A system for controlling fusion welding with filler material

Abstract: The system comprises a conventional torch (1) into which air and gas to be burned are allowed that are then guided to a mixing chamber from which they reach a burner support (6) and finally nozzles (7) that have holes (8) for the welding flame to simultaneously impinge upon the two faces of the part to be welded. The unit moreover comprises a heat sensor (11) to control the part and flame temperatures; a second heat sensor to detect flame recession; gas and oxygen electronic flow metres and control valves; gas and air flow control valves and air flow control devices.

Description: OBJECT OF THE INVENTION As explained herein, the present invention relates to a system for controlling fusion welding, particularly devised to be applied to a manual or robotised torch and allowing elements of little thickness, made of copper, aluminium, brass, iron and others to be welded, ensuring that welding is of a certain a quality and repetitive and moreover ensuring a controlled safety in using the same. BACKGROUND OF THE INVENTION The problems arising from welding with filler material in thin-walled parts are well-known for such welding must be made very precisely in order to prevent the flame applied from being excessive, in quality or in time, perforating the walls of the material being welded. This problem is even worse in the particular case of materials such as aluminium that provide no visible signs allowing the time when the filler material has melted to be told apart from the time when the actual part to be welded begins to melt (there is only a difference of 10° to 15°C between both melting points). This problem is especially important in the field of batteries for cooling circuits and, in particular, in welding battery elbows already mounted upon the battery ducts, wherein when the torch flame is applied the oxygen lying within the elbows oxidises and their inner surface will therefore have impurities arising from oxidation that are frequently unacceptable. Nitrogen is usually inserted into the ducts to avoid such oxidation and yet this method cannot ensure an absolute cleanliness of the inner surfaces. To solve this problem, for batteries as aforesaid, there is currently available a welding head having a gas premixing chamber and a double nozzle made of special materials, the nozzles being located on either side of the part to be welded, and having flame output holes that are especially designed as to size, position and method of production. With the head thus structured and applied simultaneously to the two end ducts of the elbow, welding is possible without the walls being internally oxidised, and a high heat value flame can be formed thereby to significantly reduce gas and oxygen consumption, allowing the same to be used in welding materials such as copper with a thickness of up to 0.25 mn. This is why it is very successfully used fitted on the grip of a robot to be automatically positioned, and copper-copper welding is possible by visual inspection of the operator (welding takes place until the elbow changes colour showing that it is close to melting) or by programming the welding times in the robot. Robot time programming is inconvenient due to the little reliability inherent in the fact that there are sharp drops in the gas and/or oxygen pressure which means that the set and programmed welding time is unsuitable in these cases and welding is not therefore carried out correctly. This is why welding is usually performed only with the assistance of staff who visually control the process and advise the robot when to finish each welding procedure. It has always been desirable in a large number of applications and, in particular, in the subject case of cooling batteries, to be able to replace copper with aluminium, and yet with aluminium the welding problem aforesaid is far worse inasmuch as there is no such warning colour change, and there is little margin between the melting point of the filler material and of the elbow material, wherefore a reliable welding is not possible by visual inspection due to the large quantity of flaws and hence material perforations that come about. DESCRIPTION OF THE INVENTION The control system subject hereof has been devised to fully solve the problems aforesaid and lies in fitting a number of elements onto the torch aforesaid that allow the said torch to be turned into an intelligent fusion welding head, allowing the welding of elbows and the like to be fully automatic and controlled without there being any of the process being supervised by humans. The subject control system is applicable not only to welding copper and aluminium but to materials of all kinds, such as iron and brass, with no perforations and automatically. One of the characteristics of the subject system of the present invention, as defined in claim 1, lies in the use of a temperature detection sensor that allows the true temperature to be known at all times at a specific point of the part, using this to find the temperature of the flame in real time, detecting changes in the value thereof forthwith, whether they be due to 0 2 or gas drops, at various heat dissipations through the body of the heater, or due to room temperature changes. With these data the system is able to decide the precise time the torch flame needs to be applied, or to make the necessary changes in the gas and 0 2 flows, thereby successfully ensuring that every elbow or part to be welded receives the precise flame temperature for the time required, without any human intervention, ensuring a better welding quality (no perforations due to excess flame, nor poorly welded parts for want of flame) and ensuring that this process is repetitive and hence that the welds obtained are of standard quality. However, though the function described above is of foremost importance with a view to obtaining a good welding, in a further embodiment the said temperature probe is used for two additional functions, namely: Detecting the presence or absence of an elbow or part to be welded. The system controls the temperature rise detected by the sensor and the failure to achieve a pre-established temperature after a set time obviously means that the flame temperature has not been transmitted through the part, because such is not at its working position. Detecting poor nozzle condition. In the presence of a part to be welded, the system assumes that after a set