激光塑料焊接过程

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塑料零部件的焊接工艺

不同尺寸和形状的塑料零部件在不同的应用中焊接起来。LPKF设备采用不同的焊接工艺形成笔直焊缝或者复杂3D几何图形,高质量的塑料零部件满足从安全气密性到视觉外观的高要求。

如何用激光进行塑料焊接?

透过式激光焊接技术

通过透光式激光焊接技术进行连接的塑料零部件透光率属性是不尽相同的。将透光与吸光两种热塑性材料用夹具夹在一起,透光材料在上,吸光材料在下,施以一定夹持压力。激光束穿透上层透光工作,到达下部的吸光材料表面,激光光能转变成热能,使其表面熔化,同时热量也以传导方式,从底面传递到与其压接的上层透光工件的接触面上,使其融化,从而实现激光热熔焊接。最终形成如同底层材料般可靠坚实的塑料连接体。

透光率检测设备TMG3

获取塑料焊接透光数据,更好确保焊接质量。LPKF同时提供一个透光测试设备TMG3来帮助用户更好地焊接塑料。

LPKF产品线中的特殊产品:新增针对透明对透明塑料的ClearJoining工艺流程供客户选择。

哪一种工艺是最适合您的应用?期待您的问询!

 激光塑料焊接方式


激光塑料焊接技术是通用的,然而焊接工艺是多样化的。查询以下哪种焊接方式最适合您的应用。
准同步焊接

原理应用

可靠密封传感器或电子元件外壳

主要特点:

  • 洁净可靠的二维零部件连接
  • 对加工周期短和大批量的生产性价比极高
  • 过程可监控
  • 扫描装置可编程,非常灵活
  • 纠正焊接轮廓或新产品,无需不同光学元件和掩膜;
  • 非常适合最大尺寸为 400 mm x 400 mm 的元件;
  • 相对于非激光工艺,极大的降低了夹具成本

过程:

在准同步焊接方法中,整个焊线同时塑化。激光持续提供能量直到达到指定焊接深度。 光学扫描仪沿接合线引导激光束。激光束可在 X 和 Y 方向控制。由于扫描速度快,材料沿整个焊线融化,因此焊接件沿此焊缝几乎同时被焊接。测量熔深(熔化行程监视)可定性评估焊接工艺结果。高温计控制能可靠识别焊线中的任何异常。
 

客户定制的焊接工艺

如果您有详细的具有挑战性的塑料焊接需求,如果您的项目无法用标准化设备完成。我们将接受任何挑战,并为您的具体项目准备各种型号的激光焊接塑料设备。例如:/p>

  •     激光、引导光束和控制系统的定制组合
  •     研发手动装配工作站
  •     零部件自动上料
  •     复杂的机器人工作站

LPKF应用中心的专家们凭借多年项目经验,熟悉各种生产流程。结合广泛的专业知识,我们有信心为您研发满足您需求的定制化激光焊接方案。

透明部件的激光透射焊接(透明连接)

Primary applications:

  • Medical technology applications, such as catheters and anus praeter
  • Microfluidics

 
Main characteristics:

This procedure overcomes the limits of traditional transmission welding and enables laser light to be absorbed even in clear components. 
 
Procedure:

With laser transmission welding, one of the two components needs to absorb the laser energy. So what can be done with two transparent plastic components that are to be joined with all of the benefits of laser technology? LPKF has a solution for this: the patented LPKF ClearJoining procedure for clear-clear joints without additives.
Our application engineers can tell you if this procedure is suitable for your application as well. Just get in touch with us!

复合焊接

Principal applications:

  • Automotive industry, for example taillights, headlights, speedometers
  • Large, spatial components where the weld seam is directly visible and for which there are high aesthetic demands

 
Main characteristics:

  • Reliable processing with a high level of aesthetic quality
  • Tempering after welding is omitted or greatly reduced
  • No upper die is necessary
  • No wear and no contamination
  • High level of productivity and flexibility

 
Procedure:

In patented LPKF hybrid welding, special halogen spotlights provide additional energy in the welding zone. This combination increases the process speed and processes aesthetically high-quality weld seams, while simultaneously reducing stress. LPKF hybrid welding thus achieves what other welding processes cannot always perform: reliable, impeccable, and nearly stress-free welding seams without the need for follow-up treatment.

The LPKF solution’s use of the complete weld head on a multi-axis robot allows a high level of flexibility.

