ITTO20130367A1 - Macchina a induzione per giuntare materiali compositi conduttivi e relativo metodo di giunzione - Google Patents

Macchina a induzione per giuntare materiali compositi conduttivi e relativo metodo di giunzione

Info

Publication number
ITTO20130367A1
ITTO20130367A1 IT000367A ITTO20130367A ITTO20130367A1 IT TO20130367 A1 ITTO20130367 A1 IT TO20130367A1 IT 000367 A IT000367 A IT 000367A IT TO20130367 A ITTO20130367 A IT TO20130367A IT TO20130367 A1 ITTO20130367 A1 IT TO20130367A1
Authority
IT
Italy
Prior art keywords
temperature
inductor
machine according
coil inductor
coil
Prior art date
Application number
IT000367A
Other languages
English (en)
Inventor
Silvio Pappada
Andrea Salomi
Original Assignee
Ct Di Progettazione Design & Tecnol Dei Materiali
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ct Di Progettazione Design & Tecnol Dei Materiali filed Critical Ct Di Progettazione Design & Tecnol Dei Materiali
Priority to IT000367A priority Critical patent/ITTO20130367A1/it
Priority to EP14167453.1A priority patent/EP2801472B1/en
Priority to ES14167453.1T priority patent/ES2621778T3/es
Publication of ITTO20130367A1 publication Critical patent/ITTO20130367A1/it

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914Measuring 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
    • B29C66/9161Measuring 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
    • B29C66/91651Measuring 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34Joining 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"
    • B29C65/36Joining 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
    • B29C65/3604Joining 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
    • B29C65/3608Joining 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 comprising single particles, e.g. fillers or discontinuous fibre-reinforcements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5042Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like covering both elements to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint 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
    • B29C66/112Single lapped joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint 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
    • B29C66/112Single lapped joints
    • B29C66/1122Single lap to lap joints, i.e. overlap joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint 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
    • B29C66/114Single butt joints
    • B29C66/1142Single butt to butt joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/122Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1226Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one bevelled joint-segment
    • B29C66/12261Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one bevelled joint-segment the two joint-segments being bevelled, e.g. the two joint-segments forming a V
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124Tongue and groove joints
    • B29C66/1244Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
    • B29C66/12443Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue having the tongue substantially in the middle
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124Tongue and groove joints
    • B29C66/1246Tongue and groove joints characterised by the female part, i.e. the part comprising the groove
    • B29C66/12463Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being tapered
    • B29C66/12464Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being tapered being V-shaped
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/347General 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
    • B29C66/3474General 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 perpendicular to the plane of the joint
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/348Avoiding melting or weakening of the zone directly next to the joint area, e.g. by cooling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/349Cooling the welding zone on the welding spot
    • B29C66/3494Cooling the welding zone on the welding spot while keeping the welding zone under pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General 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
    • B29C66/47Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52Joining tubular articles, bars or profiled elements
    • B29C66/524Joining profiled elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/72General 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
    • B29C66/721Fibre-reinforced materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/81General 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
    • B29C66/818General 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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8181General 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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/83General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836Moving 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
    • B29C66/8362Rollers, cylinders or drums moving relative to and tangentially to the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/84Specific machine types or machines suitable for specific applications
    • B29C66/863Robotised, e.g. mounted on a robot arm
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91211Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods
    • B29C66/91216Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods enabling contactless temperature measurements, e.g. using a pyrometer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91221Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914Measuring 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
    • B29C66/9141Measuring 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 temperature
    • B29C66/91411Measuring 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 temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91951Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to time, e.g. temperature-time diagrams
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/96Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process
    • B29C66/961Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving a feedback loop mechanism, e.g. comparison with a desired value
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34Joining 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"
    • B29C65/36Joining 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
    • B29C65/3604Joining 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
    • B29C65/3608Joining 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 comprising single particles, e.g. fillers or discontinuous fibre-reinforcements
    • B29C65/3612Joining 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 comprising single particles, e.g. fillers or discontinuous fibre-reinforcements comprising fillers
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    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C65/36Joining 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
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    • B29C65/3608Joining 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 comprising single particles, e.g. fillers or discontinuous fibre-reinforcements
    • B29C65/3616Joining 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 comprising single particles, e.g. fillers or discontinuous fibre-reinforcements comprising discontinuous fibre-reinforcements
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    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34Joining 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"
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    • B29C66/7375General 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 state of the material of the parts to be joined uncured, partially cured or fully cured
    • B29C66/73751General 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 state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being uncured, i.e. non cross-linked, non vulcanized
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    • B29C66/73753General 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 state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being partially cured, i.e. partially cross-linked, partially vulcanized
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    • B29C66/7392General 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
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    • B29C66/7394General 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 thermoset
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    • B29C66/80General aspects of machine operations or constructions and parts thereof
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    • B29C66/824Actuating mechanisms
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    • B29K2507/00Use of elements other than metals as filler
    • B29K2507/04Carbon
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    • B29L2031/3055Cars
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29L2031/00Other particular articles
    • B29L2031/30Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076Aircrafts

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Robotics (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • General Induction Heating (AREA)

Description

DESCRIZIONE
“MACCHINA A INDUZIONE PER GIUNTARE MATERIALI COMPOSITI CONDUTTIVI E RELATIVO METODO DI GIUNZIONEâ€
La presente invenzione à ̈ relativa a una macchina ad induzione per giuntare elementi di materiali compositi elettricamente conduttivi a matrice polimerica.
