Classifications

• • 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
  • B23K15/00—Electron-beam welding or cutting

Definitions

• the present invention relates to welding equipment and structures.
• the most common method for welding structural components is to use a movable electron gun to weld the components to be welded.
• JP 2013-240830 A discloses the following invention.
• the welding apparatus of JP2013-240830A generates a first laser beam projected onto a joint area between two or more workpieces to generate a first laser beam projection on adjacent surfaces of the workpieces and move the first laser beam projection along the joint area and penetrate into the joint area.
• the welding apparatus also generates an electric arc to generate an arc projection that surrounds the first laser beam projection and moves with the first laser beam projection along the joint area to form a molten weld pool.
• the welding apparatus generates a pair of lateral laser beams that generate lateral laser beam projections that are surrounded by the arc projections and spaced apart laterally from the joint area to interact with a portion of the weld pool that solidifies to define a molten toe of the weld joint.
• JP 2013-240830 A discloses that the welding process can be applied to aerospace applications, it does not disclose an invention for stabilizing the relative position between the welding device and the workpiece in outer space. As a result, the relative position between the welding device and the workpiece becomes unstable in outer space.
• the object of the present invention is to stabilize the relative position between the welding device and the component in space.
• a welding device for welding components of a structure in space comprising: a first welding unit located on a first surface side of the member; a second welding unit located on a second surface side of the member, The first welding unit and the second welding unit clamp the member and change their relative positions with respect to the member. It is a welding device.
• FIG. 2 is an explanatory diagram of the flow from launch to operation in this embodiment.
• 2 is a cross-sectional view in the Y-axis direction of a first example of the welding device of the present embodiment.
• FIG. 2 is a cross-sectional view in the Z-axis direction of a first example of the welding device of the present embodiment.
• FIG. 10 is a cross-sectional view in the Y-axis direction of a second modified example of the first example of the welding device of the present embodiment.
• FIG. 6 is a cross-sectional view in the Y-axis direction of a second example of the welding device of the present embodiment.
• FIG. FIG. 11 is a cross-sectional view in the Y-axis direction of a third example of the welding device of the present embodiment.
• FIG. 11 is an XY plan view of a member of a modified example 1 of the third example of the welding device 30 of the present embodiment.
• 13A to 13C are explanatory diagrams of the operation (welding and movement) of the welding device according to the first modified example of the third example of the welding device 30 of the present embodiment.
• 13 is an explanatory diagram of the operation (direction change) of the welding device of the first modified example of the third example of the welding device 30 of the present embodiment.
• FIG. 13 is an explanatory diagram of the operation (direction change) of the welding device of the first modified example of the third example of the welding device 30 of the present embodiment.
• FIG. 13 is an explanatory diagram of the operation (direction change) of the welding device of the first modified example of the third example of the welding device 30 of the present embodiment.
• FIG. 13 is an explanatory diagram of the operation (direction change) of the welding device of the first modified example of the third example of the welding device 30 of the present embodiment.
• FIG. 13 is a cross-sectional view in the Y-axis direction of a modified example 2(1) of the third example of the welding device.
• FIG. 13 is a cross-sectional view in the Y-axis direction of a modified example 2(2) of the third example of the welding device.
• FIG. 13 is a cross-sectional view in the Y-axis direction of a third modified example of the welding device.
• FIG. 11 is a cross-sectional view in the Y-axis direction of a fourth example of the welding device of the present embodiment.
• FIG. 11 is a cross-sectional view in the Y-axis direction of a fifth example of the welding device of the present embodiment.
• FIG. 13 is a cross-sectional view in the Y-axis direction of a sixth example of the welding device of the present embodiment.
• 5 is a cross-sectional view taken along the Y axis for explaining a first example of a welding flow according to the present embodiment.
• FIG. 5 is a cross-sectional view in the Z-axis direction for explaining a first example of a welding flow according to the present embodiment.
• FIG. 6 is a cross-sectional view in the Y-axis direction for explaining a second example of a welding flow of the welding device of the present embodiment.
• FIG. 13 is a cross-sectional view in the Y-axis direction for explaining a fourth example of a welding flow of the welding device of the present embodiment.
• FIG. 13 is a cross-sectional view in the Y-axis direction for explaining a fourth example of a welding flow of the welding device of the present embodiment.
• FIG. FIG. 2 is a plan view of the structure of the present embodiment.
• FIG. 1 is an explanatory diagram of the flow from launch to operation of this embodiment.
• the present embodiment includes a launch process, an installation process, a welding process, and an operation process.
• a launch device R e.g., a rocket
• the installation device 10 installs the member 51 in space.
• the members 51 are joined together by welding using the welding device 30.
• the welding process is performed after the installation process or in parallel with the installation process.
• a structure 50 composed of requested components 51 is operated in space.
• the structure 50 includes, for example, at least one of the following: ⁇ Parabolic antenna
• the first example of the welding device 30 of the present embodiment is an example in which the first welding unit 30a and the second welding unit 30b are kept in contact with the member 51 by an external force.
• Fig. 2 is a cross-sectional view of the first example of the welding device according to the present embodiment taken along the Y-axis direction.
• Fig. 3 is a cross-sectional view of the first example of the welding device according to the present embodiment taken along the Z-axis direction.
• the welding device 30 includes a pair of welding units (first welding unit 30a to second welding unit 30b).
• the pair of welding units are configured to clamp member 51 to be welded from the Z-axis direction (i.e., a direction perpendicular to the arrangement direction of members 51a to 51b to be welded) and move along the X-plane, thereby changing the relative positions of the pair of welding units with respect to members 51a to 51b.
• the first welding unit 30a is located on one side (U side) of the members 51a to 51b in the Z-axis direction.
