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CN103781618A - 用于实施和监控塑料激光透射焊接工艺的装置和方法 - Google Patents

用于实施和监控塑料激光透射焊接工艺的装置和方法 Download PDF

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CN103781618A
CN103781618A CN201280037045.5A CN201280037045A CN103781618A CN 103781618 A CN103781618 A CN 103781618A CN 201280037045 A CN201280037045 A CN 201280037045A CN 103781618 A CN103781618 A CN 103781618A
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measuring beam
interface
light
reflected
detecting unit
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CN103781618B (zh
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M·西本
D·赫特勒
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LPKF Laser and Electronics AG
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82Testing the joint
    • B29C65/8253Testing the joint by the use of waves or particle radiation, e.g. visual examination, scanning electron microscopy, or X-rays
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1629Laser beams characterised by the way of heating the interface
    • B29C65/1635Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B29C65/1638Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding focusing the laser beam on the interface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1629Laser beams characterised by the way of heating the interface
    • B29C65/1674Laser beams characterised by the way of heating the interface making use of laser diodes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112Single lapped joints
    • B29C66/1122Single lap to lap joints, i.e. overlap joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/95Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/952Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the wavelength
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/064Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
    • B23K26/0648Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms comprising lenses
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125Weld quality monitoring
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1629Laser beams characterised by the way of heating the interface
    • B29C65/1635Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1629Laser beams characterised by the way of heating the interface
