阅读说明：本技术 模块化焊头组件 (Modular weld head assembly ) 是由 E·E·汉森 于 2018-06-18 设计创作，主要内容包括：本公开涉及一种模块化功能块的系统,其可以用于促进以多种不同配置中的任何一种容易地组装焊头组件以允许在模块化功能块的整个互连组件上分配焊丝、气体、冷却流体和其他介质。因而,根据正在进行的焊接工艺,可以根据需要将模块化功能块混合并匹配成任何期望的配置。模块化功能块可以是一种或多种不同的焊丝输送块、气体输送块、冷却水输送块、垫板、端板、防护杯、盖板、绝缘板等的形式。(The present disclosure relates to a system of modular functional blocks that may be used to facilitate easy assembly of a welding head assembly in any of a number of different configurations to allow for distribution of welding wire, gas, cooling fluid, and other media across the entire interconnected assembly of modular functional blocks. Thus, the modular functional blocks may be mixed and matched as needed to any desired configuration, depending on the welding process being performed. The modular functional blocks may be in the form of one or more different wire feed blocks, gas feed blocks, cooling water feed blocks, backing plates, end plates, shield cups, cover plates, insulation plates, and the like.)

1. A bonding tool assembly, comprising:

a plurality of modular functional blocks, each modular functional block being interconnectable with another of the plurality of modular functional blocks such that the weld head assembly is configurable into a plurality of different configurations;

wherein the plurality of modular functional blocks comprises one of a laser beam feed block, a welding wire feed block, a gas feed block, and a fluid feed block.

2. The weld head assembly of claim 1, wherein each of the plurality of modular functional blocks includes a male portion and a female portion for interconnection with the other of the plurality of modular functional blocks.

3. The weld head assembly of claim 1, wherein each of the plurality of modular functional blocks includes one or more channels for receiving and conducting a flow of at least one of a fluid and a gas.

4. The weld head assembly of claim 3, wherein the one or more channels include a threaded opening for generating a controlled fluid or air flow through the one or more channels within each modular functional block.

5. The weld head assembly of claim 3, wherein one of the one or more channels in a first modular functional block is aligned with another of the one or more channels in a second modular functional block when connected to one another to provide distribution of fluid or gas through the weld head assembly.

6. The weld head assembly of claim 3, wherein, when connected to one another, a plurality of the one or more channels formed in a first modular functional block are aligned with a plurality of the one or more channels formed in a second modular functional block to generate a network of channels in the weld head assembly for supplying one or more of a gas and a fluid.

7. The bonding tool assembly of claim 1, further comprising one or more of an insulating spacer, an end plate, a cover plate, a backing plate, and a cover.

8. The bonding tool assembly of claim 5, further comprising one or more of an insulating spacer, an end plate, a cover plate, a backing plate, and a cover.

9. The weld head assembly of claim 1, wherein the plurality of modular functional blocks includes at least one sensor block in the form of a touch sensor block, a haptic seam tracker block, an optical seam tracker block, or a camera.

10. The weld head assembly of claim 5, wherein the plurality of modular functional blocks includes at least one sensor block in the form of a touch sensor block, a haptic seam tracker block, an optical seam tracker block, or a camera.

11. A kit of modular functional blocks for configuring and assembling a welding head into any one of a plurality of different configurations, the kit comprising:

a plurality of modular functional blocks, each modular functional block being interconnectable with another modular functional block such that the welding head is configurable into a plurality of different configurations;

wherein the plurality of modular functional blocks includes one or more of a laser feed block, a wire feed block, a gas feed block, and a fluid feed block.

12. The kit of claim 11, wherein each of the plurality of modular functional blocks comprises a male portion and a female portion for interconnecting with another modular functional block of the plurality of modular functional blocks.

13. The kit of claim 12, wherein each of the plurality of modular functional blocks comprises one or more channels to receive one of a fluid and a gas.

14. The kit of claim 11, wherein each of the plurality of modular functional blocks comprises one or more channels to receive one of a fluid and a gas.

