Abstract:
The method of controlling a linear vibration welding apparatus, in accordance with the invention, may comprise the steps of: fastening a first workpiece portion in a fixed position; fastening a second workpiece portion to a reciprocating member; energizing a first single winding magnet with direct current power to create a magnetic field; sensing a location of the reciprocating member with respect to a zero point; and energizing a second magnet when the reciprocating member has crossed the zero point when moving towards the first magnet. The linear vibration welding apparatus in accordance with the invention may comprise: a frame; a flexure array; a first magnet assembly; a second magnet assembly; a digital controller; and direct current amplifiers for powering the magnet assemblies.

Description:
[0001]    This application claims the benefit of priority to U.S. provisional application No. 60/277,755, filed on Mar. 21, 2001 and U.S. provisional application No. 60/277,757, filed on Mar. 21, 2001, both incorporated herein by reference in their entirety. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to vibration welding machinery, and more particularly to an apparatus and method for controlling the motion of a linear vibration welding device.  
         BACKGROUND OF THE INVENTION  
         [0003]    Vibration welding is used to join two workpieces made of thermoplastic. Items such as automobile bumpers, interior decorations, grilles, and lights are commonly formed using vibration welding techniques. An advantage of the vibration welding process is the reduced joining time when compared to adhesive bonding and heated tool welding.  
           [0004]    Vibration welding works by frictionally working two plastic pieces under pressure, thereby heating and melting their contact surfaces. Once the whole surface is melted, reaching the so-called steady-state melt flow phase, the friction generating process is stopped and the parts form a bonded high-strength structure upon cooling.  
           [0005]    Friction is generated by rubbing the two pieces together in an oscillatory fashion under pressure. There are two main types of vibration welding. The first, linear, involves one-dimensional oscillation of a workpiece. The second, orbital, involves biaxial oscillation of a workpiece. The range of oscillation frequencies used is typically between 80 and 300 Hz. In contrast, ultrasonic welding operates at frequencies of about 25 KHz. The amplitude of the oscillations for linear vibration welding is typically between 50 and 100 thousandths of an inch. The clamping force between the two parts is typically between 1000 and 5000 pounds force.  
           [0006]    A linear vibration welding device most generally comprises a flexure member and a means for vibrating the flexure member. The prior art devices, such as U.S. Pat. No. 3,920,504, to Shoh et al., utilize one electromagnet at each end of the flexure array to generate a magnetic field to cause the flexure array to vibrate. These electromagnets are driven by a three-phase alternating current (AC) drive source, such as a variable frequency drive (VFD). This prior art AC drive system possesses several undesirable characteristics.  
           [0007]    The use of three-phase AC power requires a large power input for a given amount of work output. Three-phase AC power possesses three poles separated by 120 degrees of phase between each pole. This makes AC well suited to rotary motion but not linear motion, which requires a 180 degree linear oscillatory motion. To make the AC system function, one of the two electromagnets receives both power coils, while the other magnet receives a single coil. A Scott T-connection is used, as shown in FIG. 10 of Shoh, to approximate a 180-degree phase alternation of the current. However, the approximated two-phase system does not eliminate all three-phase properties. Therefore, there is a series of counterproductive forces introduced to the system.  
           [0008]    The counterproductive forces are those forces that urge the flexure array in a direction opposite that of its intended movement. Such forces work against the drive force, resulting in a net reduction in the drive force. A significantly larger drive is therefore required to achieve the necessary net drive force to weld a workpiece. The large drive consumes a correspondingly larger amount of power. Additionally, the frame for such device must be larger and heavier to handle the competing forces without premature failure.  
           [0009]    The startup time for the prior art AC drive system is also disadvantageously lengthy. Startup time is the time it takes the machine to reach a constant maximum amplitude at the resonance frequency for the system. The startup time directly affects the welding process. Vibration speeds of about 35 inches per second and higher cause melting for most plastics. Speeds below about 20 inches per second will only cause the material to heat, not melt. The vibration speeds between these two values cause considerable amounts of particulates to be generated. This may cause poor welds, environmental concerns, machine interference and mess.  