    • B29C65/1654Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/83General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91211Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods
    • B29C66/91216Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods enabling contactless temperature measurements, e.g. using a pyrometer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9161Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
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    • B29C66/96Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process
    • B29C66/961Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving a feedback loop mechanism, e.g. comparison with a desired value
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01JMEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
    • G01J5/00Radiation pyrometry, e.g. infrared or optical thermometry
    • G01J5/0014Radiation pyrometry, e.g. infrared or optical thermometry for sensing the radiation from gases, flames
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01JMEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
    • G01J5/00Radiation pyrometry, e.g. infrared or optical thermometry
    • G01J5/48Thermography; Techniques using wholly visual means

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
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  • Electromagnetism (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Length Measuring Devices By Optical Means (AREA)
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Abstract

本发明涉及一种用于实施和监控塑料激光透射焊接工艺的装置和方法,包括:工艺光束源,其用于将工艺光束发射至两个接合元件(2,3)之间的接合区域(1)内从而形成焊缝(4);测量光束源(6),其利用测量光束(7)照射测量区域(12);检测单元(13),其用于检测由接合元件(2,3)内的位于焊缝(4)与其周围区域之间的界面(5)所反射的测量光束(7);和评价单元(15),其连接至检测单元(13),用于由检测到的被反射的测量光束(7)来确定接合元件(2,3)内的界面(5)的深度位置。

Description

用于实施和监控塑料激光透射焊接工艺的装置和方法
技术领域
本发明涉及用于实施和监控塑料激光透射焊接工艺的装置和方法,分别具有如在权利要求1或11前序部分中所述的技术特征。
背景技术
塑料激光透射焊接技术在多篇文献中已有所公开,例如EP 1 575 756B1或者DE 10 2004 036 576 B4。
通常说来,激光工艺光束的透射性的接合元件被放置在吸收所述光束的接合元件上。当位于该两个接合元件之间的相应的接合区域被暴露至穿过透射性的接合元件而发射的光束中时,会在吸收性的接合元件中产生熔池。由于与透射性的接合元件的接触,相应量的热能会被传送至透射性的接合元件中,导致透射性的接合元件也在焊接区域中熔融,其结果导致相应的材料混合发生在两个接合元件之间。当材料已被冷却时,焊缝形成在两个接合元件之间,该焊缝在横向于焊缝方向的方向上具有结块状轮廓。由于两个接合元件以及焊缝区域中的混合材料的不同的折射能力,因此在接合元件中结块状轮廓相对于其周围区域的界面是能够反射光束的光学活性界面。
根据DE 101 21 923 C2,通过激光照射的方式来制造和监控焊缝的方法利用了下述特征:将该文献中称为控制光束的光束发射至包括焊缝的测量区域中,并且将通过界面反射后的测量光束传送至用于检测的检测单元。
在焊缝上实施的该现有的监控方法仅允许确定由焊缝内的缺陷所导致的、检测到的被反射测量光束内的扰动,这被认为会引起反应。这种类型的反应可能导致确定为有缺陷的工件被拒收。该监控方法中没有提供对于焊缝的更细致的说明。
发明内容