15. The kit of claim 14, wherein at least one of the channels comprises a threaded opening for producing a controlled flow of the fluid or gas within each modular functional block.

16. The kit of claim 14, wherein, when connected to each other, one of the channels in a first modular functional block of the plurality of modular functional blocks is aligned with another one of the channels in a second modular functional block of the plurality of modular functional blocks to provide for distribution of fluid or gas through the weld head assembly.

17. A method of assembling a bonding tool, comprising:

selecting one of a plurality of modular functional blocks according to a welding process to be performed; and

coupling the selected modular functional block to a second modular functional block of the plurality of modular functional blocks;

wherein the plurality of modular functional blocks includes at least one of a laser beam feed block, a wire feed block, a shielding gas block, and a cooling water block.

18. The method of claim 17, wherein each of the plurality of modular functional blocks is interconnectable with another of the plurality of modular functional blocks such that the weld head assembly is configurable into a plurality of different configurations.

19. The method of claim 17, wherein the plurality of modular function blocks includes at least one sensor block in the form of a touch sensor block, a haptic seam tracker block, an optical seam tracker block, or a camera.

20. The method of claim 18, wherein each of the plurality of modular functional blocks comprises one or more channels to receive one of a fluid and a gas.

Technical Field

The present disclosure relates generally to a weld head assembly for use in a welding device or system, and more particularly, to a modular weld head assembly that allows the weld head assembly to be easily personalized and customized as needed for a particular application.

Background

Welding devices and processes, including hybrid laser welding devices, are well known. Such hybrid systems may include laser components and welding components, such as Gas Metal Arc Welding (GMAW) components or Submerged Arc Welding (SAW) components. One drawback of current hybrid laser welding devices is the number, placement, and management of incoming wire and other ancillary service lines to be handled (e.g., shielding gas delivery, flux delivery, torch tip cooling, etc.). As a result, the size of the horn assembly may become large and cumbersome.

Current solutions suffer from other drawbacks as well. For example, current concentric or coaxial torch devices have torch tips, gas supplies, gas diffusion, and gas shielding mechanisms all arranged coaxially, making it difficult to place multiple torches close together. Current integrated dual or in-line torch designs have very limited support for adjusting the placement of various process components, including spacing, working angle, and push/drag angle. In the hybrid laser arc welding process, current integral torch designs make it difficult to fit multiple welding wires in a small space immediately adjacent to the laser focus location, as well as gas shielding and cooling.

It would be beneficial to provide a weld head apparatus that overcomes the above-mentioned problems.

Disclosure of Invention

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

A system of modular functional blocks is disclosed herein that may be used to facilitate assembly of a welding head in any of a variety of different configurations to allow for distribution of welding wire, gas, cooling fluid, and other media throughout an interconnected assembly of modular functional blocks. Thus, the modular functional blocks may be mixed and matched as needed to any desired configuration depending on the welding process being performed. The modular functional block may take the form of one or more different wire feed blocks, gas feed blocks, cooling water feed blocks, backing plates, end plates, shield cups, cover plates, insulation plates, and the like. Additionally, the modular functional blocks may take the form of one or more electromechanical devices such as, but not limited to, seam trackers, cameras, solder delivery blocks, and the like.

In one exemplary embodiment, the present disclosure is directed to a weld head assembly including a plurality of modular functional blocks. Each modular functional block of the plurality of modular functional blocks may be interconnectable with another modular functional block of the plurality of modular functional blocks such that the weld head assembly is configurable into a plurality of different configurations. The modular functional block may include one of a laser beam delivery block, a wire delivery block, a gas delivery block, and a fluid delivery block.

Each of the modular functional blocks may include a male part and a female part for interconnection with the other of the plurality of modular functional blocks.

Each of the modular functional blocks may include one or more channels for receiving at least one of a fluid and a gas. The channels may include threaded openings for creating a controlled flow of fluid or air through the one or more channels in each block. Thus, when connected, one channel in a first modular functional block of the plurality of modular functional blocks may be aligned with another channel in a second modular functional block of the plurality of modular functional blocks to provide for distribution of fluid or gas through the weld head assembly. Thus, when connected, a plurality of channels formed in a first modular functional block of the plurality of modular functional blocks may be aligned with a plurality of channels formed in a second modular functional block of the plurality of modular functional blocks to create a network of channels in the weld head assembly for supplying one or more of a gas and a fluid.

