Patent ID: 12194688

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In the following, an embodiment of the inventive method is explained based on the functioning of a respective welding device. For increasing the understanding of the technical effects of the welding method, first the known procedure is illustrated based inFIGS.1to5.

The welding device1comprises an upper tool12mounted to an upper support10and a lower tool16mounted to a lower support14. The upper tool12and the lower tool16are movable relative to each other by a first drive30along a first axis32. In the present example, the upper support10to which the upper tool12is rigidly mounted is an upper tool plate and the lower support14to which the lower tool16is mounted is a lifting table. As a result, in such an exemplary arrangement, only the lifting table as the lower support14will be moved along the first axis32.

Further, the welding device1comprises a preheating arrangement18having a first preheating device20and a second preheating device22. The first preheating device20is arranged on an upper side facing in a preheating position the upper tool12and the second preheating device22is arranged on a lower side facing in the preheating position the lower tool16. Further, the preheating arrangement18comprises a second drive40for movement along a second axis42. The second axis42is perpendicular to the first axis32. Further, a third drive50is provided for a movement of the preheating arrangement18along a third axis52. The third axis52is parallel to the first axis32.

InFIG.1, the upper tool12and the lower tool16of the respective welding device1are arranged in an initial position, i.e., a starting position. The preheating arrangement18is arranged in a parking position.

Due to the shape of the components to be welded, which is reflected by the shape of the upper tool12and the lower tool16, an undercut is present. An undercut is an element, which protrudes from the respective component such that it covers an area of the component depending on the orientation of the component in the space. In the example, the upper tool12is formed like a roof having a gable or, in other words, it provides a reversed V-shape. The lower tool16has a complementary shape. The first component and the second component are formed such that they match the form provided by the upper tool12and the lower tool16. Further, the first preheating device20and the second preheating device22have also a shape matching the form provided by the respective tools12,16.

If the reverse V-shaped upper tool12is viewed from below, i.e., from the lower tool16along the first axis32, it does not contain an undercut since all areas are freely accessible. However, if the upper tool12is viewed from the side, then one side, namely the left side, covers respectively the other side, namely the right side. One side thus covers the other side depending on the orientation in the space. The respective left side thus represents an undercut in terms of the present disclosure. For clarification, the undercut is thus assumed to be an imaginary point or a curve, which represents the undercut and must be circumnavigated. Only after this circumnavigation can the preheating arrangement18be arranged next to the surface of the first component to be heated. Further, it also follows from the above explanation that a movement of the preheating arrangement18towards a surface covered by the undercut, for example a surface to be heated, may not be possible with a single straight-line movement.

The operation is such that in a first step a user places the second component on the lower tool16. Subsequently, the user positions the first component on the second component in the lower tool16. Then, the lower support14with the lower tool16and the components arranged thereon moves from an initial position in the direction of the upper tool12until the first component abuts the upper tool12. This movement takes place along the first axis32by means of the first drive30. The first axis32is vertical with respect to the floor or ground on which the welding device1is arranged. Then, the lower support14moves along this vertical first axis32back into a position in which the preheating arrangement18can be arranged between the components, here the initial position. For example, the lifting table moves back into the initial position.

For circumnavigating the undercut, the preheating arrangement18is moved in a second step by the second drive40along the second axis42perpendicular to the first axis32, i.e., horizontal with respect to the floor or ground, from a parking position into an aligning position between the components to be welded. This position is shown inFIG.2. The respective movement curve realized by the second drive40over time is indicated inFIG.5by reference sign44.

After the preheating arrangement18has been arranged between the two components in the aligning position, the preheating arrangement18is moved in a third step by the third drive50along the third axis52into the preheating position. This position is indicated inFIG.3. The corresponding movement curve realized by the third drive50over time is indicated inFIG.5by reference sign54.

In a fourth step and after the preheating arrangement18has reached the preheating position, the lower tool16is moved along the first axis32into a position adjacent to the preheating arrangement18. This position is also called the adjacent position and is indicated inFIG.4. The movement curve realized by the first drive30over time is indicated inFIG.5by reference sign34.