           [0010]    The use of three-phase AC power also disadvantageously requires the use of an autotuning system. The spring constants for flexure arrays used in vibration welders are very high, such as several hundred thousand pounds force per inch. Consequently, the flexure array will only move at or around its resonance frequency. This resonance frequency varies with the weight of the tool attached to the array. Therefore, the welding device must be “tuned” prior to use with a given tool.  
           [0011]    The tuning step for conventional vibration welders relies on approximation based upon the user&#39;s best guess. The operator simply varies the frequency input to the drive motor and listens to the audible hum. When the hum reaches its loudest point, the operator assumes that the amplitude has peaked.  
           [0012]    An autotuning procedure became feasible with the advent of cost effective controls. Autotuning comprises the provision of an amplitude sensor and automated frequency adjustment controls to the welding apparatus. The frequency is first “turned on” at a predetermined starting level with a low power input. Then the frequency is stepped in increments of approximately 0.1 Hz while the sensor measures the amplitude. At the point where the amplitude begins to drop off, the stepping is discontinued. From the plot of amplitude versus frequency (at a fixed power level), the operating frequency is chosen where the peak displacement occurred.  
           [0013]    A so-called soft start is used when autotuning. The power input is initially started low to ensure that the flexure member does not overextend and damage the drive magnets. Once the resonance frequency is determined, the power input is then increased to achieve a desired amplitude. This autotuning procedure adds time to the welding process, which reduces productivity.  
           [0014]    An alternative method of autotuning is to introduce a known frequency to the system and monitor how it responds. The response is measured. Then a resonance frequency can be determined based upon the measured response. This method of autotuning exhibits the same deficiencies as the above-described stepping method.  
           [0015]    The drive frequency of the prior art apparatus cannot be easily varied during a welding procedure. The viscosity of the interface between two work pieces being joined by vibration welding varies with the temperature and matter phase of the interface between the pieces. The viscosity may either increase or decrease, depending on the properties of the materials being joined, during a given weld procedure. The amplitude will increase given a decrease viscosity and constant power and frequency inputs. The opposite is true for increasing viscosity. Therefore, the prior art AC devices must vary one of the power or frequency inputs to the system to ensure that the amplitude is kept within a range to prevent damage to the machine and to ensure a good weld.  
           [0016]    The prior art mechanisms do not have the ability to vary frequency during the weld process, so the power must be adjusted. The power rating of the drive mechanisms must be sufficiently oversized to allow for increased power needs of the system. Larger drive motors increase the cost of the overall apparatus.  
           [0017]    The amplitude adjustment of the prior art devices is reactionary. The controller uses position information to compare the allowable amplitude range to a measured amplitude value. The controller is then able to determine whether the amplitude value is over or under the pre-set amplitude. The controller varies the power input to the drive motors to correct for the over or under amplitude condition. Then the amplitude is again compared to determine if the correction brought the amplitude back into a proper range.  
           [0018]    This prior art reactionary method of adjusting the amplitude involves a considerable lag time between initial apprehension of the out of bounds condition until the condition is corrected. Several periods of flexure travel may occur before the problem is corrected. This lag in response time can have adverse effects on both the workpiece and on the apparatus itself. Some thermoplastic materials used in vibration welding processes can change viscosities very rapidly during a joining process. Because of this quick change and lag in apparatus adjustment, damage to the workpiece and the drive magnets can occur due to an over-amplitude condition.  
           [0019]    Finally, the prior art three-phase AC drive vibration welders do not provide for the ability to weld by energy. Welding by energy, as is often used in ultra-sonic welding, involves inputting a known amount of energy into the workpiece to create a weld. Welding by energy requires knowing how much energy is inputted in to the system and what percentage of that energy actually goes into the given workpiece. True weld by energy cannot be used with a three-phase AC system because one cannot easily measure the deductions necessary to account for the counterproductive forces.  
           [0020]    In summary, conventional vibration welders have several significant disadvantages. Their AC power systems require large and costly drive motors, the frame must be correspondingly large and the overall system is slow to come up to speed. The AC drive system requires an autotuning function with a soft start. The method of adjusting the amplitude is reactionary and there is no method for welding by power. Additionally, the prior art apparatuses tend to be complex, costly and inefficient. Therefore, there is a need to provide a method and apparatus for vibration welding that addresses these disadvantages in whole or in part.  
