Beitrag lesen - Wolf Produktionssysteme GmbH

Transcription

PRODUKTIONSSYSTEME
Russek Nr. ERW 185 A
Vortrag Technologieseminar 2008
Anwendererfahrungen im Kunststoffschweißen mit konkreten Fallbeispielen
Dr. Ulrich A. Russek
Huf Tools GmbH, Velbert
Huf Hülsbeck & Fürst
Technologie Seminar 2008 – Kunststoffschweißen und Beschriften mit Laser
Huf Tools
Freudenstadt, 24.09.2008, Dr. U.A. Russek
Anwendererfahrung beim Kunststoffschweißen
mit konkreten Fallbeispielen
•
Process / Methods
•
Process Stability
Process Control
Quality Assessment
•
Industrial Application 1
•
Stability of Material and Optical Properties
Clamping Technique
Data Management
•
Summary
1 / 20
Huf Tools
2 / 20
Seite 1
Huf Tools
Process / Methods
Process
• Laser Penetration / Transmission Welding
Methods
• Contour, Mask, Quasi-Simultaneous, Simultaneous
Globo Welding, Hybrid Welding
Process Conditions
• Polymer Compatibility, Optical Properties, Thermal Contact
Process Advantages
• Hidden Weld Seams (Design Options, TP / TPE)
• Precise Contactless Energy Input
• No Thermal, Mechanical Load
• No Particle Generation, No Pollution
f
Process Hurdles
• Necessity of Different Optical Properties
• Necessity of Small Shape Tolerances
Outlook / Potentials
• Extension All Part Colours
• Increasing Process Stability, Part Size
Laser Transmission Welding of Polymers
3 / 20
Huf Tools
Process Stability, Process Control, Quality Assessment – ” Birds Eye View ”
Process Stability
∝
Constancy / Reproducibility of Process Technical Requirements / Quality
Along Entire Production Chain ⇔ Early and Continuous Over-All Consideration
Pre-Process
• Material
• Joining Parts
• Pre-Assembly
• Parameter Inspection
Constant Laser Process Conditions
Optical Properties, . . .
Design, Manufacturing, . . .
Reproducibility, Handling, . . .
Components, Machine, Laser, . . .
In-Process
• Motion System
• Clamping Device
• Process Monitoring
• Data Acquisition
Constant Laser Processing
Exact, Reproducible Movement, . . .
Homogeneity, Residual Gaps, . . .
Pyrometry, Melt Way, . . .
Post-Process
• Quality Assessment
• Data Analysis
Data Evaluation, Traceability
Photometry, Pressure Test, . . .
Optical
Penetration Depth
a.c.
Gap Bridging
Capability
Interaction Marks
a.c.
a.c.
4 / 20
Seite 2
Huf Tools
Process Control, Quality Assessment – Pyrometry / Photometry – ” μ-View ”
Pyrometry - Process Monitoring
- Contour Welding
- Heat Radiation
Option
- Closed Feedback Loop
(Power Control)
- Process Stability
Photometry - Quality Assessment
- Contour, QS-Welding
- Reflected Laser Radiation
Option
- Seam Interruption
- Seam Contraction
- Decomposition
Pyrometry ⇔ AUXILIARY TOOLS ⇔ Photometry
5 / 20
Huf Tools
Process Control, Quality Assessment – Modular System
GOAL
•
Modular Solution / Strategies for
- Monitoring Process
- Controlling Process
- Assessing Quality
Concept
•
Classes of Defects and Strategies
- Correspondence Defect / Signal / Strategy
- Integral Measurement (IM)
- Spatially Resolved Measurement (SRM)
•
Modular Working Head
- Optics, Filters
- Illumination (coaxial, side)
- Detectors
Stiftung Industrieforschung „ProTest“
Huf Tools
6 / 20
Seite 3
Huf Tools
Process Control, Quality Assessment
Employment Capability
•
Modular Processing Head
•
Illumination / Reaction Strategies
•
IM:
SRM:
integral measurement
spatial resolution measurement
- Laser Power
- Pyrometry
- Photometry
- Camera
Here: showing 3 movies
Huf Tools
7 / 20
Huf Tools
PA / PA, 1 / 1 mm, Different Process Parameters, 100 Hz
Good Bonding
Decomposition
Decomposition
Huf Tools
8 / 20
Seite 4
Huf Tools
PC / PC, 2 / 2 mm, 21,5 W, 2 m/min, 365 Hz
“Zero-Gap”
50 μm Gap
100 μm Gap
Huf Tools
9 / 20
Huf Tools
Process Control, Quality Assessment – Photometry
Results
a. u.
a. u.
• Seam Interruption
• Seam Contraction
• Decomposition