• the second welding unit 30b is located on the other side (L side) of the members 51a to 51b in the Z-axis direction.
• the first sputter receiver 34a is disposed in the XY plane so as to surround the joint CP between the members 51a and 51b, the first jig 32a, and the electron gun 36 (FIG. 3A). As a result, the first sputter receiver 34a is configured to receive sputters generated when the members 51a and 51b are welded together.
• the first robot arm 35a operates in response to a drive signal generated by the first control unit.
• the first robot arm 35a is configured to move the first welding unit 30a along the XY plane so that the first rotating body 33a abuts against the U-side surfaces of the members 51a to 51b ( Figure 3).
• the electron gun 36 is configured to heat the member 51a to be welded by irradiating it with an electron beam.
• the electron gun 36 is configured to be movable on the XY plane. As the electron gun 36 moves, it is aligned with the position to be welded (hereinafter referred to as the "welding position").
• the first position sensor is configured to detect the position of the area to be welded (i.e., between member 51a and member 51b).
• the first position sensor is, for example, an image sensor.
• the power source is configured to provide power to the welding device 30.
• the power source may include, for example, at least one of the following: Battery (for example, at least one of a solar cell, a lead-acid battery, a lithium-ion battery, an all-solid-state battery, and a fuel cell) Capacitor
• the first control unit is configured to generate a drive signal for driving the first robot arm 35a in accordance with the position detected by the first position sensor, and a control signal for emitting an electron beam from the electron gun 36.
• the second welding unit 30b includes a second housing 31b, a second jig 32b, a second rotating body 33b, a second spatter receiver 34b, a second robot arm 35b, a second position sensor, and a second control unit (not shown).
• the second jig 32b is disposed inside the second sputter receiver 34b in the XY plane (FIG. 3B).
• a second rotating body 33b is disposed at the tip of the second jig 32b.
• the second rotating body 33b is configured to rotate in at least one of the X and Y directions while abutting against the L-side surfaces of the members 51a to 51b. This applies a holding force in the Z-axis direction to the members 51a to 51b, which is opposite to the force applied by the first jig 32a.
• the second rotating body 33b has a movable range in the Z-axis direction.
• the second rotating body 33b is, for example, one of the following.
• - Wheels - Combination of tracks and wheels (i.e. crawlers) This allows the second welding unit 30b to move smoothly along the U-side surface regardless of the curvature or relative angle of the surfaces of the members 51a to 51b.
• the second sputter receiver 34b faces the L-side surfaces of the members 51a to 51b.
• the second sputter receiver 34b is disposed so as to surround the joint CP between the members 51a and 51b and the second jig 32b in the XY plane (FIG. 3B).
• the second sputter receiver 34b is configured to receive sputters generated when the members 51a and 51b are welded together.
• the second robot arm 35b operates in response to a drive signal generated by the second control unit.
• the second robot arm 35b is configured to move the second welding unit 30b along the XY plane so that the second rotating body 33b abuts against the L-side surfaces of the members 51a to 51b ( Figure 3). This keeps the second welding unit 30b in contact with the members 51a to 51b.
• the second position sensor is configured to detect the position of the area to be welded (i.e., between member 51a and member 51b).
• the second position sensor is, for example, an image sensor.
• the second control unit is configured to generate a drive signal for driving the second robot arm 35b in synchronization with the generation of the drive signal by the first control unit. This causes the second welding unit 30b to move in synchronization with the first welding unit 30a.
• the first modified example of the first example of the welding device 30 of the present embodiment is an example in which the first welding unit 30a and the second welding unit 30b do not move in synchronization with each other, but the second welding unit 30b moves in response to the movement of the first welding unit 30a (i.e., one welding unit follows the other welding unit).
• the second position sensor and the second control unit may be omitted.
• the first control unit generates a first drive signal for driving the first robot arm 35a and a second drive signal for driving the second robot arm 35b.
• the second drive signal causes the second welding unit 30b to move following the first welding unit 30a.
• the first position sensor and the first control unit may be omitted.
• the second control unit generates a first drive signal for driving the first robot arm 35a and a second drive signal for driving the second robot arm 35b.
• the first drive signal causes the first welding unit 30a to move following the second welding unit 30b. This changes the relative positions of the pair of welding units with respect to the members 51a to 51b.
• the first position sensor and the first control unit, or the second position sensor and the second control unit are omitted, so that the control system can be simplified. This can reduce manufacturing costs and the failure rate.
• FIG. 4 is a cross-sectional view in the Y-axis direction of a second modified example of the first example of the welding device of this embodiment.
• the first jig 32a is disposed outside the first sputter receiver 34a in the XY plane.
• the second jig 32b is disposed outside the second sputter receiver 34b in the XY plane.
• the first sputter receiver 34a and the second sputter receiver 34b are closer to the joint CP than in Figures 2 and 3. This makes it possible to better prevent the scattering of sputter.
• FIG. 5 is a cross-sectional view of a second example of the welding device according to this embodiment taken along the Y axis.
• the welding device 30 includes a pair of welding units (first welding unit 30a to second welding unit 30b).
• the pair of welding units are configured to clamp member 51 to be welded from the Z-axis direction (i.e., a direction perpendicular to the arrangement direction of members 51a to 51b to be welded) and move along the X-plane, thereby changing the relative positions of the pair of welding units with respect to members 51a to 51b.
• the first welding unit 30a is located on one side (U side) of the members 51a to 51b in the Z-axis direction.
• the second welding unit 30b is located on the other side (L side) of the members 51a to 51b in the Z-axis direction.
• the first welding unit 30a includes a first housing 31a, a first jig 32a, a first rotating body 33a, a first sputter receiver 34a, an electron gun 36, a first magnet 37a, a power supply (not shown), a first control unit (not shown), a first position sensor (not shown), and a first motor (not shown).