         SUMMARY OF THE PRESENT INVENTION  
         [0021]    Disclosed are a method for controlling a linear vibration welding apparatus and an apparatus for same. The method, in accordance with the invention, may comprise the steps of: fastening a first workpiece portion in a fixed position; fastening a second workpiece portion to a reciprocating member; energizing a first single winding magnet with direct current power to create a magnetic field; sensing a location of the reciprocating member with respect to a zero point; and energizing a second magnet when the reciprocating member has crossed the zero point when moving towards the first magnet. The linear vibration welding apparatus in accordance with the invention may comprise: a frame; a flexure array; a first magnet assembly; a second magnet assembly; a digital controller; and direct current amplifiers for powering the magnet assemblies.  
           [0022]    The present invention addresses the disadvantages present in conventional linear vibration welders. The present invention possesses increased efficiency by driving the electromagnet assemblies with direct current. The use of direct current eliminates the counterproductive forces present in three phase AC drive systems. The increased efficiency allows the apparatus to perform with approximately twice the welding power relative to a comparably sized conventional linear vibration welder. The DC drive system, in conjunction with digital controls, allows for dynamic modulation and predictive adjustment of the amplitude of the flexure array during a welding process. This eliminates the need for autotuning of the apparatus and minimizes the risk of overdrive related damage. The digital controls also allow for welding by power to be implemented. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]    [0023]FIG. 1 is a front view of a linear vibration welding apparatus in accordance with the present invention;  
         [0024]    [0024]FIG. 2 is an end view of a linear vibration welding apparatus in accordance with the present invention;  
         [0025]    [0025]FIG. 3 is an end view of a linear vibration welding apparatus in accordance with the present invention;  
         [0026]    [0026]FIG. 4 is an electromechanical schematic diagram of the linear vibration welding apparatus in accordance with the present invention.  
         [0027]    [0027]FIG. 5 is a graph illustrating the energization of the electromagnets and the position of the flexure array with respect to time of the linear vibration welding apparatus.  
         [0028]    [0028]FIG. 6 is one period taken from the graph from FIG. 5 showing the relative phase of the magnetic field with respect to position and applied voltage of the flexure assembly of the linear vibration welding apparatus; and  
         [0029]    [0029]FIG. 7 is a logic flowchart depicting program control of the linear vibration welding apparatus.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0030]    [0030]FIG. 1 illustrates a linear vibration welding apparatus  20  according to the present invention. The welding apparatus  20  generally comprises a frame  22 , a flexure or vibratory assembly  24  provided to the frame  22 , an extendable table assembly  26  provided below the flexure assembly  24  and a control housing  46  electrically connected to the table assembly  26  and the flexure assembly  24 .  
         [0031]    The table assembly  26  comprises a base or table  28  supported by one or more hydraulic struts  32 . The table assembly  26  is rigidly fastened to the floor below the flexure assembly  24  or, alternatively, to the frame  22 . The struts  32  enable the table  28  to be controllably raised and lowered during the welding process. The struts  32  are preferably capable of generating between 1000 and 5000 pounds of force. A first clamp  30  is rigidly fastened to the base  28 . The first clamp  30  is configured to securely hold a work piece first portion  34  during the welding operation.  
         [0032]    The control housing  46  comprises an electrical cabinet  47  for housing a plurality of electrical, power and control devices. The cabinet  47  is preferably provided with a graphical display  48  for displaying system functions and status information, and an input device  50  for allowing a user to input commands into the control devices. Alternatively, the display  48  is a touch screen that integrates the input device functions. The control housing  46  is electrically connected to a power source, the flexure assembly  24  and the table assembly  26 .  
         [0033]    Referring to FIGS. 1, 2 and  3 , the flexure assembly  24  comprises two frame connection members  62 , two flexure members  68 , a base plate  66 , a force transfer member  68  and a transverse brace  64 . The frame connection members  62  are secured to the frame  22  and to the top of the flexure member  60 . The base plate  66  is secured to the bottom of the flexure member  60 . The base plate  66  receives a second clamp  40  for securing a workpiece second portion  36 . The force transfer member  68  is fastened to the base plate  66 . Alternatively, the base plate  66  and force transfer member  68  are unitarily formed.  