Il fattore chiave per l’incremento dell’utilizzo di materiali compositi a matrice polimerica in numerosi settori ad elevato valore aggiunto, quale quello aerospaziale o dei trasporti, à ̈ legato spesso alla possibilità di migliorare singolarmente o in combinazione il livello di automazione del processo di giunzione, la resistenza meccanica della giunzione e la qualità della finitura superficiale del prodotto giuntato. Preferibilmente, ad esempio nel settore aerospaziale o dei trasporti, occorre massimizzare gli indicatori riferiti alle prestazioni nei vari ambiti sopra specificati. In particolare, alcuni controlli di qualità prevedono un esame ottico del prodotto giuntato e in caso di imperfezioni superficiali sono previsti approfondimenti che nel migliore dei casi generano costi legati a procedure di accertamento e nel peggiore incrementano ulteriormente i costi poiché il pezzo difettoso viene scartato.
Il processo di saldatura ad induzione à ̈ un processo di giunzione che non prevede necessariamente l’impiego di materiale d’apporto e viene eseguito nel caso più semplice per sovrapposizione di due lembi di un primo e un secondo pezzo da saldare (detti anche aderendi) mantenuti a contatto tra loro. In un processo di saldatura ad induzione la matrice (termoplastica oppure sensibile alla temperatura) di uno od entrambi gli aderendi viene portata ad una temperatura di rammollimento o fusione, in maniera da promuovere un legame di natura chimica e/o meccanica tra gli aderendi e successivamente raffreddata per rendere definitiva l’adesione. Esempi di giunto tipicamente realizzati, che comprendono la sagomatura, sono riportati in fig.4.
In questa tecnologia il campo elettromagnetico variabile, generato da un induttore, provoca l’induzione di correnti parassite nel materiale composito conduttivo, le quali, per effetto Joule, riscaldano la matrice sino alle condizioni di fusione o rammollimento. Successivamente, una volta portati gli aderendi alla temperatura ritenuta ideale, si può applicare una pressione meccanica, detta pressione di consolidamento, atta a promuovere l’adesione degli aderendi. L’azione di un sistema compattatore riveste un’importanza fondamentale per la creazione del giunto saldato. Quindi tipicamente all’azione dell’induttore à ̈ associata l’azione del sistema compattatore.
La modalità di realizzazione del giunto può essere statica o dimanica a seconda che la bobina e/o il sistema di compattazione possano assumere posizioni diverse nel tempo rispetto al materiale da saldare.
Il sistema di compattazione à ̈ costituito tipicamente da un pistone metallico che può assumere diverse forme a seconda della modalità di funzionamento e/o geometria del pezzo. Forme tipiche del pistone compattatore sono quelle di piastra, rullo cilindrico o sferico ecc. il pistone compattatore può comprendere un circuito interno di raffreddamento. Tale pistone ha quindi la duplice funzione di applicare la pressione di consolidamento e di raffreddare il materiale.