• the first housing 31a, the first jig 32a, the first sputter receiver 34a, the electron gun 36, the power supply, and the first position sensor are the same as those in the first example of the welding device (FIG. 2).
• the first rotating body 33a is connected to a first motor.
• the first rotating body 33a is configured to rotate in at least one of the X direction and the Y direction.
• the first magnet 37a is disposed inside the first rotor 33a. If the members 51a to 51b are magnetic, the first magnet 37a and the members 51a to 51b are attracted to each other by magnetic force. This keeps the first welding unit 30a in contact with the members 51a to 51b.
• the first motor operates in response to a drive signal generated by the first control unit.
• the first motor is configured to rotate the first rotating body 33a.
• the first control unit is configured to generate a drive signal for driving the first motor in accordance with the position detected by the first position sensor, and a control signal for emitting an electron beam from the electron gun 36.
• the second welding unit 30b includes a second housing 31b, a second jig 32b, a second rotating body 33b, a second sputter receiver 34b, a second magnet 37b, a second position sensor, a second control unit (not shown), and a second motor (not shown).
• the second housing 31b, the second jig 32b, the second sputter receiver 34b, the second robot arm 35b, the second position sensor, and the second control unit are similar to those in the first example of the welding device (FIG. 2).
• the second rotating body 33b is connected to a second motor.
• the second rotating body 33b is configured to rotate in at least one of the X direction and the Y direction.
• the second magnet 37b is disposed inside the second rotor 33b. If the members 51a to 51b are magnetic, the second magnet 37b and the members 51a to 51b are attracted to each other by magnetic force. This keeps the second welding unit 30b in contact with the members 51a to 51b.
• the second motor operates in response to a drive signal generated by the second control unit.
• the second motor is configured to rotate the second rotating body 33b.
• the second control unit is configured to generate a drive signal for driving the second motor in accordance with the position detected by the second position sensor, and a control signal for emitting an electron beam from the electron gun 36.
• the second example of the welding device 30 can be applied to the second example of the welding device 30.
• the modification of the second example of the welding device 30 of the present embodiment is an example in which the first welding unit 30a and the second welding unit 30b do not move in synchronization with each other, but the second welding unit 30b moves in response to the movement of the first welding unit 30a (i.e., one welding unit follows the other welding unit).
• the second position sensor and the second control unit may be omitted.
• the first control unit generates a first drive signal for driving the first motor and a second drive signal for driving the second motor, and the second welding unit 30b moves following the first welding unit 30a in response to the second drive signal.
• the first position sensor and the first control unit may be omitted.
• the second control unit generates a first drive signal for driving the first motor and a second drive signal for driving the second motor, and the first drive signal causes the first welding unit 30a to move following the second welding unit 30b.
• the first position sensor and the first control unit, or the second position sensor and the second control unit are omitted, so that the control system can be simplified. This can reduce manufacturing costs and the failure rate.
• the first magnet 37a and the second magnet 37b may be electromagnets.
• FIG. 6 is a cross-sectional view of a third example of the welding device according to this embodiment taken along the Y axis.
• the welding device 30 includes a pair of welding units (first welding unit 30a to second welding unit 30b).
• the pair of welding units are configured to clamp member 51 to be welded from the Z-axis direction (i.e., a direction perpendicular to the arrangement direction of members 51a to 51b to be welded) and move along the X-plane, thereby changing the relative positions of the pair of welding units with respect to members 51a to 51b.
• the first welding unit 30a is located on one side (U side) of the members 51a to 51b in the Z-axis direction.
• the second welding unit 30b is located on the other side (L side) of the members 51a to 51b in the Z-axis direction.
• the first welding unit 30a comprises a first housing 31a, a first jig 32a, a first rotating body 33a, a first sputter receiver 34a, a first robot arm 35a, an electron gun 36, a first caster 39a, a power supply (not shown), a first control unit (not shown), a first position sensor (not shown), and a first motor (not shown).
• the first housing 31a, the first jig 32a, the first sputter receiver 34a, the electron gun 36, the power supply, the first control unit, the first position sensor, and the first motor are the same as those in the second example of the welding apparatus 30 (FIG. 5).
• the first rotating body 33a engages with rails 51aa to 51ba (FIG. 6B) formed on the U-side surfaces of the members 51a to 51b.
• the first rotating body 33a is a drive wheel.
• the rails 51aa to 51ba have a concave shape. This keeps the first welding unit 30a in contact with the member 51.
• the second welding unit 30b includes a second housing 31b, a second jig 32b, a second rotating body 33b, a second sputter receiver 34b, a power source (not shown), a second control unit (not shown), a second position sensor (not shown), and a second motor.
• the second housing 31b, the second jig 32b, the second sputter receiver 34b, the power supply, the second control unit, the second position sensor, and the second motor are the same as those in the second example of the welding device 30 (FIG. 5).
• the second rotating body 33b engages with rails 51ab-51bb (Fig. 6B) formed on the L-side surfaces of the members 51a-51b.
• the second rotating body 33b is a drive wheel.
• the rails 51ab-51bb are concave. This keeps the second welding unit 30b in contact with the member 51.
• Fig. 7 is an XY plan view of the components of Modification 1 of the third example of welding apparatus 30 of the present embodiment.
• a rail 51aa and a tip-over prevention rail 51ac are formed on the surface of the member 51a.
• a rail 51ba and a tip-over prevention rail 51bc are formed on the surface of the member 51b.
• a rail 51ca and a tip-over prevention rail 51cc are formed on the surface of the member 51c.