         [0034]    The force transfer member  68  is aligned with a respective first magnet assembly  42  and second magnet assembly  44 . The force transfer member  68  is attractable to the magnet assemblies  42 ,  44  when said assemblies  42 ,  44  are energized to create an attractive magnetic field. Thus, the flexure member  60  is subjected to a shearing force due to its bottom portion moving with respect to its fixed top portion. A transverse brace  64  is secured to the respective frame connection members  62 . The transverse brace  64  adds rigidity to the assembly  24  and counters resonation of the frame  22  and assembly  24  combination. Collectively, the base plate  66 , flexure members  60  and force transfer members  68  may be referred to as the flexure array  38 .  
         [0035]    One or more position sensors  52 ,  56  are provided to the welding apparatus  20  as shown in FIGS.  1 - 3 . The sensors may be either analog sensors  52  or digital encoders  56 . The analog sensor  52  is fastened to the transverse brace  64 . A target  54  is provided to the top of the flexure array  38 . The analog sensor  52  determines the distance between the target  54  and the sensor  52 . This information is then relayed to control devices.  
         [0036]    A digital encoder  56  may be used in addition to or in place of the analog sensor  52 . The digital encoder  56  is preferably a digital optical linear encoder. The encoder  56  functions as a feedback device to provide flexure array position information to control devices. The encoder  56  is preferably provided to a portion of the frame  22  as shown in FIGS. 1 and 2. A target  58  is affixed to the side of the base plate  66 . The encoder  56  determines the position of the array  38  by sensing the relative position of the target  58 . The target  58  is a sticker with visible gradations scannable by the encoder  56 .  
         [0037]    The electrical schematic for the vibration welding apparatus according to the present invention is illustrated in FIG. 4. A mass  72  is provided to the flexure array  38  to adjust the weight of said array  38 . The weight of the array  38  affects the resonance frequency. Less mass equals higher resonance frequencies. Conversely, more mass equals lower frequencies. Flexure member  60  and force transfer member  68  are shown to represent the flexure array  38  in FIG. 4. The load  74  represents the frictional force acting on the system during a welding operation.  
         [0038]    A first magnet assembly  42  and second magnet assembly  44  are provided to either side of the force transfer member  68 . Each magnet assembly  42 ,  44  is secured to the frame  22 . The magnet assemblies  42 ,  44  may be designated as right M R  and left M L  for control purposes, which will be explained further hereinbelow. Each electromagnet assembly  42 ,  44  comprises a magnetic core  88  and a single coil of wire  90  wound around that core  88  to provide a pair of opposed single pole electromagnets.  
         [0039]    The magnet assemblies  42 ,  44  are each operably connected to a respective amplifier  78 ,  80 . Amplifiers  78 ,  80  may be designated as A R  and A L  for control purposes. The amplifiers  78 ,  80  are preferably bi-polar DC amplifiers, such as commercially available four quadrant DC brush servo amplifiers.  
         [0040]    An AC-DC power source  82  provides the power to the amplifiers. The input current  84  is AC three-phase and the output current  86  is a constant DC voltage. Typically, the input voltage is 240 VAC and the output is 375 VDC. Suitable AC-DC power sources  82  are known to those skilled in the art and are available from a variety of commercial suppliers.  
         [0041]    A digital processor unit (DPU)  76  is operably connected to the DC amplifiers  78 ,  80 . The DPU  76 , in the most basic sense, controls the timing of the magnetic field generation that drives the flexure array  38  in a linear periodic fashion. The DPU  76  is programmed to perform a variety of control functions, as will be described below. The DPU  76  used in the preferred embodiment is a servo motion controller. Suitable servo motion controllers are available from Delta Tau Data Systems, Inc.  
