮桁条结构,桁条两侧均需要连接,若采用单侧感应顺序连接时,难免会发生结构变形大,焊后应力大等问题。为了解决上述问题,本发明提出了一种热塑复合材料蒙皮桁条结构双线圈感应焊接的装置及方法。
发明内容:
为了克服现有感应焊接技术对焊接蒙皮桁条结构产生的结构变形大、焊后应力大等问题,本发明提供了一种热塑复合材料蒙皮桁条结构双线圈感应焊接的装置及方法。该装置使用双线圈对桁条结构两侧进行同时焊接,且使用压辊对蒙皮桁条结构进行施压,不仅解决了焊接该结构的变形应力大等问题,还使焊接过程更加高效。同时,结合激光测距仪的使用,可使该装置能适应不同桁条宽度结构的焊接。
为了实现上述目的,本发明采用的技术方案为如下:
一种热塑复合材料蒙皮桁条结构双线圈感应焊接的装置,其特征在于:该焊接装置包括感应焊机(1)、计算机控制系统(2)、冷却装置(3)以及双线圈感应装置:
双线圈感应装置、计算机控制系统(2)和感应焊机(1)两两采用导线连接,双线圈感应焊接装置与冷却装置(3)采用冷却水管(9)进行连接:
双线圈感应装置上端由机器人连接头(4)与机器人连接,实现焊接头在不同方位的移动;双线圈感应装置为对称结构,两侧均安装有导轨和滑块(6),滑块均连接压辊(8)和盘式线圈(10);在滑轨上方做镂空处理,冷却水管(9)穿过镂空区域连接滑块(6)与冷却装置(3);双线圈感应装置架(5)中间放置滑轨电机(13),并通过导线分别与两块滑块(6)连接,双线圈感应装置架(5)下方正中安装激光测距仪(7),激光测距仪(7)与计算机控制系统(2)连接;压辊(8)位于盘式线圈(10)之前,盘式线圈(10)在导轨滑块(6)中与冷却水管(9)连接。
其中,导轨滑块(6)可移动的距离范围为0~80mm;压辊(8)所用材料为陶瓷材料;在水平方向上,盘式线圈(10)比压辊(8)高10mm。
一种热塑复合材料蒙皮桁条结构双线圈感应焊接的方法,其特征在于:将蒙皮桁条结构装夹固定在工装平台上,双线圈感应装置移动至结构上方;激光测距仪(7)测量桁条(11)宽度,并将测量结果实时反馈给计算机控制系统(2);计算机控制系统(2)控制滑轨电机(13)运行,滑轨电机(13)带动两块滑块(6)分别移动,每块滑块(6)的移动距离为桁条(11)宽度的一半;待滑块(6)停止移动后,将双线圈感应装置移动至蒙皮桁条结构始焊位置并打开感应焊机(1)电源以及冷却装置(3)进行焊接;在焊接过程中,由压辊(8)对蒙皮桁条结构进行施压,在压辊(8)的压力下,两个盘式线圈(10)分别对桁条结构(11)两侧同时进行焊接,蒙皮桁条在压力以及热作用下实现高效的连接。
其中,所述两块导轨滑块(6)的移动方式为对称相向运动;所述感应焊机(1)的工作频率为200kHz。
本发明对于现有技术,至少具有如下优点及效果:
1)能够实现热塑性复合材料蒙皮桁条结构的两侧同步感应焊接,相比于单侧感应焊接更加高效;
2)能够有效减小蒙皮桁条结构的焊后变形以及焊后应力,相比于单侧感应焊接的焊后成形质量更高;
3)能够适应不同桁条宽度的感应焊接。
附图说明:
图1为一种热塑复合材料蒙皮桁条结构双线圈感应焊接的装置及方法的工作示意图。
图中:1、感应焊机,2、计算机控制系统,3、冷却装置,4、机器人连接头,5、双线圈装置架,6、滑块,7、激光测距仪,8、压辊,9、冷却水管,10、盘式线圈,11、热塑复合材料桁条结构,12、热塑复合材料蒙皮结构。
图2为双感应线圈装置的后视图。
图中:13、滑轨电机。
具体实施方式:
为方便本领域技术人员理解,下面结合具体实施案例对本发明进行进一步地详细描述。
如图1所示,本发明公开了一种热塑复合材料蒙皮桁条结构双线圈感应焊接的装置,该焊接装置包括感应焊机(1)、计算机控制系统(2)、冷却装置(3)以及双线圈感应装置;双线圈感应装置、计算机控制系统(2)和感应焊机(1)两两采用导线连接,双线圈感应焊接装置与冷却装置(3)采用冷却水管(9)进行连接;双线圈感应装置上端由机器人连接头(4)与机器人连接,实现焊接头在不同方位的移动;双线圈感应装置为对称结构,两侧均安装有导轨和滑块(6),滑块均连接压辊(8)和盘式线圈(10);在滑轨上方做镂空处理,冷却水管(9)穿过镂空区域连接滑块(6)与冷却装置(3);双线圈感应装置架(5)中间放置滑轨电机(13),并通过导线分别与两块滑块(6)连接,双线圈感应装置架(5)下方正中安装激光测距仪(7),激光测距仪(7)与计算机控制系统(2)连接;压辊(8)位于盘式线圈(10)之前,盘式线圈(10)在导轨滑块(6)中与冷却水管(9)连接。