• the rails 51aa to 51ca and the tip-over prevention rails 51ac to 51cc are connected before the multiple members 51a to 51c are joined by welding. This allows the welding device 30 to travel along the rails 51aa to 51ca and the tip-over prevention rails 51ac to 51cc (that is, the surface of the member 51a).
• Fig. 8 is an explanatory diagram of the operation (welding and movement) of the welding device according to the third embodiment of the present invention.
• the first welding unit 30a includes a first caster 39a in addition to the same configuration as in Fig. 6.
• the first caster 39a is a non-driven wheel.
• the first caster 39a engages with anti-tip rails 51ac to 51cc formed on the U-side surfaces of the members 51a to 51c.
• the second welding unit 30b includes a second caster 39b in addition to the same configuration as that shown in FIG.
• the second caster 39b engages with an anti-tip rail (not shown) formed on the L-side surface of the members 51a to 51c.
• the second caster 39b is a non-driven wheel.
• welding device 30 is in a proximity state when welding members 51a and 51b. Specifically, first welding unit 30a and second welding unit 30b are brought into close proximity to each other by clamping members 51a and 51b to be welded.
• the welding device 30 is in a spaced apart state when moving or turning. Specifically, the first welding unit 30a and the second welding unit 30b are moved away from each other in the Z direction (i.e., moved along the Z axis away from the members 51a and 51b), thereby entering the separated state.
• FIG. 9 is an explanatory diagram of the operation (direction change) of the welding device of the modified example 1 of the third example of the welding device 30 of this embodiment.
• FIG. 10 is an explanatory diagram of the operation (direction change) of the welding device of the modified example 1 of the third example of the welding device 30 of this embodiment.
• FIG. 11 is an explanatory diagram of the operation (direction change) of the welding device of the modified example 1 of the third example of the welding device 30 of this embodiment.
• FIG. 12 is an explanatory diagram of the operation (direction change) of the welding device of the modified example 1 of the third example of the welding device 30 of this embodiment.
• the welding device 30 moves on the XY plane along the rail 51aa formed on the member 51a and the rail 51ba formed on the member 51b (i.e., the members 51a and 51b) while switching between a close state and a separated state, and welds the members 51a and 51b.
• welding device 30 when welding device 30 reaches the branching point of rails 51aa to 51ca (that is, the branching point of members 51a to 51c), it becomes in a separated state and then rotates counterclockwise along the XY plane.
• the second rotating body 33b engages with the rail 51ca (FIG. 11). This causes the direction of travel of the welding device 30 to change.
• the welding device 30 moves on the XY plane along the rail 51aa and anti-tip rail 51ac formed on member 51a, and the rail 51ca and anti-tip rail 51cc formed on member 51c (i.e., members 51a and 51c), switching between a close state and a separated state, and welds members 51a and 51c.
• rails 51aa to 51ba and anti-tip rails 51ac to 51cc are formed on both sides (the U-side surface and the L-side surface) of members 51a to 51b.
• the first modified example of the third example of the welding device can also be applied to an example in which the rails 51aa to 51ba and the anti-tip rails 51ac to 51cc are formed on one side (the U-side surface or the L-side surface) of the members 51a to 51b.
• the second modified example of the third example of the welding device 30 of the present embodiment is an example in which the first welding unit 30a and the second welding unit 30b are provided with a mechanism (hereinafter referred to as an "alignment mechanism") for bringing the members 51a and 51b closer to each other.
• an alignment mechanism for bringing the members 51a and 51b closer to each other.
• FIG. 13 is a cross-sectional view of Modified Example 2(1) of the third example of the welding apparatus in the Y-axis direction.
• FIG. 13A shows the structure of a welding unit of a second modified example of the third example of the welding device.
• FIG. 13B is an enlarged view of region W of FIG. 13A.
• the welding device 30 includes a pair of welding units (first welding unit 30a to second welding unit 30b).
• the pair of welding units are configured to clamp member 51 to be welded from the Z-axis direction (i.e., a direction perpendicular to the arrangement direction of members 51a to 51b to be welded) and move along the X-plane, thereby changing the relative positions of the pair of welding units with respect to members 51a to 51b.
• the first welding unit 30a is located on one side (U side) of the members 51a to 51b in the Z-axis direction.
• the second welding unit 30b is located on the other side (L side) of the members 51a to 51b in the Z-axis direction.
• the first welding unit 30a comprises a first housing 31a, a first jig 32a, a first rotating body 33a, a first sputter receiver 34a, a first robot arm 35a, an electron gun 36, a power supply (not shown), a first control unit (not shown), a first position sensor (not shown), and a first motor (not shown).
• the first housing 31a, the first sputter receiver 34a, the electron gun 36, the power supply, the first control unit, the first position sensor, and the first motor are the same as those in the second example of the welding device 30 (FIG. 5).
• the first rotating body 33a is similar to that in the third example of the welding device 30 (FIG. 6).
• the first jig 32a has a tapered portion 32aa (Fig. 13B).
• the first jig 32a is configured to apply a force to the multiple members 51 in a direction in which they approach each other (the X direction in Fig. 13B).
• the second welding unit 30b includes a second housing 31b, a second spatter receiver 34b, a support 38, a power source (not shown), a second control unit (not shown), a second position sensor (not shown), and a second motor.
• the second housing 31b, the second sputter receiver 34b, the power supply, the second control unit, the second position sensor, and the second motor are the same as those in the second example of the welding device 30 (FIG. 5).
• the support portion 38 is configured to support the L-side surfaces of the members 51a and 51b.
• Fig. 14 is a cross-sectional view of Modified Example 2(2) of the third example of the welding apparatus in the Y-axis direction.
• welding device 30 includes a pair of welding units (first welding unit 30a to second welding unit 30b).