基于这些现有技术的方法,本发明的目的在于提供用于实施和监控塑料激光投射焊接方法的装置和方法,其允许接合元件内在焊缝与其周围区域之间的界面的检测被极为明显地改善。
该目的通过装置权利要求1的特征部分所述的涉及装置的方面以及方法权利要求11的特征部分所述的步骤方面而实现。据此,装置和方法构造成使得由检测单元所检测到的被反射的测量光束被传送至相应的评价单元,从而通过检测到的被反射的测量光束来确定接合元件内的界面的深度位置。这就允许更加精确的焊接工艺检查,因为利用界面的深度位置不仅能够确定两个接合元件之间的接合区域内的焊缝的绝对深度位置,而且能够确定两个接合元件之间是否存在足够的焊缝横截表面或者是否存在焊缝本身。
在下文中称为“焊接深度监控”的用于确定界面深度位置的光学技术过程可以通过不同的装置和方法而实现。例如在权利要求2或12中,提出使用点光源来产生测量光束,该测量光束能在测量区域上通过设置在测量光束的光路内的聚焦光学系统可变地聚焦。光检测装置被用作为检测单元以检测取决于焦点相对于界面的位置的、被反射的测量光束的强度。如果焦点位于界面内,则反射强度高。因此,聚焦光学系统的位置和被反射的测量光束的强度之间的相关性使得能够确定界面的深度位置。
根据分别在权利要求4至7或13中所描述的用于确定深度位置的另一种替换实施方式,可以使用彩色共焦测量系统。据此,测量光束源为多色点光源,其通过设置在测量光束的光路内的聚焦光学系统以按距离编码的方式聚焦在测量区域上,并根据各自的波长聚焦至数个部分测量光束内。用作检测单元的光谱敏感光检测装置检测取决于焦点相对于界面的位置的、被反射的具有最高强度的局部测量光束,从而确定界面的深度位置。部分测量光束的按距离编码可以使用距离编码透镜、特别是构造为菲涅耳透镜来实施。在根据权利要求6的优选实施方式中,光谱敏感光检测装置还可以通过分光计/光谱仪来形成,该分光计包括在其前方设置的孔。
根据权利要求7的优选实施方式,为了简化对于工艺和测量光束的光束引导,分别提供光学波导以将测量光束引导至聚焦光学系统和将被反射的测量光束引导至检测单元,这些光学波导随后通过光纤耦合器而被结合,从而在聚焦光学系统和测量区域内形成一公共光路。
用于焊接深度监控的光学系统的另一种替换实施方式分别在权利要求8或14中表征。据此,采用了测量光束源和检测单元的三角测量布置,该布置自身是已知的。据此,测量光束通过被发射至焊接区域内的三角测量激光束而产生,其中,根据界面的深度位置而被反射的测量光束由图像传感器形式的检测单元进行检测。其结果被用于根据激光三角测量原理来确定界面的深度位置。
类似的替换性的光学原理是所谓的光切法,其在权利要求9或15中被描述为另一种替换实施方式。据此,提供光切传感器,其包括测量光束源和检测单元。测量光束源构造成用于将测量光线发射至测量区域上,换句话说,发射至要被检查的焊缝上。光切传感器内的成像光学系统将测量光线的被反射的测量图像成像在相应的图像传感器上,其可被评价以根据光切法原理确定在接合元件内的位于焊缝与其周围区域之间的界面的深度位置。
如在权利要求10和16中所描述的,根据本发明的焊接深度监控方法可以以特别有利的方式被应用在从上文提及的EP 1 575 756 B1中已知的所谓的激光混合焊接方法中。该文献所描述的第二光源可被用作为根据本发明的用于焊接深度监控的测量光束源。
总之,本发明特别适合在绕焊或激光混合焊接领域中执行的塑料激光透射焊接工艺中用于过程控制,该过程控制的操作原理是基于光在材料界面上的反射以及所获得的焊缝界面的“深度测量”。
附图说明
本发明其它的特征、细节和优点将根据结合附图对于示例性实施方式的说明而变得明显,其中
图1示出用于焊接深度监控的光学测量装置的第一实施方式的示意图;
图2示出该实施方式所提供的可移位的聚焦光学系统的示意图;
图3示出用于焊接深度监控的光学测量装置的第二实施方式的示意图;
图4示出该实施方式所提供的被距离编码的聚焦光学系统的示意图;
图5和6示出在两个接合元件之间执行焊接之前和之后根据图3的光学测量装置的更加详细的示意图;
图7示出根据图3的光学测量装置的替换实施方式;
图8和9示出在基于激光三角测量方法的另一种实施方式中、在塑料激光透射焊接工艺中用于实施和监控焊接深度的装置的示意图;
图10示出在基于光切法的另一种实施方式中用于实施和监控塑料激光透射焊接工艺的装置的示意图。
具体实施方式
图1示出用于实施和监控塑料激光透射焊接工艺的装置的第一实施方式。用于产生并发射激光束——该激光束用作进入两个接合元件2、3的接合区域1内的工艺光束——的工艺光束源并未被更加详细地示出,因为其对应于在传统激光透射焊接中所使用的工艺光束源。该工艺光束源被用于形成两个接合元件2、3之间的焊缝4,如在根据图1的两个接合元件2、3之间以横截面视图示出的。
为了确定在焊缝4与接合元件2、3之间的界面5的深度位置,换句话说,在相应的激光透射焊接工艺中为了进行焊接深度监控,提供点光源形式的测量光束源6,其测量光束7通过透镜8和孔9进行处理以获得聚焦光束,该聚焦光束随后通过聚焦光学系统穿过分束器10而被发射至焊缝4区域内的测量区域12内。测量光束7的相应的焦斑/焦点通过焊缝4与接合元件2之间的光学活性界面5而被反射,并通过聚焦光学系统11和分束器10而穿过孔14向检测单元13内成像。在该实施方式中,检测单元13是光检测装置,其被连接至相应的评价单元15。界面5的深度位置的测量原理基于这样的事实,即当界面5位于聚焦平面内时,测量光束源6被良好地聚焦在检测单元13上,从而能够测量到高光强度。当界面5位于聚焦平面外时,测量光束源6较差地聚焦在检测单元13的光检测装置上,其结果是强度相应地会较低。