The weld head assembly may further include one or more of an insulating spacer, an end plate, a cover plate, a backing plate, and a cap. The weld head assembly may also include one or more optional sensor blocks. The sensor tile may include one of a touch sensor tile, a haptic seam tracker tile, an optical seam tracker tile, and a camera.

In another exemplary embodiment, the present disclosure is directed to a kit of modular functional blocks for configuring and assembling a welding head into any of a plurality of different configurations. The kit may include a plurality of modular functional blocks, wherein each modular functional block may be interconnectable with another modular functional block such that the welding head is configurable into a plurality of different configurations. The plurality of modular functional blocks may include one or more of a laser feed block, a wire feed block, a gas feed block, and a fluid feed block.

In yet another exemplary embodiment, the present disclosure is directed to a method of assembling a bonding tool. The method may comprise the steps of: one of a plurality of modular functional blocks is selected according to a welding process to be performed, and the selected modular functional block is coupled to a second modular functional block of the plurality of modular functional blocks. The plurality of modular functional blocks may include at least one of a laser beam delivery block, a wire delivery block, a shielding gas block, and a cooling water block. Each of the plurality of modular functional blocks may be interconnectable with another of the plurality of modular functional blocks such that the weld head assembly is configurable into a plurality of different configurations.

Drawings

By way of example, specific embodiments of the disclosed apparatus will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view illustrating various exemplary functional blocks and other components that may be provided as part of an exemplary system or kit according to the present disclosure;

FIG. 2 illustrates a perspective view of exemplary functional blocks of the system or kit shown in FIG. 1;

FIG. 3A illustrates a front view of exemplary functional blocks of the system or kit shown in FIG. 1;

FIG. 3B illustrates a side view of the exemplary functional block shown in FIG. 3A;

FIG. 3C illustrates a top view of the exemplary functional block shown in FIG. 3A;

FIG. 4A illustrates a front view of an exemplary welding assembly for a gas metal arc welding ("GMAW") system;

FIG. 4B illustrates a side view of the exemplary GMAW welding assembly shown in FIG. 4A;

FIG. 4C illustrates a top view of the exemplary GMAW welding assembly shown in FIG. 4A;

FIG. 5A illustrates a front view of an exemplary welding assembly for a sub-arc welding ("SAW") system;

FIG. 5B illustrates a top view of the exemplary SAW welding assembly illustrated in FIG. 5A;

FIG. 6A illustrates a front view of an exemplary welding assembly for a hybrid laser arc welding ("HLAW") system;

FIG. 6B illustrates a top view of the exemplary HLAW weld assembly shown in FIG. 6A;

FIG. 7A illustrates a perspective view of an embodiment of a welding assembly for an HLAW system with a single arc tail process;

FIG. 7B shows a perspective view of the HLAW weld assembly shown in FIG. 7A;

FIG. 7C shows a side view of the HLAW weld assembly shown in FIG. 7A;

FIG. 7D illustrates a top view of the HLAW weld assembly shown in FIG. 7A;

FIG. 8 illustrates a perspective view of alternative embodiments of a welding assembly;

fig. 9 illustrates a perspective view of an exemplary horn assembly arranged to perform a butt welding process according to the present disclosure; and

fig. 10 illustrates a perspective view of an exemplary horn assembly arranged to perform a fillet welding process according to the present disclosure.

Detailed Description

Apparatuses, systems, and methods according to the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the apparatuses, systems, and methods are shown. The disclosed devices, systems, and methods may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the devices, systems, and methods to those skilled in the art. In the drawings, like numbering represents like elements throughout.