• the second welding unit 30b is similar to that shown in FIG.
• the pair of welding units are configured to clamp member 51 to be welded from the Z-axis direction (i.e., a direction perpendicular to the arrangement direction of members 51a to 51b to be welded) and move along the X-plane, thereby changing the relative positions of the pair of welding units with respect to members 51a to 51b.
• the first welding unit 30a is located on one side (U side) of the members 51a to 51b in the Z-axis direction.
• the second welding unit 30b is located on the other side (L side) of the members 51a to 51b in the Z-axis direction.
• the first welding unit 30a comprises a first housing 31a, a first jig 32a, a first rotating body 33a, a first sputter receiver 34a, a first robot arm 35a, an electron gun 36, a power supply (not shown), a first control unit (not shown), a first position sensor (not shown), and a first motor (not shown).
• the first housing 31a, the first sputter receiver 34a, the electron gun 36, the power supply, the first control unit, the first position sensor, and the first motor are the same as those in the second example of the welding device 30 (FIG. 5).
• the first rotating body 33a is similar to that in the third example of the welding device 30 (FIG. 6).
• the first jig 32a has an end 32ab (FIG. 14B) that extends in the Z-axis direction.
• the first jig 32a is configured to apply a force to the multiple members 51 via the end 32ab in a direction that brings them closer to each other (the X-direction in FIG. 14B).
• the first welding unit 30a applies a force in a direction (X direction) that brings the members 51a and 51b closer to each other along the X axis by moving the tapered portion 32aa against the tapered portion 51ad formed on the U-side surfaces of the members 51a and 51b.
• the first welding unit 30a applies a force in a direction (X direction) that brings the members 51a and 51b closer to each other along the X axis by moving the end 32ab against the X direction surface (surface extending in the Z axis direction) formed on the U side surfaces of the members 51a and 51b.
• the second welding unit 30b applies a force in the U direction along the Z axis to the members 51a and 51b by moving while abutting the support part 38 against the L side faces of the members 51a and 51b.
• the members 51a and 51b are displaced in a direction in which their relative positions along the X axis approach each other, while their relative positions along the Z axis are fixed with respect to the first welding unit 30a and the second welding unit 30b. This allows the members 51a and 51b to be welded while being in contact with each other.
• first welding unit 30a and the second welding unit 30b are provided with an alignment mechanism.
• the first welding unit 30a includes a first alignment mechanism that engages with rails formed on first surfaces of the members 51a and 51b.
• the second welding unit 30b includes a second alignment mechanism that engages with rails formed on the second surfaces of the members 51a and 51b.
• the alignment mechanism and the rails are configured to apply a force in a direction that brings the members to be welded (for example, members 51a and 51b) closer to each other each time first welding unit 30a and second welding unit 30b move.
• the positions of the members to be welded are aligned. Specifically, in response to the movement of the first welding unit 30a and the second welding unit 30b, the members 51a and 51b move closer to each other so as to fill the gap between them. As a result, the positions of the members to be welded are aligned.
• the first welding unit 30a and the second welding unit 30b stop at the welding position, the first welding unit 30a and the second welding unit 30b weld the member 51a and the member 51 whose gaps are filled together.
• variant 2 of the third example of the welding device 30 can also be applied when the rail has a convex shape (for example, variant 1 of the third example of the welding device 30).
• FIG. 15 is a cross-sectional view of the third modification of the third example of the welding device taken along the Y axis direction. Fig. 15 shows an enlarged view of an area Q in Fig. 8A.
• a rail 51aa of a member 51a of a modification 3(1) of the third example of welding device 30 has a convex portion 51aaa.
• a first welding unit 30a of the third example (1) of the third example of the welding apparatus 30 has a grip portion 40a. That is, the grip portion 40a is disposed in the first welding unit 30a including the electron gun 36.
• the grip portion 40a is at least one of the following: -Roller that can rotate in X and Z directions -Grip arm -Electromagnet
• the grip portion 40a is a roller or an electromagnet, the grip portion 40a continues to contact the protrusion 51aaa while the first welding unit 30a is moving. This keeps the relative positions of the first welding unit 30a and the member 51a (the relative positions on the X-axis and the Z-axis) fixed even while the first welding unit 30a is moving, and allows the first welding unit 30a to move smoothly.
• the grip portion 40a When the grip portion 40a is an arm, the grip portion 40a releases contact with the protrusion 51aaa while the first welding unit 30a is moving. This allows the first welding unit 30a to move smoothly even while it is moving.
• the relative positions of the first welding unit 30a and the member 51 can be fixed more reliably.
• a rail 51ab of a member 51a of a modification 3(2) of the third example of a welding device 30 has a convex portion 51aba.
• Second welding unit 30b of third example (2) of welding apparatus 30 has grip portion 40b. That is, grip portion 40b is disposed in second welding unit 30b that does not include electron gun 36.
• the grip portion 40b is at least one of the following: -Roller that can rotate in X and Z directions -Grip arm -Electromagnet
• the grip portion 40b fixes the relative position between the second welding unit 30b and the member 51a by contacting the protrusion 51aba while the electron beam is being irradiated onto the member 51a to be welded.
• the grip portion 40b is a roller or an electromagnet, the grip portion 40b continues to contact the protrusion 51aba while the second welding unit 30b is moving. This allows the relative positions (relative positions on the X-axis and the Z-axis) between the second welding unit 30b and the member 51a to be fixed even while the second welding unit 30b is moving, and allows the second welding unit 30b to move smoothly.
• the grip portion 40b When the grip portion 40b is an arm, the grip portion 40b releases contact with the protrusion 51aba while the second welding unit 30b is moving. This allows the second welding unit 30b to move smoothly even while the second welding unit 30b is moving.