time the temperature of the part must achieve a given value and will otherwise check whether the pressures of the fluids are correct or whether such are bringing about a temperature shift. When the pressures are correct, the system warns that there must be some problem with, damage to or obstruction in the nozzle. It seems clear from the description of the subject system that due to its situation the part temperature sensor withstands high temperatures, which effect will not allow a new reading to be made until such temperature drops sufficiently, and a waiting time will therefore be required which would slow the production chain down unnecessarily. To prevent this problem, air piping means are provided, governed by the system control, in order for cooling air to be injected onto the sensor to rapidly lower its temperature and allow this operation to take place while the torch is being positioned upon the next elbow to be welded, thereby fully avoiding time losses (with cooling air, temperature can be lowered 450°C in 300 seconds). The subject system moreover allows the safety in using a torch of this kind to be enhanced, to which end a second temperature sensor fitted lies at the mixing chamber to detect forthwith any possible recession in the flame, acting through the control system to shut the gas and 0 2 valves immediately, thereby yielding a far speedier and hence safer reaction than mechanical flame recession systems. In view of its features, the system described, subject of the invention, allows the welding operations of elbows or thin-walled parts, made of materials such as copper, aluminium, iron, brass and others, to be fully robotised, but it is also applicable to hand torches allowing, for instance, any operator to make aluminium welding repairs locally with the resulting advantages and cost reductions. DESCRIPTION OF THE DRAWINGS In order to provide a fuller description and contribute to the complete understanding of the characteristics of this invention, a set of drawings is attached to the specification which, while purely illustrative and not fully comprehensive, shows the following: Figure 1 .- Is a schematic view of the said control system, and the connection thereof to the sensing devices and actuators fitted in the torch. Figure 2 .- Is a schematic sectional view of the said torch, with the flame recession and product temperature control sensors fitted at their respective locations. Figure 3 .- Is a front and profile view of the said torch, showing how the part to be welded is acted upon. PREFERRED EMBODIMENT OF THE INVENTION With reference to the figures, and in particular figure 1, the control system subject hereof comprises a number of signal sensing devices and actuating means fitted onto an improved torch (a), coupled to a robot (b) and a central external programmable system (c) assessing the data received and hence generating actuation data allowing the relevant operating sequences to be activated, keeping all process variables within the working ranges and generating the necessary warning signals to ensure a safe operation of the controlled system. The improved torch (a) aforesaid is the apparatus for which an improved operation and control is sought, and comprises a conventional torch (a) that is provided through the relevant ducts (2) and (3) with the air and gas to be burned and which are driven by means of a coupling element (4) to a mixing chamber (5) where the mixture is homogenised and the homogeneous mixture formed is then taken through a body to a burner support (6) and finally to the two nozzles (7) where two special holes (8) are provided in order for the welding flame at the output to simultaneously impinge upon the two faces of the part to be welded (d). The rear of the mixing chamber (5) is closed by a cover (9) that allows the same to be fitted onto the robot arm through a fixing member (10). The system proposed for the attainment of the functions described has the following devices fitted in or outside the torch (a): A heat sensor (11) lying on a pneumatic cylinder (12) and coated with a ceramic material (11'), arranged axially inside the torch body (6), its sensing portion lying between the burners (8) and being used firstly to control the part (d) and flame temperatures, having a precision equal to or in excess of 1% and at a response speed of 0.2 seconds and, secondly, acting as a spring keeping the part (d) and the robot (a) in contact at all times, providing the robot, as it reciprocates, with the reference of the position of the part to be welded (while it welds, the robot must reciprocate for if it stays still throughout the welding the parts will melt due to the high temperature applied) and damping the effect of the robot moving against the part (d) to be welded after the first contact is made between the two. A heat sensor (13) lying in the head mixing chamber (5) with technical features similar to the above, its function being to detect flame recession. Electronic gas and oxygen flow metres (14) and (15) respectively located on the gas and air input ducts (2) and (3) to control the consumption of the burners and the exact proportion of the mixture used. Proportional gas and air flow control valves (16) and (17) located on the gas and air input ducts (2) and (3) to control a greater or smaller opening of the said ducts. Gas and oxygen position control valves (18) and (19) and the relevant pressure metres (20) and (21). Devices for controlling the air driven through the burner support ducts towards the temperature sensor (11), thereby lowering the cooling time thereof. In order to control all the data compiled, the use of a central programmable system (c) is provided, being a logic programmable or like controller, fitted with the required input (22) and output (23) cards and moreover having a data processing unit (24) having a specific program that allows data to be received and assessed, decisions to be made and commands to be sent to the actuators, in real time, in order that in the event of any process change, variation or trouble ensuing, the same may be suitably corrected forthwith or the process stopped. We feel that the description need not be extended any longer for any expert in the art to have grasped the full scope of the invention and the advantages it offers. The materials, shape, size and layout of the elements may be altered provided that this entails no modification of the essential features of the invention.