3D摆振焊接

Principal applications:

Welding large 3D components with a variable weld seam width, e.g. taillights in cars
 
Main characteristics:

Patented, newly developed high-performance welding system

  • For series production of plastic components up to 1000 mm x 750 mm in size
  • The weld seam width can be infinitely adjusted from 1.5 mm to 5 mm
  • Flexibility in the Z direction: height differences up to 400 mm
  • Following the welding process through seam monitoring
  • Very short cycle time
  • Robust process

 
Procedure:

Wobble welding is a special welding process for large 3D components. Using additional amplitudes in a quasi-simultaneous welding process, the laser beam is deflected perpendicular to the feed direction, thereby making it possible to produce different weld seam widths between 1 mm and 5 mm with particularly homogeneous temperature distribution. Local tolerances are balanced out. Machine-specific software automatically activates the wobble function and calculates uniform energy input levels, even when there are differences in height.

径向焊接

Principal applications:

Joining cylindrical bodies
 
Main characteristics:

  • Simpler and more robust system structure
  • Faster welding process through rotating movement
  • Reliable process monitoring
  • Possibility of adjusting parameters
  • Dependable quality with an unbeatable good parts yield rate

 
Procedure:
When a rotation body is being joined, the component is rotated axially multiple times in order to uniformly heat up the weld seam using a principle similar to that of contour welding. The required contact pressure comes about through the use of an interference fit between the components being joined.

If the component itself cannot be rotated, then alternative versions of this welding procedure are used: Either the optics spin around the stationary component, or a mirror and scanner-based laser head focus the laser beam on a revolving, horizontal welding plane.
 

轮廓焊接

Principial applications:

Small to large components, such as classic, car lights, and solar panels, including 3D applications and microfluid components.

 

Main characteristics:

  • A predefined contour is traced during the welding process.
  • Local heating
  • Process monitoring
  • Handled through a scanning unit, robot, or axis

 

Procedure:

Contour welding is used to process both small and large components, such as chassis, car lights, and solar panels. It differs to widespread quasi-simultaneous and simultaneous versions mainly in its feed rate.

A positioning system guides the laser beam along the weld seam once, with the laser either directly moved by the robot or coupled to moving focusing optics by means of glass fibers.

准同步焊接

Principal applications:

Sealing large quantities of sensor or electronic housings

Main characteristics:

  • Clean and reliable two-dimensional component joints
  • Particularly cost-effective due to short cycle times and large batch numbers
  • Process monitoring
  • Very flexible due to the ability to program the scanning units
  • Corrections of the welding contour or new products without the need for other optics or masks
  • Ideal for components up to at most 400 mm x 400 mm in size
  • Significantly reduced tooling costs compared to non-laser-based processes

Procedure:

In quasi-simultaneous welding, the laser beam is guided along the weld seam and can be steered in the X and Y directions. The laser continues to deliver energy until the desired welding depth has been reliably attained. Due to the high scanning speed, the material melts along the entire weld seam, causing the components to join more or less at the same time. Seam monitoring allows qualitative statements to be made about the welding result. Pyrometer monitoring reliably detects flaws in the weld seam.
 

轮廓焊接

Principial applications:

Small to large components, such as classic, car lights, and solar panels, including 3D applications and microfluid components.

 

Main characteristics:

  • A predefined contour is traced during the welding process.
  • Local heating
  • Process monitoring
  • Handled through a scanning unit, robot, or axis

 

Procedure:

Contour welding is used to process both small and large components, such as chassis, car lights, and solar panels. It differs to widespread quasi-simultaneous and simultaneous versions mainly in its feed rate.

A positioning system guides the laser beam along the weld seam once, with the laser either directly moved by the robot or coupled to moving focusing optics by means of glass fibers.

径向焊接

Principal applications:

Joining cylindrical bodies
 
Main characteristics:

  • Simpler and more robust system structure
  • Faster welding process through rotating movement
  • Reliable process monitoring
  • Possibility of adjusting parameters
  • Dependable quality with an unbeatable good parts yield rate

 
Procedure:
When a rotation body is being joined, the component is rotated axially multiple times in order to uniformly heat up the weld seam using a principle similar to that of contour welding. The required contact pressure comes about through the use of an interference fit between the components being joined.

If the component itself cannot be rotated, then alternative versions of this welding procedure are used: Either the optics spin around the stationary component, or a mirror and scanner-based laser head focus the laser beam on a revolving, horizontal welding plane.
 