• modified example 3(2) can stabilize the posture of the first welding unit 30a while the electron gun 36 is irradiating it with the electron beam, and can reduce the gap in the rails 51ab.
• Variation 2 of the first example of the welding device 30 and variation 2 of the second example are also applicable to the third example of the welding device 30.
• FIG. 16 is a cross-sectional view of a fourth example of the welding device according to the present embodiment taken along the Y axis.
• the welding device 30 includes a pair of welding units (first welding unit 30a to second welding unit 30b).
• the pair of welding units are configured to clamp member 51 to be welded from the Z-axis direction (i.e., a direction perpendicular to the arrangement direction of members 51a to 51b to be welded) and move along the X-plane, thereby changing the relative positions of the pair of welding units with respect to members 51a to 51b.
• the first welding unit 30a is located on one side (U side) of the members 51a to 51b in the Z-axis direction.
• the second welding unit 30b is located on the other side (L side) of the members 51a to 51b in the Z-axis direction.
• the first welding unit 30a comprises a first housing 31a, a first jig 32a, a first rotating body 33a, a first sputter receiver 34a, a first robot arm 35a, an electron gun 36, a power supply (not shown), a first control unit (not shown), a first position sensor (not shown), and a first motor (not shown).
• the first housing 31a, the first jig 32a, the first sputter receiver 34a, the electron gun 36, the power supply, the first control unit, the first position sensor, and the first motor are the same as those in the second example of the welding apparatus 30 (FIG. 5).
• the first rotating body 33a is configured to rotate in at least one of the X and Y directions.
• the surface of the first rotating body 33a has an adhesive microstructure.
• the microstructure is formed of, for example, carbon nanotubes.
• the second welding unit 30b includes a second housing 31b, a second jig 32b, a second rotating body 33b, a second sputter receiver 34b, a power source (not shown), a second control unit (not shown), a second position sensor (not shown), and a second motor.
• the second housing 31b, the second jig 32b1, the second sputter receiver 34b, the power supply, the second control unit, the second position sensor, and the second motor are the same as those in the second example of the welding device 30 (FIG. 5).
• the second rotating body 33b is configured to rotate in at least one of the X direction and the Y direction.
• the surface of the second rotating body 33b has a microstructure similar to that of the surface of the first rotating body 33a. This causes the second welding unit 30 b to continue to be in contact with the member 51 .
• Variation 2 of the first example of the welding device 30 and variation 2 of the second example are also applicable to the fourth example of the welding device 30.
• FIG. 17 is a cross-sectional view of a fifth example of the welding device according to this embodiment taken along the Y axis.
• the welding device 30 includes a pair of welding units (first welding unit 30a to second welding unit 30b).
• the pair of welding units are configured to sandwich the member 51 to be welded in a non-contact manner from the Z-axis direction (i.e., a direction perpendicular to the arrangement direction of the members 51a to 51b to be welded) and move along the X-plane, thereby changing the relative positions of the pair of welding units with respect to the members 51a to 51b.
• the first welding unit 30a is located on one side (U side) of the members 51a to 51b in the Z-axis direction.
• the second welding unit 30b is located on the other side (L side) of the members 51a to 51b in the Z-axis direction.
• the components of the first welding unit 30a include a first housing 31a, a first sputter receiver 34a, an electron gun 36, a power supply (not shown), a first control unit (not shown), a first position sensor (not shown), a first distance sensor, and a first robot arm 35a.
• the first housing 31a, the electron gun 36, the power supply, and the first position sensor are similar to those in the second example of the welding device 30 (FIG. 5).
• the first robot arm 35a is configured to move the first welding unit 30a according to a drive signal generated by the first control unit.
• the first distance sensor is configured to detect the distance between the first welding unit 30a and the members 51a to 51b.
• the first distance sensor is, for example, at least one of the following: Optical sensor (for example, an image sensor or an infrared sensor)
• the first control unit is configured to generate, in accordance with the position detected by the first position sensor, a drive signal for driving the first robot arm 35a so as to keep the distance detected by the first distance sensor constant, and a control signal for emitting an electron beam from the electron gun 36. This allows the first welding unit 30a to move to the joint CP while maintaining a constant distance in the Z-axis direction between the first welding unit 30a and the member 51, and to weld the joint CP with the electron gun 36.
• the second welding unit 30b includes a second housing 31b, a second sputter receiver 34b, a power source (not shown), a second control unit (not shown), a second position sensor (not shown), a second distance sensor (not shown), and a second robot arm 35b.
• the second housing 31b, the power source, and the second position sensor are similar to those in the second example of the welding device 30 (FIG. 5).
• the second robot arm 35b is configured to move the second welding unit 30b according to a drive signal generated by the second control unit.
• the second distance sensor is configured to detect the distance between the second welding unit 30b and the members 51a to 51b.
• the second distance sensor is, for example, at least one of the following: Optical sensor (for example, an image sensor or an infrared sensor)
• the second control unit is configured to generate, in accordance with the position detected by the second position sensor, a drive signal for driving the second robot arm 35b so that the distance detected by the second distance sensor is kept constant, and a control signal for emitting an electron beam from the electron gun 36. This allows the second welding unit 30b to be moved to the joint CP while maintaining a constant distance in the Z-axis direction between the second welding unit 30b and the member 51.
• Variation 2 of the first example of the welding device 30 and variation 2 of the second example are also applicable to the fifth example of the welding device 30.
• the fifth modification of welding apparatus 30 of the present embodiment is an example in which first welding unit 30a and second welding unit 30b move autonomously without contacting members 51a and 51b.
• the first welding unit 30a is equipped with a first movement mechanism (not shown) instead of the first robot arm 35a.
