• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:

    公开号:SE1050705A1
    申请号:SE1050705
    申请日:2010-06-28
    公开日:2011-10-29
    发明作者:David R Sigler；Michael J Karagoulis
    申请人:Gm Global Tech Operations Inc；
    IPC主号:
    专利说明:

    With regard to spot welding of steel, it is known that for a number of welds, the copper electrode will soften and flatten into the mold due to the combined effect of the clamping pressure, high temperature and the alloy of copper with the galvanized steel surface. Accordingly, it has been apparent from the prior art that when the copper electrode is used to weld steel or galvanized steel, the electrode must be periodically machined to recreate the electrode to prolong its useful life and maintain the welding quality.
    With reference to the use of a copper electrode for welding aluminum pieces, it is known that a build-up of aluminum from aluminum layers on the electrode surface can result in the formation of eutectic Cu-Al with a low melting point which ultimately gives pits in the electrode surface. To minimize the point grip reaction, the prior art has discovered that the copper electrode used for welding aluminum pieces occasionally needs to be recoated to remove the contaminants from the surface thereof.
    Accordingly, with respect to welding from aluminum to aluminum, U.S. Pat. Patent 6,861, 609, assigned to the assignee of this invention, texturing the electrode side by blasting with small sand grain particles or grinding with coarse sandpaper to clean and reproduce the surface of the copper electrode. In addition, the American patent application describes serial no. 11/536 001, filed September 28, 2006, also assigned to the assignee of this invention, a method of using a tool for machining the tip of the copper electrode and designing a series of concentric rings thereon. Cutting or trimming the surface during the formation of the concentric rings was created to both clean the electrode surface and form a texture.
    Thus, although the prior art has developed techniques for welding steel to steel, and techniques for welding aluminum to aluminum, welding of steel to steel and aluminum to aluminum using a welding gun has not been performed for two primary reasons. First, welding electrodes 10 for spot welding of one of the materials are typically not suitable for spot welding of the other material. For example, a ball tip electrode used for spot welding of steel causes superfluous layer deformation and weld metal ejection when used for spot welding of aluminum. Second, contamination of aluminum pieces with iron-containing particles transferred by the welding electrode can cause galvanic corrosion and premature sheet metal breakage.
    It would therefore be desirable to provide further improvements in the welding process so that a single welding gun, using the same pair of copper electrodes, can perform both welds to steel pieces and also aluminum to aluminum pieces without causing the problems described above.
    SUMMARY OF THE INVENTION A method of welding a plurality of aluminum to aluminum welds and a plurality of steels to steel welds using the same welding equipment comprises providing a resistive spot welding device having a pair of welding electrodes having an electrode side with a welding radius in the interval between 20 mm 40 mm. The electrode material is selected with sufficiently high temperature strength so that the steel welding process does not overly soften the electrode and damage the efficiency of the texture used for aluminum spot welding. Series of aluminum to aluminum welds are performed, and then after completion of aluminum to aluminum welds, series of steel to steel welds are performed. After completion of steel for steel welds, the welding electrodes are cleaned with an abrasive to remove any build-up or contamination of iron on the electrodes. In the event that the electrodes have been flattened, machining of the electrodes is then provided and then abrasive cleaning is performed to recreate the texture of the surface. Additional areas of use of the present invention will become apparent from the detailed description provided hereinafter.
    It is to be understood that the detailed description and the specific examples, in describing exemplary embodiments of the invention, are intended for illustrative purposes only and are not intended to limit the scope of the invention.
    BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be more fully explained in the detailed description and the accompanying drawings, in which: Fig. 1 is a schematic illustration of a welding device used for welding electrodes according to this invention in spot welding of both aluminum to aluminum and steel to steel.
    Fig. 2 is a perspective view of an electrode for practical use of this invention.
    Fig. 3 is a plan side view of the electrode according to Figs. 2 with parts removed.
    Fig. 4 is a planar side view of a pair of electrodes being cleaned and re-textured by a grinding wheel.
    Fig. 5 is another planar side view of a pair of electrodes being cleaned and re-textured by a grinding wheel.