Referring to fig. 1 and 2, the present disclosure relates to a system of modular functional blocks 20, which may be provided, for example, as a kit. Modular functional block 20 may be used to facilitate easy assembly of the welding head assembly in any of a variety of different configurations to allow for distribution of welding wire, gas, cooling fluid, and other media throughout the interconnected assembly of modular functional blocks. Thus, the modular functional blocks 20 may be mixed and matched as needed to any desired configuration depending on the welding process being performed. For example, referring to fig. 1, modular functional block 20 may be in the form of one or more different wire feed blocks 22, gas feed blocks 24, cooling water feed blocks 26, aperture blocks 28 (e.g., for receiving a torch or, in the case of a laser welding process, a laser optics extension tube 30 and a laser focusing cone 32 therethrough), laser beam feed blocks 29 (as shown in fig. 6A and 6B), etc., as well as one or more backing plates 40, end plates 42, shield cups 44, cover plates 46, fillet adapters 48, insulation plates 49 (as shown in fig. 4A-5B), etc. Depending on the requirements of the welding process being performed, the wire feed block 22 may be in the form of an arc wire feed block, a flux feed block, a powdered metal feed block for feeding additional material, or the like. One or more of the pads 40 may be used to provide a desired separation distance between the various functional blocks 20. That is, one or more of the pads 40 may be used to adjust the spacing between different functional blocks 20. In this manner, the shim plate 40 eliminates the need for fine adjustment of adjustment spacers that can be used with existing devices. The insulating plate 49 may serve as an electrical insulator and may therefore be used to separate, for example, a current carrying wire feed block from other blocks. Modular functional block 20 may also include one or more contact tips 50 for coupling to, for example, wire feed block 22 in order to receive and guide the wire dispensed through wire feed block 22 in a desired manner. The modular function block 20 may also include one or more sensor blocks 60 (as shown in fig. 5A-6B), such as touch sensor blocks, tactile seam trackers, optical seam trackers, cameras, and the like. Although not shown, the assembly may include a housing to cover the entire assembly or one or more components thereof.

Modular functional blocks 20 may be configured to interconnect by any means now known or later developed to provide custom components. For example, referring to fig. 3A-3C, in one embodiment, modular functional block 20 may include interconnecting male and female portions 100, 101 for coupling together. In some embodiments, the male part 100 and the slidably fitted female part 101 are arranged on lateral sides of the modular functional block 20. The illustrated embodiment shows that adjacent modular functional blocks 20 may be coupled by a dovetail joint arrangement such that when connected, adjacent blocks 20 are transversely coupled to each other. Alternatively or additionally, the modular functional blocks 20 may be interconnected by fasteners or the like. For example, the modular functional blocks 20, the backing plates 40, the insulating plates 49, etc. may have flat abutting surfaces so that abutting portions of block-to-block, plate-to-block, gasket-to-block, plate-to-gasket, etc. may be flat, and the gasket, plate, block, etc. may be fixed by using bolts or fasteners. In this arrangement, referring to fig. 2, each manifold (e.g., gas manifold 122, water supply manifold 126, water return manifold 128, etc.) may include an annular recess 127 circumferentially surrounding the manifold, e.g., for receiving a seal such as an O-ring, to seal the connection of block-to-block, plate-to-block, gasket-to-block, plate-to-gasket, etc.

Referring to fig. 3A-3C, each individual modular functional block 20 may include one or more internal channels 130 to allow fluid (e.g., liquid and/or gas) to flow between interconnected modular functional blocks 20. That is, the functional block 20 may include one or more channels 130 formed therein such that gas and/or cooling water may be distributed to various components of the system through the interconnected functional blocks. Additionally, referring to fig. 2, one or more of the functional blocks may include a manifold 119 for providing gas or fluid distribution from one modular functional block 20 to the next. The manifold 119 may have a larger diameter than the cooling channels 130. Additionally, the cooling channels 130 may intersect the manifold 119 to, for example, circulate fluid or gas through each functional block 20 in three dimensions. Each manifold 119 may include a recessed boss 127 (e.g., an enlarged opening) around the circumference of the manifold 119, for example, for receiving a seal such as an O-ring to seal the connection of block-to-block, plate-to-block, gasket-to-block, plate-to-gasket, or the like. For example, the functional block 20 may include an air inlet 120, an air manifold 122, an air diffuser 124, a water supply manifold 126, and a water return manifold 128. In addition, the functional block 20 may include a cooling channel 130. The functional block 20 may also include an access hole 132 for receiving a threaded hole for controlling the flow of gas from the main gas supply manifold to the gas passages within the block. In use, the channels, ports and manifolds may create a network of openings and channels for supplying gas and/or cooling water flow between the various interconnected modular function blocks, such that supply and return conduits for gas and/or water may be connected to the system to provide and/or recycle gas and/or liquid through the function blocks 20.