• the first movement mechanism operates in response to a drive signal generated by the first control unit.
• the first movement mechanism moves the first welding unit 30a a predetermined distance away from the members 51a-51b while maintaining a constant distance between the first welding unit 30a and the members 51a-51b.
• the first movement mechanism is, for example, a propulsion device capable of moving in outer space.
• the second welding unit 30b is equipped with a second movement mechanism (not shown) instead of the second robot arm 35b.
• the second movement mechanism operates in response to a drive signal generated by the second control unit.
• the second movement mechanism moves the second welding unit 30b a predetermined distance away from the members 51a-51b while maintaining a constant distance in the Z-axis direction between the second welding unit 30b and the members 51a-51b.
• the second movement mechanism is, for example, a propulsion device capable of moving in outer space.
• FIG. 18 is a cross-sectional view of a sixth example of the welding device according to this embodiment taken along the Y axis.
• the first welding unit 30a includes a first housing 31a, a first jig 32a, a first rotating body 33a, a first sputter receiver 34a, a first robot arm 35a, an electron gun 36, a first magnet 37a, a power supply (not shown), a first control unit (not shown), a first position sensor (not shown), and a first motor (not shown).
• the first housing 31a, the first jig 32a, the first sputter receiver 34a, the electron gun 36, the power supply, the first control unit, the first position sensor, and the first motor are the same as those in the second example of the welding device 30 (FIG. 5).
• the first rotating body 33a is similar to that in the third example of the welding device 30 (FIG. 6).
• the first magnets 37a are positioned at each end of the first housing 31a.
• the second welding unit 30b includes a second housing 31b, a second jig 32b, a second rotating body 33b, a second sputter receiver 34b, a second magnet 37b, a power source (not shown), a second control unit (not shown), a second position sensor (not shown), and a second motor.
• the second housing 31b, the second jig 32b, the second sputter receiver 34b, the power supply, the second control unit, the second position sensor, and the second motor are the same as those in the second example of the welding device 30 (FIG. 5).
• the second rotating body 33b is similar to that in the third example of the welding device 30 (FIG. 6).
• the second magnets 37b are disposed at each end of the second housing 31b.
• the polarity of the second magnets 37b is the same as or opposite to the polarity of the first magnets 37a.
• the first magnet 37a arranged at each end of the first housing 31a and the second magnet 37b arranged at each end of the second housing 31b attract each other.
• the polarity of the second magnet 37b is opposite to the polarity of the first magnet 37a, the first magnet 37a arranged at each end of the first housing 31a and the second magnet 37b arranged at each end of the second housing 31b repel each other. As a result, the postures of the first welding unit 30a and the second welding unit 30b can be stabilized.
• the sixth example of the welding device 30 can be applied to any of the first to fifth examples of the welding device 30.
• the first magnet 37a and the second magnet 37b may be electromagnets.
• FIG. 20 is a cross-sectional view in the Z-axis direction for explaining a first example of a welding flow according to the present embodiment.
• the first control unit adjusts the relative position and angle of the electron gun 36 with respect to the members 51a and 51b to be welded, and generates a control signal.
• the electron gun 36 irradiates the members 51a and 51b to be welded with an electron beam in response to a control signal generated by the first control unit, thereby heating the members 51a and 51b (FIG. 19A). This welds the joint CP between the members 51a and 51b.
• the first control unit When the joint CP between the members 51a and 51b is welded, the first control unit generates a drive signal.
• the electron gun 36 moves in the Z-axis direction away from the members 51a and 51b (FIG. 19B).
• first welding unit 30a and second welding unit 30b move in the XY plane to the next joint CP (for example, joint CP between members 51b and 51c) (FIG. 20).
• the electron gun 36 irradiates the members 51b and 51c to be welded with an electron beam to heat them. This welds the joint CP between the members 51b and 51c.
• FIG. 21 is a cross-sectional view in the Y-axis direction for explaining a second example of the welding flow of the welding device of this embodiment.
• the first jig 32a, the first sputter receiver 34a, and the electron gun 36 move along the XY plane in response to drive signals generated by the first control unit.
• the second jig 32b and the second sputter receiver 34b move along the XY plane in synchronization with or following the first jig 32a, the first sputter receiver 34a, and the electron gun 36 in response to a drive signal generated by the second control unit. This allows the relative position of a part of the welding device 30 and the member 51 to be changed.
• FIG. 22 is a cross-sectional view in the Y-axis direction for explaining a fourth example of the welding flow of the welding device of this embodiment.
• the first sputter receiver 34a and the electron gun 36 move along the XY plane in response to a drive signal generated by the control unit.
• the second jig 32b does not need to be moved.
• the second sputter receiver 34b moves along the XY plane in synchronization with or following the first sputter receiver 34a and the electron gun 36 in response to a drive signal generated by a second control unit. This allows the relative position of a part of the welding device 30 and the member 51 to be changed.
• FIG. 23 is a cross-sectional view in the Y-axis direction for explaining a fourth example of the welding flow of the welding device of this embodiment.
• the electron gun 36 moves along the XY plane in response to a drive signal generated by the control unit.
• the second jig 32b and the second sputter receiver 34b do not need to be moved. This allows the relative position of a part of the welding device 30 and the member 51 to be changed.
• Fig. 24 is a plan view of the structure of this embodiment.
• the structure 50 in FIG. 24A is a parabolic antenna for use in space.
• each member 51 constitutes a reflector (FIG. 24B).
• the welding device 30 remains on the last welded member 51z.
• the power source of the welding device 30 is configured to provide power to the structure 50.
• the welding device 30 is used not only for assembly purposes (e.g., welding purposes) but also for operational purposes after the structure 50 is completed.