         [0042]    The DPU  76  is electrically connected to a position sensor, such as the analog sensor  52  or the digital sensor  56 . These sensors  52 ,  56  provide the DPU  76  with position information for the flexure array  38 . The DPU  76  uses the positional information to predict the position and/or the amplitude of the flexure array for a subsequent swing of the flexure array  38 . Said prediction, or peak displacement, of the amplitude is based upon calculating the velocity of the array  38  at the point it passes through the zero point. The array  38  is at its maximum velocity at such time. The DPU  76  can then signal the appropriate amplifiers  78 ,  80  to dynamically adjust the amplitude, frequency or both of the flexure array  38 . The DPU  76  can also measure the desired weld energy input as defined by the user. The DPU  76  then performs a weld operation to input the desired weld energy, often defined in joules, to the workpiece and ceases the welding operation when the defined energy has been transferred.  
         [0043]    The particular energization scheme of the present invention allows the welding apparatus  20  to have a significantly increased efficiency with respect to conventional linear vibration welders. FIG. 5 graphically illustrates the energization of the flexure array  38  with respect to array position P. The left vertical axis represents the voltage input into each of the respective first  42  and second  44  magnet assemblies M L  and M R  as provided from a respective amplifier A L  and A R . (The amplifiers  78 ,  80  and magnet assemblies  42 ,  44  could receive the opposite designations as well.) The right vertical axis represents the position of the flexure array  38 . Zero is taken to be the relaxed position for the array  38 . Positive and negative values are either right or left of center, respectively, depending on the designation of one direction being positive and the other negative. Here, positive values are defined to be left of center. The horizontal axis of FIG. 5 represents elapsed time.  
         [0044]    Starting at zero seconds, the array  38  is centered at the zero position. The first electromagnet M R  is then energized. The input voltage is represented as a square wave because it is a DC voltage. The right electromagnet M R  then generates a magnetic field that attracts the array  38  to the right, as shown. Then the magnet M R  is pulsed with the opposite polarity to repel the array  38  from the right and urge it to the left. After the repulsion, the left magnet M L  is energized to pull the array  38  to the left as well. This right pull followed by a left push, left pull is only employed to start the flexure array  38  oscillating from rest. Following this startup routine the M R  and M L  magnets are alternatingly energized for the remainder of the weld process. During the welding process, the input energy is varied to each of the magnet assemblies  42 ,  44  by the DPU  76  to maintain the desired amplitude of the flexure array  38 .  
         [0045]    It will be appreciated that the plot of position P versus the energization of the respective magnets  78 ,  80  reveals that a given magnet  78 ,  80  is first energized when the array passes the zero point going away from that magnet  78 ,  80 . This can be more clearly seen in FIG. 6, which presents only one period of flexure array travel. As shown, as soon as the array  38  passes to the right of zero, the left magnet M L  is energized. This may be seemingly counterproductive; however, the magnetic field takes time to build in the electromagnet. This lag time is shown in the graph to be approximately one quarter of a period.  
         [0046]    The advantage of driving the array  38  with such timing is that the array  38  is at its farthest amplitude, away from a given magnet  78 ,  80  when that magnet begins to pull the array  38  towards that magnet. Thus, the array  38  is urged in the new direction by both the spring force of the flexure members  60  and by the magnetic force of the electromagnet  78 ,  80 . This increases the efficiency of the overall apparatus  20  compared with conventional vibration welders because there are no wasted forces to overcome. This increased efficiency allows the welding apparatus  20  to use approximately half the drive force for a comparative load or, to drive twice the load for comparatively sized drive motors.  
         [0047]    The algorithm  100  employed by the present invention is represented in the logic diagram of FIG. 7. This algorithm  100  allows the welding apparatus to operate without the need to autotune and to dynamically and predictively adjust the amplitude of the flexure array  38 . The logic indicated in FIG. 7 and described herein is programmed into a control chip included in the DPU  76  using a programming language suited to controls and known to those of ordinary skill in the art.  
         [0048]    This algorithm is performed each clock cycle. The indicated process starts with a commutation enablement routine  101 . This signifies that the routine to be run is for a continuous operation, such as the welding of a part. From there, the position sensor  52 ,  56  provides a tool position reading. The tool refers to either the flexure array  38  or the workpiece second portion  36 . The zero point is the centered position between the first magnet  42  and second magnet  44 . The position sensor  52 ,  56  reports whether the position P is positive or negative  104 . Positive values for this description are defined as any value right of center and negative as those left of center. Those skilled in the art will recognize that the positive and negative definitions could be chosen in an opposite manner.  