Nei sistemi di saldatura a induzione tradizionali, tenendo presente una dipendenza con il quadrato della distanza dalla bobina, l’azione riscaldante dovuta alle correnti parassite tende a concentrarsi sulla superficie direttamente esposta all’induttore. Si innesca quindi un conseguente gradiente di temperatura molto elevato che promuove la fusione della matrice superficiale piuttosto che quella nella zona di adesione degli aderendi: questo impatta negativamente sulla qualità della saldatura e sulle caratteristiche meccaniche della giunzione così ottenuta. Inoltre il verso di tale gradiente di temperatura, nella direzione dello spessore, si traduce in una temperatura massima sulla superficie affacciata alla bobina e minima sulla superficie di giunzione. Quindi per raggiungere la temperatura ideale sulla superficie di adesione degli aderendi si avrà una temperatura eccessiva nelle zone più esterne e ciò può comportare una degradazione della matrice del composito. La presenza di questo gradiente limita quindi notevolmente lo spessore possibile degli aderendi. Analogamente sui bordi dei pezzi da saldare si ha una forte concentrazione di correnti e quindi si instaurano su di essi gradienti di temperatura spesso inaccettabili che possono portare ancora una volta alla degradazione del materiale. Per evitare tale inconveniente à ̈ possibile eseguire la saldatura lontano dai bordi del pezzo di materiale composito ma ciò comporta, a causa di una non completa saldatura del giunto, un decadimento della resistenza meccanica del prodotto finito e/o la creazione di zone dove l’innesco di cricche à ̈ favorito. Alternativamente à ̈ possibile prevedere l’utilizzo di un suscettore metallico, ad esempio una griglia, sull’interfaccia di saldatura per concentrare l’azione delle correnti parassite nell’area di interesse. In tal caso tuttavia l’area di saldatura comprede un corpo estraneo e ciò impatta negativamente sulla resistenza meccanica della giunzione saldata.
Un’altra problematica relativa ai sistemi di saldatura tradizionali risiede nel fatto che il pistone di compattazione deve essere tenuto molto vicino all’induttore, a causa del gradiente di temperatura non ottimizzato: infatti occorre applicare la pressione di consolidamento prima che la temperatura della matrice nella zona di giunzione scenda al di sotto della temperatura di fusione. La vicinanza del cilindro metallico alla bobina di induzione causa una perturbazione del campo elettromagnetico difficile da controllare, con conseguente perdita di efficacia del riscaldamento per induzione all’interno del materiale composito e l’esigenza di svolgere numerose prove preliminari prima di ottenere una saldatura di buona qualità. Le prove preliminari possono essere eseguite tramite strumenti di calcolo comprendente il calcolo agli elementi finiti e/o prove di laboratorio.
Inoltre nei sistemi tradizionali, in cui si ha la fusione della matrice dalla superfice esposta alla bobina di induzione sino all’interfaccia da saldare (a meno che non si utilizzano suscettori) à ̈ possibile che il pistone di compattazione lasci un’impronta sulla superficie del giunto esposta direttamente sulla bobina di induzione, con conseguenti impatti negativi nel caso di verifiche di qualità che prevedono l’esame ottico della zona saldata.
Per i motivi sopra elencati, i procedimenti di saldatura a induzione tradizionali presentano esigenze di controllo tali da rendere scarso il livello di automatizzazione delle linee di produzione.
Lo scopo della presente invenzione à ̈ di realizzare una macchina a induzione per giuntare, consolidare e/o riparare materiali compositi a matrice polimerica esente dagli inconvenienti sopra specificati con un elevato livello di automazione delle linee di produzione.
Lo scopo della presente invenzione viene raggiunto tramite una macchina di giunzione a induzione secondo la rivendicazione 1 e tramite un metodo di giunzione a induzione secondo la rivendicazione 9.
L’invenzione verrà ora descritta con riferimento ai disegni annessi, che ne illustrano esempi di attuazione non limitativi e si riferiscono:
- Figura 1: a una vista prospettica di una macchina di giunzione a induzione secondo la presente invenzione: per semplicità si riporta lo schema di una macchina mobile su assi cartesiani;
- Figure 2 e 3: sono grafici di rilievi comparativi di temperatura eseguiti su un pezzo giuntato rispettivamente con e senza la macchina di saldatura secondo la presente invenzione; e
- Figura 4: esempi di saldature realizzabili tramite una macchina a induzione su elementi di materiali composito conduttivo a matrice polimerica.
In figura 1 à ̈ illustrata con 1 nel suo insieme una macchina di saldatura a induzione comprendente una base 2 e una testa di saldatura 3 mobile su tre assi cartesiani rispetto alla base 2 in modo noto e un gruppo motorizzato (non illustrato in maggiore dettaglio) per movimentare la testa di saldatura 3. Nel caso più complesso la testa di saldatura può essere montata su un braccio robotizzato. In particolare, la testa di saldatura 3 presenta da tre a sei gradi di libertà.
La macchina di saldatura 1 comprende inoltre un dispositivo di raffreddamento a flusso di gas 4 e un sensore di temperatura 5 montati preferibilmente a bordo della testa di saldatura 3.