一种用于感应焊接热塑复合材料蒙皮桁条结构的方法,可通过如下步骤实现:
步骤一:首先将碳纤维增强PEEK树脂基复合材料蒙皮桁条结构装夹在工作台上,该焊接结构为帽型蒙皮桁条结构,蒙皮尺寸为80mm×100mm×2mm,桁条帽型宽度为20mm,两侧焊接宽度为20mm,机器人控制双线圈装置移动至蒙皮桁条结构上方;
步骤二:启动激光测距仪(7),激光测距仪(7)自动测量桁条(11)宽度为20mm,随后将测量结果实时反馈给计算机控制系统(2);
步骤三:由计算机控制系统(2)计算得出每块滑块(6)的移动距离并控制滑轨电机(13)运行,滑轨电机(13)带动两块滑块(6)分别向两端移动,每块导轨滑块(6)的移动距离为10mm;
步骤四:待滑块(6)停止移动后,将双线圈感应装置移动至蒙皮桁条结构始焊位置并打开感应焊机(1)电源以及冷却装置(3)。设置感应线圈频率为200kHz,输入电流为10A,设置冷却水箱温度为25℃;
步骤五:根据蒙皮桁条结构,机器人设定焊接起点和焊接终点,焊接路径为直线,焊接距离为100mm;
步骤六:在焊接过程中;由压辊(8)对复合材料蒙皮桁条结构进行施压,在压辊(8)的压力下,两个感应线圈(10)分别对桁条结构(11)两侧同时进行焊接;
步骤七:焊接结束后,将双线圈感应装置移动至安全位置并关闭感应焊机以及冷却装置电源。
以上实施例仅为本发明的示例性实施例,不用于限制本发明,本发明的保护范围由权利要求书限定。本领域技术人员可以在本发明的实质和保护范围内,对本发明做出各种修改或等同替换,这种修改或等同替换也应视为落在本发明的保护范围内。
Claims (4)
1.一种热塑复合材料蒙皮桁条结构双线圈感应焊接的装置,其特征在于:该焊接装置包括感应焊机(1)、计算机控制系统(2)、冷却装置(3)以及双线圈感应装置:
双线圈感应装置、计算机控制系统(2)和感应焊机(1)两两采用导线连接,双线圈感应装置与冷却装置(3)采用冷却水管(9)进行连接:
双线圈感应装置上端由机器人连接头(4)与机器人连接,实现焊接头在不同方位的移动;双线圈感应装置为对称结构,两侧均安装有导轨和滑块(6),滑块均连接有压辊(8)和盘式线圈(10);在滑轨上方做镂空处理,冷却水管(9)穿过镂空区域连接滑块(6)与冷却装置(3);双线圈感应装置架(5)中间放置滑轨电机(13),并通过导线分别与两块滑块(6)连接,双线圈感应装置架(5)下方正中安装激光测距仪(7),激光测距仪(7)与计算机控制系统(2)连接;压辊(8)位于盘式线圈(10)之前,盘式线圈(10)在导轨滑块(6)中与冷却水管(9)连接。
2.根据权利要求1所述一种热塑复合材料蒙皮桁条结构双线圈感应焊接的装置,其特征在于:滑块(6)可移动的距离范围为0~80mm;压辊(8)所用材料为陶瓷材料;在水平方向上,盘式线圈(10)比压辊(8)高10mm。
3.利用权力要求1所述装置进行的一种热塑复合材料蒙皮桁条结构双线圈感应焊接的方法,其特征在于:将蒙皮桁条结构装夹固定在工装平台上,双线圈感应装置移动至结构上方;激光测距仪(7)测量桁条(11)宽度,并将测量结果实时反馈给计算机控制系统(2);计算机控制系统(2)控制滑轨电机(13)运行,滑轨电机(13)带动两块滑块(6)分别移动,每块滑块(6)的移动距离为桁条(11)宽度的一半;待滑块(6)停止移动后,将双线圈感应装置移动至蒙皮桁条结构始焊位置并打开感应焊机(1)电源以及冷却装置(3)进行焊接;在焊接过程中,由压辊(8)对蒙皮桁条结构进行施压,在压辊(8)的压力下,两个盘式线圈(10)分别对桁条结构(11)两侧同时进行焊接,蒙皮桁条在压力以及热作用下实现高效的连接。
4.根据权利要求3所述的一种热塑复合材料蒙皮桁条结构双线圈感应焊接的方法,其特征在于:所述两块滑块(6)的移动方式为对称相向运动;所述感应焊机(1)的工作频率为200kHz。
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