Abstract:
A method for regulating a coupling formation includes sensing a temperature of a coupling with a non-contact sensor and sending the temperature to a control unit that regulates the temperature of the coupling formation. In addition, a system for regulating a temperature of a coupling formation includes a temperature control unit and a non-contact sensor in flow communication with the temperature control unit.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates generally to couplings and, more particularly, to coupling formations. 
     During soldering, welding, brazing and other coupling applications heat is typically applied to melt metal or plastic for coupling. To couple two components, the components are positioned such that there is at least one contact location between the components and molten material is then applied to the contact location. After an elapsed time period, the molten material cools to solidify and couple the components together. Alternatively, a molten material is applied to a first component and then a second component is placed in contact with the molten material. After the molten material cools, the components are then coupled. 
     The structural integrity and strength of the coupling may be dependent upon a temperature of the molten material applied to the components. If the temperature of the molten material is too high the molten material may flow too freely and form a thin bond. Conversely, if the temperature is too low, the molten material may not melt sufficiently and may not bond effectively between the components. 
     To ensure successful coupling formation, visual inspections are performed during the coupling of the components. Such visual inspections reveal only visibly poor couplings and do not reveal temperature fluctuations that may be indicative of a heat coupling process drift. As a result, additional inspections are done after the coupling is formed and include various non-destructive inspections and destructive inspections. Typically, the non-destructive inspections include ultrasound inspections and x-ray inspections, and the destructive inspections include stress tests and pressure tests. However, such inspections are costly and are only reliable after the component coupling is completed. 
     Moreover, since visual inspections and post-formation inspections are only effective after a poor coupling is completed, process drift is not corrected until the drift is such that poor couplings are completed. 
     BRIEF SUMMARY OF THE INVENTION 
     A method for regulating a coupling formation includes sensing a temperature of a coupling with a non-contact sensor and sending the temperature to a control unit that regulates the temperature of the coupling formation. In addition, a system for regulating a temperature of a coupling formation includes a temperature control unit and a non-contact sensor in flow communication with the temperature control unit. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of an embodiment of a heat coupling control system; 
     FIG. 2 is a plan view of a table mounted heat coupling control system; and 
     FIG. 3 is a side view of the table mounted heat coupling system shown in FIG.  2 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 is a perspective view of an exemplary embodiment of a control system  10  used to monitor a temperature of a coupling formation  12 . Control system  10  includes a sensor  14  and a soldering gun  16  including a tip  18 . In one embodiment, sensor  14  is an infrared sensor. A control circuit  20  is electronically coupled to control system  10  and accepts an output of sensor  14  and controls a temperature of tip  18 . Control system  10  further includes solder  22 , molten solder pool  24 , and a plurality of components  26 . Molten solder pool includes a surface  28 . 
     During operation, infrared sensor  14  monitors coupling  12  being formed by soldering gun  16  and solder  22 . Control circuit  20  controls an amount of electrical current supplied to tip  18  to regulate a temperature of solder pool  24  within a pre-defined range. Regulating a temperature of solder pool  24  enables components  26  to be coupled. In an exemplary embodiment, sensor  14  is an OS 20  Infrared Pyrometer available from Omega Engineering, Inc. In an alternative embodiment, control system utilizes other types of non-contact temperature sensors. 
     A position of sensor  14  relative to surface  28  of pool  24  is selected to enable measurement of either the entire pool  24  or a particular portion of pool  24 . Alternatively, sensor  14  is positionable such that the temperature of tip  18  may be monitored if desired. In an alternative embodiment, control system  10  controls various temperature sensitive coupling methods other than soldering, including, but not limited to, welding, brazing, cryogenic coupling, hot wedge, hot air, hot air seam sealing and ultrasound applications. 
     FIG. 2 is a plan view and FIG. 3 is a side view of a table mounted control system  30  including a table  32  and a heat coupling device  34  that is slidably coupled to a guide rod  36 . Heat coupling device includes an infrared sensor  38 . Guide rod  36  is mounted to table  32  with a plurality of support arms  40 . A welding finger  42  is coupled to heat coupling device  34 . 
     During operation, after at least two components (not shown) to be welded are placed on table  32  such that a desired coupling area is under a path of welding finger  42 , heat coupling device  34  traverses guide rod  36  and sensor  38  provides a temperature feedback to heat coupling device  34 , thus permitting a continuous temperature monitoring of a welding operation. 
     In an exemplary embodiment, welding finger  42  includes at least one orifice (not shown) to dispense a molten material appropriate for welding metal components together, such as, for example, a molten metal. In operation, at least two metal components (not shown) are placed such that a desired coupling area (not shown) is under a path (not shown) of welding finger  42 . Typically, the metal components include edges positioned approximately abutting under the path of welding finger  42 . As heat coupling device  34  traverses guide rod  36 , welding finger  42  dispenses molten material while sensor  38  senses a temperature of the molten material and the temperature is regulated to he within a pre-defined temperature range. The molten material is dispensed through the orifice and, after an elapsed time period, the molten material cools and solidifies, thus coupling the components. 
     In an alternative exemplary embodiment, the welding finger includes at least one orifice (not shown) to dispense a molten material appropriate for welding plastic components together, such as, for example, a molten plastic. In operation, at least two plastic components (not shown) are placed such that a desired coupling area (not shown) is under a path (not shown) of the welding finger. Typically, the plastic components include edges that are positioned approximately abutting under the path of the welding finger. As the heat coupling device traverses the guide rod, the welding finger dispenses molten material while a sensor senses a temperature of the molten material and the temperature is regulated to be within a pre-defined temperature range. The molten material is dispensed through the orifice and, after an elapsed time period, the molten material cools and solidifies, thus coupling the components. 
     In a further alternative exemplary embodiment, a welding finger includes a transducer (not shown) appropriate for welding plastic components (not shown) together. In operation, at least two plastic components are placed such that a desired coupling area is under a path of the welding finger. Typically, the plastic components include edges that are overlapped under the path of the welding finger. As a heat coupling device traverses a guide rod, the transducer of the welding finger emits ultrasonic sound waves that heat the plastic under the path of the welding finger. A sensor senses the temperature of the plastic. In applications with heat the control device having a velocity along the guide rod, a coupling time is regulated by regulating the velocity. Transducer parameters and/or the coupling time are regulated such that the temperature of the plastic under the welding finger is within a pre-defined temperature range. Transducer parameters include frequency of sound waves and amplitude of sound waves. Accordingly, the plastic components are coupled with a seam weld. 
     In a further alternative exemplary embodiment, a welding finger includes a conductor (not shown) appropriate for resistively welding metallurgical components together. In operation, at least two metallurgical components (not shown) are placed such that a desired coupling area is under a path of the welding finger. The path includes a metal plate (not shown) to complete an electrical circuit (not shown) including the metal plate, the welding finger, and the metallurgical components to be welded. Typically, the metallurgical components include edges that are overlapped under the path of the welding finger. As a heat coupling device traverses a guide rod, the welding finger supplies an amount of electrical current that passes through the metallurgical components to the metal plate. A resistive heating occurs in the metallurgical components and a sensor senses the temperature of the components and the amount of electrical current is regulated such that the temperature of the metal under welding finger is within a pre-defined range. 
     In an alternative exemplary embodiment, a velocity of a heat coupling device traversing a guide rod is regulated such that the temperature of the metal under a welding finger is within a pre-defined temperature. In a further alternative exemplary embodiment, a heat coupling device is stationary and a coupling time is controlled. An amount of electrical current passes through the components until a sensor senses that the temperature of the metal under a welding finger is within a pre-defined range and the current is stopped. 
     While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.