The water delivery block 26 may provide for the distribution of cooling water. The gas delivery block 24 may provide for the distribution of gas. That is, the blocks 24, 26 may include one or more manifolds, channels, inlets and outlets for distributing water and gas within the block to adjacent connecting blocks. The block 20 may also include threaded openings and threaded plugs for sealing the ends, passages, inlets, outlets of the manifold as desired. That is, the manifold, channels, inlets, outlets may include threaded openings for receiving threaded plugs to create controlled flow channels within each block for distributing and metering gases and fluids. A threaded plug and orifice (not shown) may be threaded into the threaded opening to control/meter the flow rate of gas or fluid therethrough. As previously described, O-rings (not shown) may be provided between the functional blocks 20 to ensure proper sealing between the blocks 20 and thus ensure fluid and gas integrity. For example, O-rings may be positioned between corresponding openings of adjacent modular functional blocks 20.

The modular functional block 20 may be made of any suitable material now known or later developed, for example, the functional block may be made of a suitable metal such as brass. In addition, the functional blocks 20 may vary in size and shape to suit the desired application.

In use, the weld head assembly may be broken down into individual modular functional blocks 20, where each block 20 may be responsible for one or more of gas, wire, and cooling distribution. It should be understood that the disclosed arrangement may allow a user to mix and match various blocks to achieve a desired weld head configuration for the welding process being performed. Thus, the modular functional block 20 may provide a variety of different configurations for the bond head assembly.

Referring to fig. 4A-4C, an exemplary embodiment of a welding assembly 200 for a gas metal arc welding ("GMAW") process is illustrated. A variation of the GMAW welding assembly 200 may include first and second wire feed blocks (e.g., arc welding wires) 22 separated by an insulating spacer 49. Each of the first and second wire feed blocks 22 may be coupled to or may contain a contact tip 50 for introducing the wire to a desired location below the assembly. Although not shown in fig. 4A-4C, it should be understood that variations of the GMAW welding assembly 200 may also include one or more of the gas delivery block 24, cooling water delivery block 26, orifice block 28, backing plate 40, end plate 42, shield cup 44, cover plate 46, insulator plate 49, and other blocks, as desired.

Referring to fig. 5A and 5B, an exemplary embodiment of a welding assembly 300 for a submerged arc welding ("SAW") process is illustrated. Variations of the SAW welding assembly 300 may include first and second subassemblies 310, 320. The first subassembly 310 may include first and second wire feed blocks (e.g., arc wires) 22 on either side of a third wire feed block (e.g., neutral wire feed block) 22 a. Each wire feed block may be coupled to or may contain a contact tip 50 for introducing the wire to a desired location below the assembly. The second subassembly 320 may include a wire feed block (e.g., arc welding wire), a flux feed block 22b, and a sensor block (e.g., a tactile seam tracking sensor block) 60. Wire feed block 22 may be coupled to or may include a contact tip 50. The first and second subassemblies 310, 320 may be separated by one or more insulator plates 49. The flux feed block 22b may be separated from the arc wire feed block 22 by one or more insulating plates 49. It should be understood and not shown in fig. 5A and 5B that variations of SAW welding assembly 300 may also include one or more of gas delivery block 24, cooling water delivery block 26, orifice block 28, backing plate 40, end plate 42, shield cup 44, cover plate 46, insulator plate 49, and other blocks as desired.