仅能通过如在图2中所示的测量光束7在测量区域12内的可变的聚焦来执行距离测量。据此,聚焦光学系统11通过扫描运动S而被移位,其中,界面5的深度位置与聚焦光学系统11的扫描位置P1、P2、P3之一相关联。强度随着聚焦平面和界面之间的距离z而根据如下的点分布函数变化:
I ( z ) = Φ [ tan ( α ) × Z × rf ] × π
定义:
α=发散角
Φ=通过工艺监控系统的光束源所发射的光通量
Z=反射平面距离焦点位置的距离
rf=(焦)斑半径
用于实施和监控塑料激光透射焊接工艺的装置和方法的另一种实施方式将通过图3至6而阐释。该实施方式以及根据图1和2的实施方式具有某些共同的特征,即测量光束源6、通过透镜8和孔9以及分束器10对其进行的处理。然而,测量光束源6为多色点光源,其测量光束7被分为数个部分测量光束7.1、7.2、7.3(图5和6),其根据它们各自的波长而被聚焦在测量区域内。为此,利用聚焦光学系统的分散作用。在这种测量配置中,聚焦光学系统由具有高阿贝值(Abbesche Konstante)的材料构成,其会导致色像差。如在图3和5中所示的,所述的色像差允许源自聚焦光学系统11的相应焦点的焦距f被按色像编码。
在该实施方式中,检测单元13是分光计19形式的光谱敏感光检测装置,其被设置在孔14的后方并允许确定经反射的测量光束的光谱强度曲线。分光计19检测取决于焦点相对于界面5的位置的、具有最高强度的被反射的波长7。这些结果随后可通过评价单元15进行评价,从而确定界面5的深度位置并由此确定焊缝4的深度位置。
这将通过图5和6而被更加详细地解释。图5示出在焊接之前的透射性的接合元件2和吸收性的接合元件3。当多色测量光束7根据其波长而被聚焦时,数个示例性的焦点20.1、20.2、20.3根据各自的波长λ1、λ2、λ3在接合元件2、3的z方向(深度)上被获得。指定给波长λ1并且其焦点20.1位于两个接合元件2、3之间的界面区域内的光束、以及指定给波长λ2并且其焦点20.2位于上接合元件2的外表面21上的部分测量光束7.2以特别高的强度被反射。这可以通过分光计19来测量,如通过碰撞在分光计19上且分别具有波长λ1,和λ2,的经反射的部分测量光束7.1和7.2所示的。这些结果通过评价单元15进行评价,从而确定在两个接合元件2、3之间的界面5以及上接合元件2的表面21的相应位置。
在实施了产生焊缝4的焊接工艺之后,如图6所示,部分测量光束7.3的焦点20.3现在将位于向上迁移至透射性的接合元件2内的界面5内,并且其在那里以特别高的强度被反射。相应的强度转变通过分光计19检测到。在焊缝4和上接合元件2之间的界面5的深度位置现在将通过以最大强度被反射的部分测量光束7.3的波长而确定。
图7示出测量装置的替换实施方式,其稍微不同于分别在图1或4中所示的实施方式。测量光束通过设有光纤耦合器23的第一光纤22从测量光束源6被导引至准直透镜(Kollimationslinse)24和聚焦光学系统11,其聚焦同样依赖于波长。被反射的测量光束7通过该光学配置而相应地成像,并通过光纤耦合器23和其它的光学波导25而被导引至分光计19。图7示出在波长λ1下具有最大强度的经反射测量光束7的光谱图。该波长可被用于确定界面5在z方向上的位置,其极限值由多色测量光束7的最小波长λmin和最大波长λmax定义。
图8和9示出用于实施和监控塑料激光透射焊接工艺的装置和相应方法的另一种实施方式。该示意图示出传统激光工艺光学系统形式的工艺光束源26,其将工艺光束27发射至透射性的接合元件2和吸收性的接合元件3之间的接合区域28内。作为结果,形成图9中所示的焊缝4,其界面5面向透射性的接合元件2的方向。
在这里所示的实施方式中,通过焊接深度监控而对焊缝4进行的监控是基于三角测量布置而实施的,该三角测量布置由用作测量光束源6的激光源和与之相对设置的用作检测单元13的图像传感器29(所谓的CCD堆栈)形式的接收器而组成。下文的信息被提供以简要地概括三角测量的背景。三角测量的总体原则是基于利用三角形几何关系所执行的距离测量。该方法是通过以特定角度被导引至反射表面的激光束而实施的。通过直接反射而折回的光束碰撞CCD阵列,该CCD阵列单向地吸收强度分布。激光束在测量装置上的入射角度被保持恒定;距离上的变化由此导致在CCD堆栈上的“水平”迁移。通过确定位置并考虑到角度关系,评价单元就能够确定传感器和测量装置之间的距离。
因为焊缝4通过激光透射焊接而形成,其会致使接合元件2、3的基体材料相混合以形成焊接结块,因此,也可以在该区域中形成的界面5处检测到被反射的测量光束7。为此,激光测量光束7以确定的角度W被耦合至材料内。通过构造为CCD堆栈的图像传感器29,反射光束的位置被确定和评价。角度关系以及如果需要的话接合元件2、3的折射性能使得能够确定上表面和界面5之间的相应的辐照光束长度以及因此确定焊缝4的深度位置。
在图10中所示的本发明实施方式是基于激光三角测量的焊接深度确定方法的进一步改进。在这种实施方式中,使用所谓的光切传感器30,其在一方面被提供有包括特定光学工艺系统32的激光二极管31,由此将测量光线33投射在要被检查的物体上。
在另一方面,光切传感器30被提供有其它的成像光学系统34,由此使得经接合元件2、3漫反射的光线33的光被成像在传感器矩阵35(例如CCD或CMOS矩阵)形式的检测单元13上。拍摄图像通过控制器形式的相应的评价单元15进行评价,从而确定相应的距离信息,换句话说,确定在z方向上的相应反射点的位置和沿着测量线33(x轴)的位置。要被测量的物体的高度轮廓——其表示焊缝4在x方向上的轮廓——随后可被显示在相应的二维坐标系中。