    Fig. 6 is another planar side view of a pair of electrodes being cleaned and re-textured by a grinding wheel. DESCRIPTION OF THE PREFERRED EMBODIMENT Fig. 1 is a schematic view of a side view of a representative spot welding device 10 with the accompanying equipment used for spot welding procedures. In such a method, a unit of two or more sheet metal pieces 13 and 14 to be welded and delivered by a conveyor or other device is prepared for the welding gun device 10. The welding gun device 10 is typically mounted on a robot capable of moving the welding gun device 10. along the metal pieces 13 and 14 to quickly produce a series of individual resistance spot welds. The metal pieces 13 and 14 can both be made of aluminum, or both can be made of steel. Fig. 1 shows the metal pieces 13 and 14 balanced between a pair of axially aligned and opposing electrodes 16 and 18 of a gun arm 20. The gun arm 20 has the shape of a C so that the opposing electrodes 16 and 18 can be moved to support and push against the opposite sides of the metal pieces 13 and 14. In the arrangement shown, the electrode 16 is mounted on a shaft 17 which is inserted into a holder 22 attached to a fixed arm 24 of the welding chair arm 20. The second electrode 18 is mounted on a shaft 19 and inserted into another holder 26 supported on an air cylinder or servomotor 28. The air cylinder or servomotor 28 is adapted to axially move the electrode 18 into clamping engagement with the outer surface of the layer 14. A high pressure air source from a remote source, supplies air through a programmable air regulator 30 through an air line 32 to the cylinder 28 to provide clamping force. Alternatively, a servomotor control provides current and voltage to the servomotor to provide clamping. During a spot welding series, advance the appropriate application of air pressure to the air cylinder 28 or the movement of the servomotor holder 26 so that the electrode 18 presses the layers 13 and 14 against the stationary electrode 16 with a force in the order of 500-1 500 pounds. Welding gun 20, typically mounted on the end of a robot arm, is connected to a robot welding control device 34. The control device 34 handles and operates the programmable air regulator 30 and also a welding control device 36.
    The welding control device 36 controls the overflow of a primary welding current to the welding transformer, which provides current to the electrodes. At the command of the welding control device 36, primary current is supplied through the primary current line 38 to the welding transformer 40. Welding transformers 40 convert primary current to a secondary welding current with lower voltage and higher current which is then provided through a secondary current line 42 and electrode holder 26 as well. as conductive gun arm 20 and electrode holder 22.
    Referring now to Fig. 2, there is described a single design of a copper electrode 16 specially designed to effect both welding of steel pieces and welding of aluminum pieces. As can be seen in Fig. 2, the electrode 16 has a round body 50 with a truncated conical end 52. The body 50 has a hollow receiver 51 adapted to receive a shaft 17 for insertion into the electrode holder 22. The welding side 54 of the truncated conical end 52 is arched. More specifically, we have found that the radius of curvature of the arched electrode welding side 54 can be in the range between 20 mm and 40 mm to provide an electrode that is effective both for turning aluminum into aluminum welds and steel into steel welds. We have also found that the diameter "B" of the curved welding side 54 of the electrode 16, Fig. 3, is a feature of the welding electrode design, and that the diameter of the electrode welding side 54 is related to the desired welding size of aluminum to the aluminum welds.
    The smallest acceptable welding diameter for aluminum to aluminum is approximately 4x (t) ”2 where t is the thickness of the thinner layer of aluminum in a two-layer stack of aluminum. We have found that the diameter B of the welding side 54 should be at least 1.5 mm larger than the acceptable welding diameter, and preferably the diameter of the electrode welding side 54 should be at least 3 mm larger than the acceptable welding diameter. As an example, if the thinner layer of aluminum is 1 mm thick, the welding diameter for welding 1 mm thick aluminum layer should be 4 mm, 4x (t) ”2 = 4 mm, and the diameter of the welding surface 10 15 20 25 30 54 should be 4 mm, plus at least 1.5 mm. The diameter B should thus be 5.5 mm in diameter. Or the diameter of the welding surface 54 should be 4 mm plus 3 mm so that the diameter becomes 7 mm.