Secondo la presente invenzione il dispositivo di raffreddamento a flusso di gas 4 viene regolato sulla base di un segnale ricevuto dal sensore di temperatura 5 per inviare una corrente di gas su un’area di un primo pezzo da saldare riscaldata in uso da un induttore 6 della testa di saldatura 3. L’induttore 6 à ̈ di tipo noto e presenta una porzione terminale ad esempio a bobina singola, doppia, elicoidale o a doppia T. La portata e/o la velocità e/o la temperatura del flusso di gas del dispositivo di raffreddamento 4 possono essere controllare sulla base del segnale del sensore di temperatura 5. Preferibilmente, la portata può essere controllata tramite la regolazione automatica o manuale di un generatore (o sorgente esterna) di flusso di gas 7 o altro fluido (compressore di qualsiasi tipo, ventilatore, pompa di qualsiasi tipo, linea esterna di qualsiasi tipo). La temperatura del flusso di gas può essere regolata tramite un elemento riscaldante o raffreddante disposto a monte della mandata e un sensore di temperatura investito dal flusso di gas alla mandata servirà come dato input per la regolazione della temperatura. Il dispositivo di raffreddamento a flusso di gas 4 comprende un condotto 8 collegato al generatore di flusso di gas 7 e avente uno o più ugelli di estremità 9 avente una posizione regolabile rispetto alla testa di saldatura 3 per poter indirizzare il flusso di gas con la direzione più opportuna in dipendenza delle fasi di saldatura e/o della forma della saldatura e/o della geometria del prodotto da saldare e/o delle dimensioni e forma della bobina dell’induttore 6. Durante la saldatura l’ugello di estremità 9 può essere sostanzialmente fisso rispetto all’induttore 6 oppure fisso rispetto alla base 2.
Preferibilmente il condotto 8 Ã ̈ portato dalla testa di saldatura 3.
Il sensore di temperatura 5 rileva una temperatura indicativa del riscaldamento di una superficie 10 del primo pezzo da saldare P1 affacciata alla porzione dell’induttore 6 alla quale corrisponde un punto scelto come riferimento sul laminato e contrapposta ad una superficie 11 del primo pezzo da saldare P1 su cui si origina la saldatura con un secondo pezzo da saldare P2. Il sensore di temperatura 5 può essere un pirometro accostato ad una testa o bobina 12 dell’induttore 6 in modo da rilevare una temperatura puntuale indicativa di quella della superficie 10 oppure una termocamera a raggi infrarossi per rilevare la temperatura della superficie 10 in due o tre dimensioni. E’ possibile impiegare ulteriori sensori di temperatura in sostituzione di quelli citati per rilevare il riscaldamento della superficie 10 durante l’energizzazione dell’induttore 6. Anche il sensore 5 può essere mobile e regolabile rispetto all’induttore 6. Durante la saldatura il sensore 5 può essere sostanzialmente fisso rispetto all’induttore 6 oppure fisso rispetto alla base 2. Preferibilmente il sensore 5 à ̈ portato dalla testa di saldatura 3.
Il segnale del sensore di temperatura 5, il dispositivo di raffreddamento a flusso di gas 4 e il sistema motorizzato per la movimentazione della testa di saldatura 3 sono collegati in scambio dati ad una centralina di controllo 13. In particolare, la centralina di controllo 13 implementa un controllo in anello chiuso per mantenere la temperatura rilevata tramite il sensore di temperatura 5 ad un livello predeterminato tramite la regolazione del dispositivo di raffreddamento a flusso di gas 4. Preferibilmente, la centralina di controllo 13 regola il dispositivo di raffreddamento a flusso di gas 4 in modo da dissipare, ad esempio per convezione, il calore agente sulla superficie 10 in modo che la temperatura effettiva sulla superficie 11 sia inferiore alla temperatura di fusione o di rammollimento della matrice del materiale composito. In questo modo, anche dopo l’esecuzione della saldatura viene preservata la finitura originaria della superficie 10 del primo pezzo da saldare, cioà ̈ la finitura della superficie 10 prima di eseguire la saldatura.
Inoltre, tramite la dissipazione di calore sulla superficie 10 ad opera del dispositivo di raffreddamento a flusso di gas 4, la temperatura di fusione sulla superficie 11 à ̈ raggiungibile mantenendo la temperatura della superficie 10 relativamente bassa. Quindi il gradiente di temperatura lungo lo spessore del primo pezzo da saldare à ̈ controllabile in modo preciso con conseguenti vantaggi per la qualità finale del giunto saldato, come descritto precedentemente. Eventualmente, qualora necessario, anche il gradiente di temperatura dell’aderendo inferiore può essere controllato utilizzando dei supporti raffreddati/riscaldati da fluidi/resistenze.