The preheating then takes place in a fifth step, in which all structural elements of the welding device are held in their position. This can be seen inFIG.5from the respective movement curves.

Subsequently to the pre-heating, the above movements are performed in a reversed order. Thus, the lower support14is moved in a sixth step along the first axis32back into a position allowing the preheating arrangement18to be moved into the parking position. According to the movement curve34, the lower support14is moved back to the initial position as indicated inFIG.3.

Next and in a seventh step, the preheating arrangement18is moved along the third axis52by the third drive50back into the aligning position shown inFIG.2. In an eighth step, the preheating arrangement18is moved along the second axis42by the second drive40into the parking position with reference toFIG.1. The respective movements and their sequence order are also indicated inFIG.5.

For welding the first component to the second component, the lower support14is now moved in a ninth step along the first axis32into the welding position. The welding of the first component to the second component takes place in a tenth step.

After finishing the welding, the lower support14moves in step eleven with the lower tool16and the compound of first and second component arranged thereon along the first axis32from the welding position back into the initial position. As soon as the lower support14has reached the initial position, the user may remove the compound of first and second component.

From the above and with respect toFIG.5, the actuation of each drive occurs only one at a time for avoiding collisions in particular in case of highly complex components to be welded. This applies for all types of drives, i.e., servo drives, pneumatic drives, or hydraulic drives.

Now referring toFIGS.6to12, an embodiment of the inventive welding method is explained in comparison to the above discussed welding method.

The welding device100used here comprises an upper tool112mounted to an upper support110and a lower tool116mounted to a lower support114. The upper112and the lower tool116are movable relative to each other by a first drive130along a first axis132. Here, the upper support110to which the upper tool112is rigidly mounted is an upper tool plate and the lower support114to which the lower tool116is mounted is a lifting table. As a result, in such an exemplary arrangement, only the lifting table as lower support114will be moved along the first axis132.

This arrangement is particularly preferred in case of a vibration welding device. Nevertheless, and in case an infrared welding method is used, a movability of the upper support110may also be provided. For the sake of completeness, it is pointed out that the first axis132is preferably a vertical axis, i.e., perpendicular to the floor on which the welding device100is arranged. Further, the first component and the second component to be welded to each other preferably consist of a plastic material.

The welding device100comprises also a preheating arrangement118having a first preheating device120and a second preheating device122. The first preheating device120is arranged on an upper side facing in a preheating position the upper tool112and the second preheating device122is arranged on a lower side facing in the preheating position the lower tool116. Further, the preheating arrangement118comprises a second drive140for movement along a second axis142. The second axis142is perpendicular to the first axis132. Further, a third drive150is provided for a movement of the preheating arrangement118along a third axis152. The third axis152is parallel to the first axis132.

Additionally, the welding device100comprises a controller for controlling, preferably electronically coupling or synchronizing, the first drive130, the second drive140and the third drive150. The controller may be the controller of one of the drives130,140,150which acts as master or host controller or a separate master or host controller. Using one of the controllers already present realizes a cost-effective embodiment. On the other hand, the usage of a separate controller as master or host controller ensures sufficient processing power and a higher variability in view of different applications.

Further, and with respect to the drives130,140and150, they are realized as servo drives. The use of such servo drives ensures a reliable control of the movements and due to the controller, a fast interruption of the movement of the drives, in particular all drives, in case of failure of one drive can be achieved, as discussed in the following. Further, servo drives have the advantage of providing fast movements compared to pneumatic or hydraulic drives while at the same time producing less noise and consuming less energy.

InFIG.8, the upper tool112and the lower tool116of the respective welding device100are arranged in an initial position, i.e., a starting position. The preheating arrangement118is arranged in a parking position.

The first step S1is identical to the above described first step for arranging the first component and the second component in the upper tool112and the lower tool116. At the end of the first step S1, the welding device100has the positions as indicated inFIG.8and by reference sign T1inFIGS.6and7. In this regard,FIG.7illustrates simplified electronic cam disks used by the controller for controlling the movement of the drives130,140and150.