    In addition, we have found that the electrode surface 54 should be textured to provide a surface roughness in the range of 2-50 microns to penetrate the strong adhesive oxide found in aluminum materials. In order for the electrode to function successfully, we have also determined that the electrode material must have a high conductivity, have a high hardness or yield strength, and be able to withstand softening at elevated temperatures. The electrode yield strength should be at least 400 MPa and preferably above 500 megapascals (MPa) for the texture to have sufficient durability during use. The alloy must withstand softening when exposed to high temperatures achieved during spot welding of steel. We have found that the alloy must not soften at a temperature of at least 400 ° C and preferably higher than 500 ° C. Finally, the alloy must have sufficient electrical conductivity to prevent overheating during the transmission of high welding current required for aluminum.
    This must be higher than 80% conductivity according to the International Annealed Copper Standard (IACS) and preferably higher than 90% IACS.
    We have also decided that during welding procedures (the use of) where a single welding gun is used, to make welds in both aluminum pieces and steel pieces, the completion of all aluminum to aluminum welds shall be included, before the performance of steel to steel welds. More specifically, we have found that the design of steel for steel welds will cause the build-up of zinc and iron impurities on the copper electrodes which will then be transferred to the aluminum pieces and prevent the achievement of an effective corrosion-resistant weld in the aluminum piece. However, even solid aluminum will be taken up by the electrode during the performance of aluminum to aluminum welds, we have found that the fouling of the steel welding with aluminum is not as problematic as the fouling of the aluminum welding with zinc and iron. Consequently, it has been decided that the sequence of aluminum to aluminum welds must be completed before the execution of steel to steel welds in order to avoid the situation in which the contamination resulting from steel to steel welds can be transferred to aluminum to aluminum welds. In addition, the design of steel for steel welds degrades the texturing faster than the design of aluminum for aluminum welds, which thus also indicates that aluminum for aluminum welds should be made before the design of steel for steel welds.
    It has also been decided that the subsequent execution of a series of steel for steel welds, the electrodes should then be cleaned and textured before aluminum for aluminum welds is started again. Cleaning and texturing the electrodes before aluminum for aluminum welding ensures that no iron or zinc fouling from galvanized steel pieces is transferred to the aluminum pieces and that the electrode has a texture that is suitable for aluminum welding.
    In addition, if extended aluminum welding is envisaged, the aluminum welding can be temporarily stopped and an intermediate cleaning and texturing process can be performed to recreate the texture and remove any existing buildup of aluminum, thus avoiding corrosion and pitting of the electrode side 54 which can be caused when Attempts are being made to make too many aluminum for aluminum welds.
    This cleaning / texturing of the welding electrodes can be accomplished most effectively by using a flexible abrasive element such as a rubber coated silicone wheel, a Scotch-Brite wheel, or a stainless steel brush wheel to both clean the electrodes and recreate the desired surface texture. The welding gun robot thus aligns the welding gun with the abrasive material and then the abrasive material can be rotated towards the electrode surface. Alternatively, the abrasive material can be held stationary and the robot can rotate or transfer the electrode side across the surface of the axed abrasive material. The abrasive both removes the build up of aluminum and also creates a series of pits or ridges in the surface to recreate the desired surface texture. The cleaning process must remove all contaminants that have built up and do so in a sufficiently short time so as not to disturb production.
    Fig. 4 shows the example of a flexible tool wheel 56 rotating on a horizontal axis 58 with the opposite electrodes 16 and 18 pressing on the edge 64 of the flexible tool wheel 56. The robot can rotate the electrodes 16 and 18 back and forth in the direction of the arrows 68 so that the entire curved surface of the side 54 of the electrodes is evenly touched by the edge 64 of the flexible tool wheel 56.
    Fig. 5 shows another example of a fixed grinding wheel 74 rotating on a horizontal axis 78 with the opposite electrodes 16 and 18 pressing on the opposite surfaces 80 and 82 of the rotating grinding wheel 74. In Fig. 5, the grinding wheel 74 is a fixed grinding wheel with curved bottom grooves 84 and 86 which matches the curvature of the electrode surface 54. The robot can rotate the electrodes 16 and 18 back and forth in the direction of the arrows 88 so that the entire surface of the electrode side 54 of the electrodes 16 and 18 will be evenly connected to the sides 80 and 82 of the grinding wheel 74.