• the welding device 30 includes a first welding unit 30a located on the first surface side of the member 51 and a second welding unit 30b located on the second surface side of the member 51.
• the first welding unit 30a and the second welding unit 30b clamp the member 51 and change their relative positions with respect to the member 51. This makes it possible to stabilize the relative position between the welding device 30 and the structural member 51 .
• the first welding unit 30a may include a first sputter receiver 34a and an electron gun
• the second welding unit may include a second sputter receiver 34b. This makes it possible to stabilize the relative position between the welding device 30 and the structural member 51 .
• the first welding unit 30a may include a first jig 32a and an electron gun
• the second welding unit may include a second jig 32b. This makes it possible to stabilize the relative position between the welding device 30 and the structural member 51 .
• the first welding unit 30a and the second welding unit 30b may change their relative positions while remaining in contact with the member 51 . This allows the first welding unit 30a and the second welding unit 30b to be moved to the welding position via the shortest route.
• the first welding unit 30a has a first rotating body 33a
• the second welding unit 30b has a second rotating body 33b
• the first welding unit 30a and the second welding unit 30b may change their relative positions while the first rotating body 33a and the second rotating body 33b are abutted against the member 51. This allows the first welding unit 30a and the second welding unit 30b to move smoothly without damaging the member 51.
• the first welding unit 30a may include a first robot arm 35a
• the second welding unit 30b may include a second robot arm 35b, where the first robot arm 35a moves the first welding unit 30a, and the second robot arm 35b moves the second welding unit 30b.
• first welding unit 30a and second welding unit 30b can be moved without providing a movement mechanism for first welding unit 30a and second welding unit 30b, which results in reduction in weight and size of welding device 30 and simplification of control.
• first welding unit 30a and the second welding unit 30b may attract the member 51 to each other by magnetic force.
• first welding unit 30a and second welding unit 30b are not physically connected to the mechanism for applying the external force and can be kept in independent contact with member 51 regardless of the welding position, leading to a reduction in weight and size of welding device 30 and simplified control.
• the first rotating body 33 a may engage with a rail formed on a first surface of the member 51
• the second rotating body 33 b may engage with a rail formed on a second surface of the member 51 .
• the first welding unit 30a and the second welding unit 30b can be reliably prevented from becoming detached from the member 51.
• the first welding unit 30a and the second welding unit 30b move along rails, so that the reliability of the movement can be ensured even if the movement control is simplified.
• the first welding unit 30a and the second welding unit 30b may be bonded to the member 51 by van der Waals forces. This eliminates the need for a mechanism for applying external force to the first welding unit 30a and the second welding unit 30b, and allows the first welding unit 30a and the second welding unit 30b to be kept in contact with the member 51 without processing the member 51, even if the member 51 is a non-magnetic material.
• the first welding unit 30 a and the second welding unit 30 b may move a predetermined distance away from the member 51 .
• the member 51 can be welded using the first welding unit 30a and the second welding unit 30b.
• one welding unit (30a or 30b) may move following the other welding unit (30b or 30a). This makes it possible to reliably move first welding unit 30a and second welding unit 30b in conjunction with each other without providing a movement mechanism for the other welding unit.
• the first welding unit 30a and the second welding unit 30b may move synchronously. This makes it possible to more reliably move the first welding unit 30a and the second welding unit 30b in conjunction with each other.
• a structure 50 operating in space includes a plurality of members 51 and a welding device 30 for the members 51, and the welding device 30 may include a power source that supplies power for assembly purposes of the structure 50 and for operational purposes of the structure. This allows the structure 50 to be used efficiently for assembly purposes and for operational purposes.
• the welding device 30 is used for the structure 50 as an antenna (i.e., a structure having a curved outer surface), but the scope of the present embodiment is not limited thereto.
• the present embodiment can also be applied to the following examples. - Structures with flat outer surfaces (e.g., radio phased arrays) ⁇ SSPS (Space Solar Power System) - Station module exterior
• the welding device 30 includes the jigs (the first jig 32a and the second jig 32b) and the sputter receivers (the first sputter receiver 34a and the second sputter receiver 34b), but the present embodiment is not limited to this.
• the present embodiment can also be applied to the following examples.
• the jig at least one of the first jig 32a and the second jig 32b
• the sputter receiver at least one of the first sputter receiver 34a and the second sputter receiver 34b
• the jig and the sputter receiver are omitted
• the first welding unit 30a includes an X-ray irradiation unit.
• the second welding unit 30b includes an X-ray receiving unit.
• the first welding unit 30a irradiates X-rays from the X-ray irradiator while moving (i.e., while welding). While moving (i.e., while welding), the second welding unit 30b receives the X-rays irradiated from the X-ray irradiator with the X-ray receiver, and transmits the reception result to an X-ray inspection unit (not shown).
• the X-ray inspection unit analyzes the light reception results transmitted from the X-ray receiving unit, and outputs the results of the X-ray inspection (for example, whether or not there are scratches on the member 51).
• Installation device 30 Welding device 30a: First welding unit 30b: Second welding unit 31a: First housing 31b: Second housing 32a: First jig 32b: Second jig 33a: First rotating body 33b: Second rotating body 34a: First sputter receiver 34b: Second sputter receiver 35a: First robot arm 35b: Second robot arm 36: Electron gun 37a: First magnet 37b: Second magnet 38: Support portion 39a: First caster 39b: Second caster 50: Structure 51: Member R: Launching device

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• 2024
  • 2024-03-22 JP JP2025516607A patent/JP7718752B2/ja active Active
  • 2024-03-22 WO PCT/JP2024/011237 patent/WO2024224892A1/ja not_active Ceased
• 2025
  • 2025-07-16 JP JP2025119403A patent/JP2025157394A/ja active Pending

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