Limiting Factors
• Product Demands
- Tight
- Strength
- Appearance
• Optical Properties
- Transmission
- Scattering
• Local Resolution
- Spot Size
- Sensitivity
• Method, Performance
of Production
Time / Place
Pre-Scan
Post-Scan
Difference
Limits
10 / 20
Seite 5
Huf Tools
Method
Contour Welding
Product
Soft Touch Opener
Laser Source
Diode (60 W, 940 nm)
Joint
Seam Length
Hard-Soft
330 mm
Cycle Time
10 s
Process Monitor
Laser Power
Quality Assess
Photometry
Here: showing a movie of the industrial plant
11 / 20
Huf Tools
Industrial Application 2 - History / Task Definition
1. Generation (BMW)
- Soft–Hard–Combination
- Joining of the Emblem
2. Generation (BMW)
- Design-Update
- Laser Joining of the Emblem
3. Generation (BMW)
- Design Update
Chrome-Plated Buttons
- 8 Laser Joints
12 / 20
Seite 6
Huf Tools
Industrial Application 2 - Task Definition – Demands, Setup
3. Generation (BMW)
- Design Update
Chrome-Plated Buttons
Hard Parts
Laser Absorbing
TPE-A (PEBAX3533)
PA12 GF30
Button Clamp
Chrome Plated Button
Emblem
Collar
Chrome Plated Button
Soft Part
Laser Transparent
Button Clamp
13 / 20
Huf Tools
Industrial Application 2 - Approach – Decision-Matrix
Security
Cycle
Invest
Realisation
Environment
Lessons
Learned
Clipping
--
+
+
--
+
+
Gluing
--
--
+
+
--
--
Ultrasonic
+
+
+
--
+
+
Laser Welding
+
+
--
+
+
+
Technology
Clipping
Insufficient Guaranty of Clipping Function
Gluing
Insufficient Process Stability
No Quality Assessment
Cyan-Acrylat
Solvent Evaporation on Electronics
Glue Hardening Time, Temperature
Embrittlement, Costs
14 / 20
Seite 7
Huf Tools
Industrial Application 2 - Solution – Laser Transmission Welding of Plastics
Button
Clamp
Collar
Emblem
(Function Button)
Function Button
(unconnected)
Process
Laser Transmission Welding
Joint
8 x Soft-Hard
Material
TPE-A / PA12 GF30
Laser
Diode (2 x 806 nm, á 60 W)
Concept
Closed Production Loop,
2 Welding Steps in Succession
4 Half Shelfs / Carrier, 17 Shifts / Week
Monitoring
Emblem (Vision System)
Laser Power (Photo Diode)
Quality (Photometry)
Hurdles
Manifold Cavities
Material / Optical Properties Stability
- Process Stability
- Small Residual Gaps
- No Interaction Marks
Pre Mounting
Clamping Technique
Process and Quality Control
Data Management
Button
Clamp
Function Button
(unconnected)
15 / 20
Huf Tools
Industrial Application 2 - Material / Optical Fluctuations
Optical
Penetration Depth
- Process In-Stability
- Residual Gaps
- Interaction Marks
- Melt Discharge
a.c.
Gap Bridging
Capability
a.c.
Interaction Marks
a.c.
16 / 20
Seite 8
Huf Tools
Industrial Application 2 - Clamping Technique
•
Parts Positioning
•
Homogeneous Pressure
•
Minimising Residual Gaps
•
Avoiding Inherent Tensions
•
No Damage of Optical Appearance
17 / 20
Huf Tools
Industrial Application 2 - Data Management (Statistics, Traceability)
S2-E2
S2-E1
S1-R3
S1-R2
S1-R1
S1-T2
S1-T1
0
25
50
75
100
125
150
175
200
100
80
60
40
20
0
WT WT WT WT WT WT WT WT WT WT WT WT WT WT WT WT
10 2
8
1
7 13 3
9
6 11 4 16 5 12 14 15
18 / 20
Seite 9
Huf Tools
Here: showing a movie of the industrial plant
19 / 20
Huf Tools
Summary
Overall Goals
• Increase:
Quality, Process Stability, Design Opportunities
• Decrease:
Costs, Cycle Times, Processing Steps.
Enhance Process Stability
• Over-all-Consideration
- Pre-Process: Product / Process Demands, . . .
- In-Process:
Handling, Clamping, Parameter Monitoring, . . .
- Post-Process: Quality Assessment, Data Management, . . .
• Auxiliary Tools
- Correspondence: Measurement Signal / Failure, Defect / Strategy
- Process Monitoring / Controlling (Pyrometry)
- Quality Assessment (Photometry, CMOS)
Roadmap
• Early and Continuous Over-All Consideration
20 / 20
Seite 10

Beitrag lesen - Wolf Produktionssysteme GmbH

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