Il controllo del gradiente di temperatura à ̈ un aspetto particolarmente importante quando lo spessore fra le superfici 10 e 11 cresce. Infatti per riscaldare adeguatamente la superficie 11 à ̈ necessaria una quantità di energia elevata che si traduce nel rapido aumento locale della temperatura sulla superficie 10 a valori anche superiori a quelli della temperatura di fusione o rammollimento. Tramite la regolazione del dispositivo di raffreddamento a flusso di gas 4, la temperatura della superficie 10 può essere mantenuta a livelli non eccessivi pur consentendo di eseguire correttamente la fusione della superficie 11 e il giunto saldato.
Inoltre, l’azione convettiva del flusso di gas riduce considerevolmente anche l’impatto negativo della concentrazione delle correnti parassite, e quindi anche i picchi di temperatura, che si rileva sui bordi di estremità degli elementi da saldare. In questo modo à ̈ possibile realizzare una saldatura di elevata qualità anche in prossimità dei bordi del primo e/o del secondo pezzo dal saldare. Preferibilmente, la macchina di saldatura 1 comprende inoltre un compattatore 14 per premere il primo pezzo da saldare sul secondo pezzo dal saldare mentre l’induttore 6 à ̈ attivo e viene eseguita la saldatura. Il compattatore 14 può comprendere un rullo girevole 15 orientabile per muoversi a contatto con la superficie 10 senza sostanziale strisciamento oppure un pistone lineare che preme e nel frattempo rimane fisso mentre l’induttore 6 à ̈ attivo per eseguire la saldatura. Il compattatore 14 può comprendere un dispositivo di movimentazione tale che durante l’esecuzione della saldatura il compattatore 14 può muoversi lungo il cordone di saldatura in modo rigido o indipendente rispetto alla testa di saldatura 3. E’ anche possibile che il compattatore 14 sia fisso mentre la testa di saldatura 3 à ̈ in movimento. Il compattatore 14 può essere montato a bordo della testa di saldatura. Tramite il dispositivo di movimentazione, il movimento verticale del compattatore 14 rispetto a quello dell’induttore 6 può essere rigido o indipendente. Il dispositivo di movimentazione del compattatore 14 può essere motorizzato e/o controllato dalla centralina di controllo 13.
Preferibilmente, il rullo 15 o il pistone lineare sono metallici e comprendono un sistema interno di raffreddamento. Il sistema di raffreddamento del rullo 15 consente di dissipare il calore dopo la fusione della matrice dovuta all’azione dell’induttore 6 per garantire una solidificazione corretta dopo la saldatura. Tramite un compattatore 14 che presenta un elemento metallico a contatta con il pezzo P1 la dissipazione del calore à ̈ migliorata. In questo modo la superficie 11 viene raffreddata più rapidamente e il compattatore 14 non viene surriscaldato eccessivamente dall’azione dell’induttore 6. La posizione del compattatore 14 à ̈ regolabile rispetto all’induttore 6 e la temperatura del compattatore à ̈ regolabile tramite la centralina di controllo 13.
Le figure 2 e 3 si riferiscono a rilievi sperimentali eseguiti su un primo pezzo da saldare opportunamente strumentato anche sulla superficie 11. In figura 3 la temperatura T1 della superficie 10 à ̈ controllata e il dispositivo di generazione di flusso di gas 4 à ̈ disabilitato. E’ evidente come la temperatura T2 sulla superficie 11 si mantenga più bassa della temperatura sulla superfice 10. In figura 2, quando il dispositivo di generazione di flusso di gas 4 à ̈ attivo, à ̈ possibile aumentare la temperatura T2 della superfice 11 mantenendo costante la temperatura T1 della superfice 10. In questo modo, l’energia assorbita dall’induttore 6 à ̈ tale da far superare la temperatura di fusione alla superficie 10 ma tramite il raffreddamento a gas la temperatura di tale superficie viene controllata per rimanere circa uguale o inferiore alla temperatura di fusione mentre l’energia che raggiunge la superficie 11 provoca il riscaldamento adatto, ad esempio la fusione, in tale zona. Quindi si può superare la temperatura di fusione della matrice sulla superfice 11 senza fondere la matrice sulla superficie 10. In altre parole, la temperatura della superficie 10 può essere controllata e mantenuta stabilmente al di sotto di quella raggiunta sulla superficie 11 tramite l’azione del dispositivo di generazione di flusso di gas 4. La differenza di temperatura fra le superfici 10 e 11 può superare i 20°. Gli andamenti di temperatura di fig 2 e 3 sono stati ottenuti in un test di saldatura su una giunzione realizzata a partire da due lamine di PPS-Carbonio bilanciato e simmetrico di spessore 2.48 mm ciascuna (nome commerciale CETEX® PPS prodotto e distribuito dalla TENCATE), con una potenza di 3kWh e una distanza della bobina dalla superfice del pezzo da saldare pari a 2 mm.