如可在图10中所看到的,该测量过程允许即时地监控通过工艺光束27刚刚产生的焊缝4的深度位置和轮廓。如果测量值偏离标准值,则可以改变工艺光束27的参数以相应地影响熔池36并因此影响在两个接合元件2、3之间形成的焊缝4。
当工艺光束27和光切传感器30在y方向上沿着要被连接的接合元件2、3一起运动时,将会允许捕捉到焊缝4的三维图像。当接合元件2、3相对于工艺光束27和光切传感器30运动的时候,会获得相同的结果。
总之,根据本发明的基于测量光束7的相应反射进行的焊接深度监控工艺能够通过测量技术方法来确定与要求尺寸之间的一致性并能够监控焊缝的整体质量。

Claims (16)

1.用于实施和监控塑料激光透射焊接工艺的装置,所述装置包括:
-工艺光束源(27),该工艺光束源用于将工艺光束(26)发射至两个接合元件(2,3)之间的接合区域(1)内从而形成焊缝(4);
-测量光束源(6),该测量光束源利用测量光束(7)照射测量区域(12);和
-检测单元(13),该检测单元用于检测由接合元件(2,3)内的位于焊缝(4)与其周围区域之间的界面(5)所反射的测量光束(7);
其特征在于
-评价单元(15),该评价单元连接至检测单元(13),用于通过检测到的被反射的测量光束(7)来确定接合元件(2,3)内的界面(5)的深度位置。
2.根据权利要求1的装置,其特征在于,所述测量光束源(6)是点光源,该点光源能够通过设置在测量光束(7)的光路内的聚焦光学系统(11)而在测量区域(12)上可变地聚焦,其中,用作检测单元的光检测装置(18)检测取决于焦点(20)相对于界面(5)的位置的、被反射的测量光束(7)的强度。
3.根据权利要求2的装置,其特征在于,所述聚焦光学系统(11)设置成在光轴方向上能够移位,以用于对测量光束的焦点(20)相对于界面(5)进行强度受控的调节,其中,所述界面(5)的深度位置能由聚焦光学系统(11)的位置而确定。
4.根据权利要求1的装置,其特征在于,所述测量光束源(6)是多色点光源,该多色点光源能够通过设置在测量光束(7)的光路内的高分散聚焦光学系统而聚焦在测量区域(12)上,从而根据各自的波长而被按距离编码,其中,用作检测单元的光谱敏感光检测装置(18)检测取决于焦点(20)相对于界面(5)的位置的、被反射的具有最高强度的部分测量光束(7),从而确定界面(5)的深度位置。
5.根据权利要求4的装置,其特征在于,所述聚焦光学系统(11)具有聚焦透镜(16)和距离编码透镜(17),该距离编码透镜特别地被构造为菲涅尔透镜。
6.根据权利要求4或5的装置,其特征在于,所述光谱敏感光检测装置(18)由分光计形成,在该分光计的前方设置有孔(9)。
7.根据权利要求4至6中任一项的装置,其特征在于,分别通过光学波导(25)将所述测量光束(7)导引至聚焦光学系统(11)和将被反射的测量光束(7)导引至检测单元(13),所述光学波导通过光纤耦合器(23)结合,以在聚焦光学系统(11)和测量区域(12)内形成一公共光路。
8.根据权利要求1的装置,其特征在于,所述测量光束源(6)和检测单元(13)相互之间以三角测量布置进行设置。
9.根据权利要求1的装置,其特征在于,设有包括测量光束源(6)和检测单元(13)的光切传感器(30),其中
-测量光束源(6)构造为将测量光线(33)投射至测量区域(12)上,以及
-设有成像光学系统(24),以用于将测量光线(33)的被反射的图像成像在用作检测单元(13)的图像传感器上。
10.根据前述权利要求中任一项的装置,其特征在于,所述测量光束源(6)是本身已知的激光束混合焊接装置的第二光束源。
11.用于实施和监控塑料激光透射焊接工艺的方法,包括如下步骤:
-将透射性的接合元件(2)和吸收性的接合元件(3)布置在接合位置内;
-利用工艺光束(27)在接合区域(1)内照射接合元件(2,3)从而形成焊缝(4),并利用测量光束(7)照射包括焊缝(4)的测量区域(12);和
-通过检测单元(13)检测由位于焊缝与其周围区域之间的界面(5)所反射的测量光束(7),
其特征在于
-通过连接至检测单元(13)的评价单元(15)对检测到的测量光束(7)进行评价,从而确定接合元件(2,3)内的被检测的界面(5)的深度位置。
12.根据权利要求11的方法,其特征在于,所述测量光束(7)通过点光源(6)产生,该点光源能够通过聚焦光学系统(11)可变地聚焦,其中,所述界面(5)的深度位置通过聚焦光学系统(11)的、与被反射的测量光束(7)的强度相关的位置(P1、P2、P3)来确定。
13.根据权利要求11的方法,其特征在于,所述测量光束(7)通过多色点光源(6)产生并被发射至测量区域(12)内,其焦点随相应的波长而变化,其中,根据界面的深度位置而被反射的测量光束(7)被光谱检测,并且通过评价被反射的测量光束(7)的最大光谱强度来确定界面(5)的深度位置。
14.根据权利要求11的方法,其特征在于,所述测量光束(7)通过被发射至测量区域(12)内的三角测量激光束而形成,其中,根据界面(5)的深度位置而被反射的测量光束(7)由用作检测单元的图像传感器(29)进行检测,并且根据激光三角测量原理来确定界面(5)的深度位置。
15.根据权利要求11的方法,其特征在于,所述测量光束(7)形成为使得其产生被投射至界面(5)上的测量光线(33),其中,测量光线的被反射的测量图像作为被反射的测量光束(7)而由用作检测单元的光切传感器(30)进行检测,并且由所述被反射的测量光束(7)根据光切法原理确定界面(5)的深度位置。
16.根据权利要求11至15中任一项的方法,其特征在于,利用激光束混合焊接过程中产生的第二光束照射所述测量区域(12)。
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