Claims: A system for controlling fusion welding with filler material, comprising a torch having a mixing chamber (5), following the gas mixer (1), provided with a double nozzle (8), which consists of two nozzles disposed in parallel with gauged flame output holes (8'), preferably designed for the flame to impinge simultaneously upon both faces of the part to be welded (d), characterised in that inside the torch body (6) there is fitted a temperature sensor (11) coated with a ceramic material (11') and mounted upon a pneumatic cylinder (12) internally and axially to the body (6) such that the probe of the said sensor (11) will be located centrally between both nozzles (8), for sensing the temperature of a point of the part to be welded (d) at all times, and sending such temperature to a central control system (c) where it will be used to control the flame temperature at all times, cooling means (7') for the said temperature sensor (11) also being provided. A system for controlling fusion welding with filler material according to claim 1, characterised in that the temperature sensor (11) constantly provides a signal that is compiled and assessed by the central control system (c) to yield the actuation values and necessary commands that are transmitted to the flow (16) and (17) and pressure (18) and (19) control valves for the gas pressures in the mixture to be controlled, also acting upon the time during which the flame is applied. A system for controlling fusion welding with filler material according to any one of the above claims, characterised in that the temperature sensor (11) lies at the end of said pneumatic cylinder (12) for damping the vertical movements of a robot arm (a) carrying the torch as the robot arm moves up and down during the welding operation, keeping the sensor (11) in contact with the part to be welded (d) at all times. A system for controlling fusion welding with filler material according to any one of the above claims, characterised in being fitted at the end of the nozzle (8) and surrounding the part temperature sensor (11) with two air piping means (7') that are commanded by the central control system (c) and inject air to cause the said sensor to be cooled down while the robot is passing from one part (d) to the next. A system for controlling fusion welding with filler material according to any one of the above claims, characterised in that the temperature sensor (11) cooling means fitted at the end of the welding nozzle are such to lower the temperature of the said sensor down to a value that is significantly below the melting temperature of the material of which the part to be welded (d) is made. A system for controlling fusion welding with filler material according to any one of the above claims, characterised in that the temperature sensor (11), in the absence of such part, sends a flame check signal that allows abnormal states of, damages to or defects in the nozzles (8) of the torch used to be known. A system for controlling fusion welding with filler material according to any one of the above claims, characterised in that the temperature sensor (11) provides a signal that allows the presence or absence of the part to be welded (d) to be detected and relevant actions to be taken. A system for controlling fusion welding with filler material according to any one of the above claims, characterised in being fitted with a temperature sensing device (13) arranged after the gas mixing chamber (5) which allows flame recession situations to be known through the central control system (c), allowing the said gas input ducts (2) and (3) to be shut.

Inventors: MONTSENY BANAJES ALBERT, MONTSENY BANAJES, ALBERT
Applicants: KOBOL SA, KOBOL S.A.
Application year: 1995
Main classification: B23K7
IPC codes: G01J5, F23N5, B23K31, B23K5, B23K7