I vantaggi che la macchina di giunzione a induzione secondo la presente invenzione consente di ottenere sono i seguenti.
A parità di spessore dei pezzi da saldare, à ̈ possibile controllare in modo affidabile il gradiente termico lungo lo spessore.
Secondo la presente invenzione, à ̈ possibile ottenere un gradiente di temperatura ottimizzato e controllato all’interno del composito da riscaldare, che può essere addirittura invertito in maniera da massimizzare la temperatura sulla superficie di giunzione degli aderendi, e minimizzarla sulla superficie esterna. Inoltre tale gradiente potrà, con la presente invenzione, essere controllato e modificato in tempo reale durante la saldatura. Tale invenzione permette quindi rispetto ai sistemi tradizionali di avere una maggiore uniformità delle proprietà fisiche e meccaniche lungo lo spessore della giunzione, di migliorare le proprietà estetiche e di uniformità superficiale della superficie esterna adiacente al giunto.
La superficie 10 affacciata all’induttore 6 può essere mantenuta ad una temperatura inferiore a quella di fusione, diminuendo notevolmente il rischio di generare imperfezioni superficiali. E’ possibile un controllo degli effetti di surriscaldamento dei bordi e dei punti critici di inizio e fine giunto tramite l’azione di un sistema di raffreddamento regolabile.
E’ inoltre possibile ampliare l’applicabilità della saldatura a induzione a spessori maggiori rispetto a quelli sinora adottati, si possono ad esempio agevolmente superare i 3 mm di spessore dell’elemento che definisce le superfici 10 e 11.
Inoltre, dal momento che à ̈ possibile scaldare in modo considerevole la superficie 11 rispetto alla superficie 10, il tempo a disposizione prima che la temperatura della superfice 11 si porti al di sotto della temperatura di solidificazione tende ad aumentare. Per questo motivo il compattatore 14 metallico può essere posizionato, su un piano orizzontale, a una distanza dall’induttore 6 superiore a 1.5cm, preferibilmente superiore a 3.5cm, in modo da non interferire eccessivamente con il campo magnetico generato dall’induttore stesso e poter comunque contribuire alla solidificazione controllata della saldatura. In questo modo il campo elettromagnetico generato dall’induttore 6 viene perturbato in modo marginale dal compattatore 14 di metallo e il riscaldamento del primo pezzo da saldare à ̈ controllabile in modo più preciso: la saldatura presenta caratteristiche meccaniche migliorate.
La macchina a induzione 1 Ã ̈ completamente automatizzabile e si presta alla realizzazione di linee di saldatura in continuo.
Tramite una macchina di saldatura secondo la presente invenzione à ̈ stato possibile realizzare giunti saldati per sovrapposizione aventi le massime proprietà di resistenza secondo quanto riportato in letteratura per tecnologie di giunzione che prevedono la fusione della matrice (saldatura a induzione, a frizione, a ultrasuoni etc) o per metodi di giunzione che prevedano l’uso di adesivi strutturali.
Tramite la presente invenzione si possono inoltre giuntare anche compositi termoindurenti già vulcanizzati o curati andando a interporre tra i laminati già vulcanizzati degli strati di materiale non vulcanizzato. In questo caso si concentrerà il riscaldamento solo nella zona dove à ̈ presente il materiale non curato, lasciando il resto della giunzione ad una temperatura inferiore a quella di cura.
Secondo la presente invenzione à ̈ possibile un’ampia libertà nella scelta delle bobine, in quanto l’ottimizzazione del campo elettromagnetico non à ̈ legata solo alla scelta della geometria della bobina, come nelle macchine tradizionali. Nella nuova macchina infatti à ̈ possibile scegliere una bobina secondo esigenze dettate dalla geometria e dalle altre caratteristiche fisicomeccaniche della giunzione da realizzare, salvo poi ottimizzare la distribuzione delle temperature all’interno della giunzione con il sistema di controllo e raffreddamento oggetto della presente invenzione.