3D摆振焊接

Principal applications:

Welding large 3D components with a variable weld seam width, e.g. taillights in cars
 
Main characteristics:

Patented, newly developed high-performance welding system

  • For series production of plastic components up to 1000 mm x 750 mm in size
  • The weld seam width can be infinitely adjusted from 1.5 mm to 5 mm
  • Flexibility in the Z direction: height differences up to 400 mm
  • Following the welding process through seam monitoring
  • Very short cycle time
  • Robust process

 
Procedure:

Wobble welding is a special welding process for large 3D components. Using additional amplitudes in a quasi-simultaneous welding process, the laser beam is deflected perpendicular to the feed direction, thereby making it possible to produce different weld seam widths between 1 mm and 5 mm with particularly homogeneous temperature distribution. Local tolerances are balanced out. Machine-specific software automatically activates the wobble function and calculates uniform energy input levels, even when there are differences in height.

复合焊接

Principal applications:

  • Automotive industry, for example taillights, headlights, speedometers
  • Large, spatial components where the weld seam is directly visible and for which there are high aesthetic demands

 
Main characteristics:

  • Reliable processing with a high level of aesthetic quality
  • Tempering after welding is omitted or greatly reduced
  • No upper die is necessary
  • No wear and no contamination
  • High level of productivity and flexibility

 
Procedure:

In patented LPKF hybrid welding, special halogen spotlights provide additional energy in the welding zone. This combination increases the process speed and processes aesthetically high-quality weld seams, while simultaneously reducing stress. LPKF hybrid welding thus achieves what other welding processes cannot always perform: reliable, impeccable, and nearly stress-free welding seams without the need for follow-up treatment.

The LPKF solution’s use of the complete weld head on a multi-axis robot allows a high level of flexibility.

透明部件的激光透射焊接(透明连接)

Primary applications:

  • Medical technology applications, such as catheters and anus praeter
  • Microfluidics

 
Main characteristics:

This procedure overcomes the limits of traditional transmission welding and enables laser light to be absorbed even in clear components. 
 
Procedure:

With laser transmission welding, one of the two components needs to absorb the laser energy. So what can be done with two transparent plastic components that are to be joined with all of the benefits of laser technology? LPKF has a solution for this: the patented LPKF ClearJoining procedure for clear-clear joints without additives.
Our application engineers can tell you if this procedure is suitable for your application as well. Just get in touch with us!

客户定制的焊接工艺

Do you have specific, challenging plastic welding tasks? And do you have the impression that your project cannot be completed using standardized machines? We will take on any challenge and prepare a wide variety of versions for customer-specific tasks for laser welding of plastics. For example:

  •     A customized combination of the laser, beam guidance, and control system
  •     Development of manual assembly workstations
  •     Automatic component feed
  •     Complex robotic stations

The experts at the LPKF application center are familiar with a wide range of production processes thanks to many years of supervising projects. You profit from this extensive expertise when we develop a customer-specific laser welding solution for you.

持续追踪助力工艺过程监控

LPKF激光塑料焊接

LPKF塑料焊接具有三个显著的优势:成本收益、技术领先且质量可靠。品质保证的重要性不断提高, LPKF激光塑料焊接确保品质输出。激光塑料焊接是一种非常可靠的焊接工艺。为了满足高的标准要求,LPKF还配备了工艺过程控制,以确保焊接过程中焊缝的质量。其优势在于是激光在加工过程中可实时修正,因此可避免报废。预加工的影响,可快速检测材料属性的变化,故障零件可从生产工艺中及时筛出。

LPKF的四个补充测试工艺

品质保证源于可靠的焊接工艺以及不断测试可行性。LPKF系统集成了工艺过程监控,以及纠正最小偏差的调节机制。

  •     熔深监控检测直接和间接缺陷,确保防护等级达到IP69。
  •     高温计监测温度变化— 检查焊接结果是否一致
  •     烧灼检测使用光学传感器找出烧灼
  •     摄像头支持的图像采集检测焊缝中最微小的缺陷。

这些不同工艺过程监控的使用取决于所选材料和焊接方式。将两个或更多方法与端到端数据采集相结合,甚至可满足不同行业苛刻的标准要求。

如果材料的激光透光率需要提前测试,则使用LPKF TMG3透光率测试仪。在进行激光塑性焊接之前,可以快速、方便地检查光传输性能。这样,当不合适的零部件进入生产流程之前,就会发现由于预加工影响而产生的材料偏差。这在保证整体质量的前提下是非常必要的。

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