Referring to fig. 6A and 6B, an exemplary embodiment of a welding assembly 400 for a hybrid laser arc welding ("HLAW") process is illustrated. Variations of the HLAW welding assembly 400 may include a laser beam feed block 29, first and second wire feed blocks 22, and a sensor block (e.g., a tactile seam tracking sensor block) 60. Wire feed block 22 may be coupled to or include a contact tip 50. It should be understood that although not shown in fig. 6A and 6B, variations of the HLAW welding assembly 400 may also include one or more of the gas delivery block 24, the cooling water delivery block 26, the orifice block 28, the shim plate 40, the end plate 42, the shield cup 44, the cover plate 46, the insulator plate 49, and other blocks, as desired.

As will be appreciated by those of ordinary skill in the art, the modular function blocks 20 may allow an end user to simply and efficiently reconfigure components by adding, removing, and/or changing the blocks as needed depending on the requirements of the welding process being performed. For example, referring to fig. 7A-7D, an exemplary embodiment of a weld assembly 500 for a single arc tail process is shown. Welding head assembly 500 may include a wire feed block 22 coupled to or including a contact tip 50, a gas feed block 24, a cooling water feed block 26, an aperture block 28 for receiving a laser optical extension tube 30 (for forming a laser focus cone), one or more backing plates 40, an end plate 42, and a shield cup 44 and a cover plate 46 (not shown in fig. 7A-7D for clarity).

Fig. 8 illustrates how a variety of different horn assemblies can be constructed using the foregoing components to construct a single arc trailing weld assembly 550, a series arc trailing weld assembly 560, and a series arc lead-lag weld assembly 570 simply by adding or changing the assembly configuration of modular functional blocks 20. In some embodiments, these different weld head configurations may be "built up" by a user, while in other embodiments, the desired configuration may be manufactured and provided to the user in an integrated form.

Additionally, weld head assembly 100 may be arranged such that the entire assembly can be rotated about an axis to achieve an additional degree of rotation. Referring to fig. 9 and 10, the modular horn assembly 100 may be rotatably coupled to the welding arm 102 such that the rotational position of the horn assembly may be adjusted depending on the type of welding process employed and the workpiece being welded. For example, fig. 9 illustrates the position of the horn assembly for a butt welding process, and the horn assembly may be rotatable about axis "a-a" to adjust the relative rotational position of the laser head and the arc horn. Fig. 10 illustrates the position of a horn assembly for a fillet welding process, wherein the horn assembly is rotatable about an axis "a-a" to adjust the relative rotational position of the laser head and the arc horn.

By breaking down a conventional weld head assembly into individual designated functional blocks, the disclosed system enables a user to customize the weld head assembly using a set of generic components. The disclosed system also enables a user the ability to position incoming welding wire and other support service lines closer to each other and to position functional blocks closer to the laser beam than conventional torches. In addition, the modular functional block may increase the user's ability to easily combine critical components in a variety of different combinations and sequences, eliminate multiple redundant media delivery and dispensing systems (thus reducing components, weight, size, cost, etc.) by using a common channel, reduce the size and weight of the welding assembly to improve part accessibility and operability, simplify the setting and calibration of critical process variables, reduce the envelope and mass of the welding head assembly, provide greater flexibility in configuring the process to suit each individual application, and integrate process sensors into functional blocks, thereby reducing size and complexity.

The figures show only an exemplary configuration of the weld head assembly, and those of ordinary skill in the art will appreciate that the actual layout and configuration of the modular functional blocks may vary to suit the needs and desires of the user. Additionally, although exemplary components for GMAW, SAW, and HLAW processes have been shown, the present system may be used in any welding process.

As used herein, an element or step recited in the singular and proceeded with the word "a" or "an" should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recited. Furthermore, references to "one embodiment" of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, for convenience and clarity, terms such as "front," "back," "outer," "inner," "top," "bottom," "upper," "lower," "upward," "downward," "vertical," "horizontal," "lateral," "longitudinal," "height," and "width" may be used herein to describe the relative positioning and orientation of the device and its various components, the geometry and orientation of each component with respect to the device as it appears in the figures. While certain embodiments of the disclosure have been described herein, it is not to be understood that the disclosure is limited thereto, but rather should be construed to be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.