         [0049]    Based upon the position P of the flexure array or tool  38  being positive or negative, the DPU  76  centers the tool  38 . For negative values, the right electromagnet M R  is energized  106 . For positive values, the left electromagnet M L  is energized  108 . The value of zero is indicative of a “power off” condition. The value of one is indicative of a “power on” condition.  
         [0050]    Next, the DPU  76  determines whether the position P of the tool  38  changed from the previous iteration of the loop  110 . The change of position is compared to the last defined position at the reference point in the previous cycle. Thus, a storage value (Pc) for the position of the tool is defined within the DPU  76 . If the status has not changed, then the absolute value of the position is compared to the Pc value  112 . If the Pc is not greater than the absolute value of the position, then the absolute value is compared to the Pc three times  114 . After three successive readings where the tool  38  has a position absolute value of less than the Pc value, the amplitude value (A) is defined as the Pc value  216 . The purpose of taking three successive readings before updating the value is for noise filtering. If there is an anomalous spiked value, this will be disregarded because three successive values are needed. Those skilled in the art will recognize that such filtering may be accomplished with more or less than 3 successive readings without departing from the scope of the invention. If the absolute value of the position is not less than the Pc value, then step  134  is invoked.  
         [0051]    If, in step  112 , the absolute value of the position is greater than the Pc value, the Pc value is updated by defining the Pc value as that absolute positional value reading  118 . Now, both of the values stored in variable placeholder A and Pc are defined for further operations.  
         [0052]    Referring back to step  110 , if the position of the tool  38  has crossed the centerline (zero position), then the tool velocity dP/dt is defined as the amplitude A in step  122 . The DPU  76  relies on a tool position P reading  124  and calculates a differential of the position with respect to time (dP/dt)  126 . The differential calculation is performed as an embedded controller function in the servo motion controller  76  used in the preferred embodiment. This embedded dP/dt function calculates such differentials as part of a servo conditioning algorithm.  
         [0053]    After the A value is established, it is stored in data placeholders. Step  128  indicates the amplitude A being stored as the most current value. Item  130  refers to an amplitude setpoint. The amplitude setpoint is an amplitude value predetermined by the operator of the welding apparatus. Both the amplitude setpoint and the amplitude A variables are fed into a proportional derivative algorithm (PID)  232  that is functionally included in the servo motion controller  76 . The PID algorithm determines error values and corrects the output for said errors before output to the DC amplifier command output  134 .  
         [0054]    The next step is the output of the amplifier commands  134 . This step takes the corrected output from step  132  and calculates a command to either turn each DC amplifier  78 ,  80  on or off. The command to the left amplifier  136  is the L value of steps  106  or  108  times the PID output value. The command to the right amplifier is the R value of steps  106  or  108  times the PID output value. Each of these Left commands and Right commands is then outputted to their respective DC amplifier  136  and  138  to either turn the amp on or off as required. The cycle is then repeated or iterated by cycling  140  back to step  104 .  
         [0055]    In operation, referring again to FIG. 1, the electromagnets  42 ,  44  alternately pull on the flexure array  38 , thereby providing a linear oscillation of the upper plate and consequently the workpiece second portion  36 . The electromagnets  42 ,  44  are alternately energized in a fashion as described above to linearly oscillate flexure array at its resonant frequency. As the workpiece second portion  36  is oscillating, the hydraulic struts  32  press the workpiece first portion  34  against the second portion  36  with a predetermined force. The resulting friction between the first  34  and second  36  portions causes heating and melting at the interface  70 . When the interface  70  is sufficiently melted, the oscillations are stopped. The workpiece is then allowed to cool, thereby fusing the first  34  and second  36  portions.  
         [0056]    Although the present invention has been described with reference to the preferred embodiments, workers skilled in the art will recognize changes may be made in form and detail without departing from the spirit and scope of the invention.