Quando viene controllata la temperatura anche dell’elemento da giuntare P2 tramite conduzione o convezione con una sorgente calda o fredda, il controllo della superficie esterna del pezzo finale ottenuto dopo la giunzione à ̈ ulteriormente migliorato.
L’impiago di un gas o qualsiasi altro elemento aeriforme convogliato sulla superficie 10 tramite uno o più ugelli consente di mantenere la superficie 10 stessa sempre visibile. In questo modo la temperatura può essere monitorato in modo semplice.
Risulta infine chiaro che alla macchina di saldatura a induzione qui descritta e illustrata à ̈ possibile apportare modifiche o varianti senza per questo uscire dall’ambito di tutela come definito dalla rivendicazioni allegate.
La macchina a induzione 1 può essere impiegata per saldare qualsiasi materiale composito a matrice termoplastica caricata con fibre o particelle elettricamente conduttive, come ad esempio le fibre di carbonio. Può essere inoltre utilizzata per la realizzazione di giunzioni incollate con materiali compositi termoindurenti non curati o parzialmente curati: in questo caso mediante la tecnologia del riscaldamento ad induzione si dovrà superare la temperatura di cura del materiale termoindurente nelle superfici di giunzione. Quando la macchina 1 viene impiegata per giuntare elementi di materiali compositi a matrice termoindurente il compattatore 14 à ̈ facoltativo.
Il dispositivo di raffreddamento 4 può generare un flusso di aria o di altri gas adatti in modo dipendente, ad esempio, dal materiale da giuntare.
La regolazione della temperatura sulla superficie 10 tramite la centralina di controllo 13 può avvenire tramite una combinazione de: controllo della temperatura e/o flusso di gas dall’ugello 8 e/o controllo della potenza elettrica dell’induttore 6 e/o controllo della distanza dell’induttore 6 dalla superficie 10.

Claims (11)

  1. RIVENDICAZIONI 1. Macchina a induzione per giuntare materiali compositi elettricamente conduttivi a matrice polimerica comprendente un induttore a bobina (6) mobile, un sensore di temperatura (5) e una centralina di controllo (13) per controllare il detto induttore a bobina (6) sulla base del segnale ricevuto dal detto sensore di temperatura (5), caratterizzato dal fatto di comprendere almeno uno o più dispositivi (9) per dirigere una portata di un gas o fluido di raffreddamento in scambio termico superficiale con una zona riscaldata (10) affacciata al detto induttore a bobina (6) di un elemento da giuntare (P1).
  2. 2. Macchina a induzione secondo la rivendicazione 1, caratterizzata dal fatto di comprendere un compattatore (14) avente una porzione metallica (15) mobile in una posizione di contatto con un pezzo da giuntare e avente un circuito di raffreddamento per raffreddare la detta porzione metallica (15), la detta porzione metallica (15) essendo inoltre disposta a una distanza superiore a 1.5 cm rispetto al detto induttore a bobina (6).
  3. 3. Macchina secondo una qualsiasi delle rivendicazioni precedenti, caratterizzata dal fatto che la detta centralina di controllo (13) à ̈ programmabile per energizzare il detto induttore a bobina (6) con un’energia tale da poter superare una fra le temperature di fusione, rammollimento o cura della matrice polimerica su una superficie (10) del detto elemento da giuntare (P1) affacciata a una porzione terminale del detto induttore a bobina (6), la detta portata di gas essendo tale da mantenere la detta superficie (10) circa alla detta temperatura o al di sotto di essa.
  4. 4. Macchina secondo la rivendicazione 3, caratterizzata dal fatto che la detta centralina di controllo (13) à ̈ programmata per controllare, sulla base del segnale proveniente dal detto sensore (5) almeno uno fra una posizione verticale e/o potenza del detto induttore a bobina (6), una velocità e/o una temperatura della detta portata di gas o fluido.
  5. 5. Macchina secondo una qualsiasi delle rivendicazioni precedenti, caratterizzata dal fatto di comprendere un sistema di movimentazione del detto induttore a bobina (6) e del detto dispositivo (9), la detta centralina (13) controllando l’avanzamento del detto induttore a bobina (6) e controllando la detta portata di fluido e/o il detto dispositivo (9) per ottenere una giunzione in continuo.
  6. 6. Macchina secondo una qualsiasi delle rivendicazioni precedenti, caratterizzata dal fatto che il detto induttore a bobina (6) e il detto dispositivo (9) sono portate da una medesima testa di lavorazione (3) mobile.