Now, and in a second step S2, the moving of the preheating arrangement18from the parking position to the preheating position by the second drive140and the third drive150occurs without intermediate position. For achieving this, the second drive140and the third drive150are controlled by the controller such that they are at least partly energized or actuated at the same time.

For example, and with respect toFIGS.6and7, after the second drive140has moved the preheating arrangement18along the second axis142for a predetermined distance (see reference sign T2inFIGS.6and7and the position shown inFIG.9), the third drive150is additionally energized or actuated so that additionally a movement along the third axis152results. The movement is thus continuous, and the combined movement is diagonal. Continuous movement defines in this regard a movement without intermediate stops or intermediate positions.

Also starting at reference sign T2, the first drive130is energized or actuated resulting in a movement of the lower support114along the first axis132(seeFIGS.6and7).

For an easier understanding,FIG.10shows the position at reference sign T3inFIGS.6and7. At the end of the second step S2, the welding device100shows the configuration ofFIG.11, which corresponds to reference sign T4.

A result of this course of procedure is that the path of the preheating arrangement118is shortened compared to the above welding method which moves the preheating arrangement18along each of the axis separately. A further reduction of the time required before the preheating of the components to be welded can take place in step S3is achieved by the movement of the lower support114from the initial position to the adjacent position at the same time as the third drive150of the preheating arrangement118is energized or actuated by the controller.

As mentioned above and for realizing such movements at the same time, the drives130,140and150are controlled together by for example electronic cam disks. Thus, the drives130,140and150are preferably coupled to or synchronized with each other. This is realized by the controller. Due to this, the respective movements depend on each other so that in case of a failure of one drive130,140,150the remaining drives are stopped, preferably automatically, due to the common control. Accordingly, a damaging of the first component, the second component, and/or the welding device100is avoidable.

Further, the second drive140acts in this example as a master drive and the remaining drives130,150act as slave-drives. This is due to the fact that the second drive140is initially energized or actuated without the remaining drives being energized or actuated. Accordingly, and only after the second drive140has realized the predetermined distance indicated by reference sign T2, the remaining drives are energized or actuated by the controller.

Next, the preheating takes place in step S3. To this end, and depending on the application, the preheating arrangement is preferably an infrared preheating arrangement.

Thereafter, the above movements are performed in the reverse order in step S4, which is indicated by the reference signs T3′, T2′ and T1′ inFIG.6. Thus, the lower tool116is moved along the first axis132from the adjacent position to a spaced position, which may be the initial position or any intermediate position allowing a movement of the preheating arrangement118into the parking position. Accordingly, and at least partly at the same time, the preheating arrangement118is moved from the preheating position to the parking position, preferably in a continuous manner, as explained above. At the end of step S4, the welding device100is arranged in the position shown inFIG.8.

Next, and in steps S5to S7, the above explained steps nine to eleven are performed. Thus, the lower tool116is moved into the welding position, the components are welded to each other and the lower tool116is moved back to the initial position so that a user may remove the produced compound of first and second component.

PARTS LIST FOR FIGS.1-12

1welding device10upper support12upper tool14lower support16lower tool18preheating arrangement20first preheating device22second preheating device30first drive32first axis34movement sequences realized by the first drive30along the first axis3240second drive42second axis44movement sequences realized by the second drive40along the second axis4250third drive52third axis54movement sequences realized by the third drive50along the third axis52100welding device110upper support112upper tool114lower support116lower tool118preheating arrangement120first preheating device122second preheating device130first drive132first axis134movement sequences realized by the first drive130along the first axis132136simplified electronic cam disk for the movement to be realized by the first drive130along the first axis132140second drive142second axis144movement sequences realized by the second drive40along the second axis42146simplified electronic cam disk for the movement to be realized by the second drive140along the second axis142150third drive152third axis154movement sequences realized by the third drive150along the third axis152156simplified electronic cam disk for the movement to be realized by the third drive150along the third axis152

It should be noted that various modifications are possible that employ one or more aspects of the invention as described herein, including the following appended claims.