  7. 7. Macchina secondo una qualsiasi delle rivendicazioni precedenti, caratterizzata dal fatto di comprendere un supporto (8) per il detto dispositivo (9) configurato per regolare la posizione del detto dispositivo (9) rispetto al detto induttore a bobina (6).
  8. 8. Macchina secondo una qualsiasi delle rivendicazioni precedenti, caratterizzata dal fatto che il detto dispositivo (9) comprende un ugello.
  9. 9. Macchina secondo una qualsiasi delle rivendicazioni precedenti, caratterizzata dal fatto di comprendere un generatore di flusso di gas o fluido (7) controllato tramite la detta centralina di controllo (13).
  10. 10. Metodo di giunzione per componenti di materiale composito elettricamente conduttivo a matrice polimerica, caratterizzato dal fatto di essere applicato tramite una macchina a induzione secondo una qualsiasi delle rivendicazioni precedenti.
  11. 11. Metodo di giunzione secondo la rivendicazione 10, caratterizzato dal fatto che il detto flusso di raffreddamento viene applicato su una faccia (10) del detto elemento da giuntare (10) affacciato al detto induttore a bobina (6) e dal fatto di controllare la temperatura tramite conduzione e/o convezione di un ulteriore elemento da giuntare (P2) che contatta il detto elemento da giuntare (P1).
IT000367A 2013-05-07 2013-05-07 Macchina a induzione per giuntare materiali compositi conduttivi e relativo metodo di giunzione ITTO20130367A1 (it)

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EP14167453.1A EP2801472B1 (en) 2013-05-07 2014-05-07 Induction machine for bonding polymer-matrix conductive composite materials and bonding method for said machine
ES14167453.1T ES2621778T3 (es) 2013-05-07 2014-05-07 Máquina de inducción para unir materiales compuestos conductores de matriz polimérica y método de unión para dicha máquina

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ES2858627T3 (es) * 2014-11-06 2021-09-30 Centro Di Progettazione Design & Tecnologie Dei Mat Método de soldadura por inducción para materiales compuestos conductores de electricidad que tienen una matriz termoendurecible
NL2021039B1 (en) * 2018-06-01 2019-12-10 Kok & Van Engelen Composite Structures B V Method and device for joining moulded parts by electromagnetic welding
US11685125B2 (en) 2018-07-16 2023-06-27 Arkema France Method for welding parts made of thermoplastic material
IT201800020524A1 (it) * 2018-12-20 2020-06-20 Leonardo Spa Dispositivo di saldatura ad induzione elettromagnetica per giuntare materiali compositi e relativo metodo di giunzione
ES2966937T3 (es) * 2019-08-06 2024-04-25 Boeing Co Detección remota de temperatura de soldadura por inducción
US20210122123A1 (en) * 2019-10-25 2021-04-29 Spirit Aerosystems, Inc. System and method for thermoplastic welding using an induced thermal gradient
FR3103408B1 (fr) * 2019-11-27 2022-12-09 Arkema France Procédé d’évaluation d’un assemblage par soudage de pièces à base de matériaux thermoplastiques
US20210291292A1 (en) * 2020-03-20 2021-09-23 Wichita State University Systems and methods for induction welding
DE102021102485A1 (de) 2021-02-03 2022-08-04 Leibniz-Institut für Verbundwerkstoffe GmbH Verfahren zum induktiven Fügen von Faser-Kunststoff-Verbundwerkstoffen mit elektrisch leitfähigen Fasern
JP6985541B1 (ja) * 2021-03-19 2021-12-22 日鉄エンジニアリング株式会社 温度計測装置、溶接システム及び溶接システムの取付け方法
JP7113953B1 (ja) * 2021-03-19 2022-08-05 日鉄エンジニアリング株式会社 温度計測装置及び溶接システム
FR3123247B1 (fr) * 2021-05-25 2023-05-05 Inst De Rech Tech Jules Verne Installation de soudage dynamique par induction
FR3123239B1 (fr) * 2021-05-25 2023-06-30 Inst De Rech Tech Jules Verne Installation de soudage dynamique par induction
FR3132662A1 (fr) 2022-02-11 2023-08-18 Institut De Recherche Technologique Jules Verne Procédé et installation de soudage
CN115056496B (zh) * 2022-05-26 2024-09-03 北京航空航天大学 一种碳纤维/聚芳醚酮复合材料层板的感应焊接系统与焊接方法
SE545931C2 (en) 2022-07-20 2024-03-19 Corebon Ab Inductive welding of workpieces

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