    Fig. 6 shows another example of a rotating grinding wheel 90 engaged in a rotating tool 92 rotating on a shaft 96 coinciding with the shaft of the opposite electrodes 16 and 18, which presses on the opposite surfaces 98 and 100 of the rotating grinding wheel 90. In Fig. 6, the grinding wheel 90 may be a fixed grinding wheel with curved bottom grooves 104 and 106 which matches the curvature of the electrode surface 54. Or the grinding wheel may be a flexible element which gives the curved shape of the electrode surface.
    In addition, we have found that the method should include monitoring of the electrodes in the event of flattening occurring, which typically occurs during spot welding of steel due to the higher temperatures and pressures that occur. The monitoring is most easily achieved by using a robot-mounted, servo gun equipment with sensors to monitor the servo frame displacement. The length of each electrode can be determined by the robot advancing the stationary electrode into contact with a reference block, such as a steel block mounted in a fixed position. The monitoring of the robot movement required for contact with the stationary electrode will provide the length of the stationary electrode. The closure of the servo gun and the monitoring of the frame movement will give the length of the movable electrode. Comparison of the electrode length that has been determined at an earlier time is used to determine the shortening of the electrode due to flattening. Once one of the electrodes has reached a predetermined degree of shortening, the electrodes will be machined and a new length reference point determined. For servo guns that are not mounted on robots, gun closure can still determine the electrode length change, but closure will give the total change of both electrodes and not the length change of individual electrodes. The determination of an electrode length will preferably be made while the pieces are transported between stations and no welding is in progress. Preferably, the proportion of shortening will not exceed 0.1 mm before machining is initiated. Alternatively, the robotic control will be designed to track the number of welds made, especially steel welds, and at a predetermined number, machining is initiated. The electrodes are machined to recreate the shape according to Figs. 2. Electrode processing equipment and processes are well known in the prior art, to restore the shape of the electrode to that shown in Fig. 2. More specifically, the machining process removes the flattened material and restores the desired side diameter and radius of curvature to electrode surface 54.
    After machining and recreating the appropriate shape, the electrodes were again scraped off the abrasive material to recreate the desired textured surface.
    Thus, it is to be understood that the invention provides a new and improved welding method which can effect welding together of both aluminum 11 to aluminum pieces and steel to steel pieces through a single welding gun in a single manufacturing cell.
    权利要求:
    Claims (18)
    [1]
    A method of welding a plurality of aluminum to aluminum welds and a plurality of steel to steel welds, by electric resistance welding, using the same welding equipment comprising: providing a resistance point welding equipment having a pair of welding electrodes having a radius of curvature of the electrode side in the interval between 20 mm and 40 mm, said electrode side being textured with a roughness in the interval 2-50 μm; first making a series of aluminum to aluminum welds; then performing a series of steels to steel welds, after completion of aluminum to the aluminum welds; then cleaning the welding electrodes, after completing steel to the steel welds, to remove any existing buildup of aluminum on the electrodes and re-texturing the electrode side to a thickness of 2-50 μm before starting a new series of aluminum to aluminum welds.
    [2]
    The method of welding according to claim 1 further comprising machining the electrodes thereafter, in the event that the electrodes have been flattened.
    [3]
    The method of claim 1 further comprising, measuring the electrodes after completion of steel to the steel welds, to determine the extent of the flattening of the electrodes, and if flattening is determined, then processing of the electrodes takes place before re-texturing the electrodes.
    [4]
    The method of claim 1 further comprising that the yield strength of the copper electrode is at least 400 MPa. 10 15 20 25 30 13
    [5]
    The method of claim 1 further comprising that the yield strength of the copper electrode is preferably higher than 500 MPa.
    [6]
    The method of claim 1 further comprising that the electrodes are of a copper alloy which does not soften at a temperature of 400 ° C.
    [7]
    The method of claim 1 further comprising the electrode having an electrical conductivity greater than 80% IACS conductivity and preferably greater than 90% IACS.
    [8]
    The method of claim 1 further comprising cleaning and re-texturing performed by a rotating grinding wheel.
    [9]
    The method of claim 8 further comprising the rotating wheel being a fixed grinding wheel having a groove therein, having a radius of curvature in the range between 20 mm and 40 mm.
    [10]
    The method of claim 8 further comprising that the rotating wheel is of a flexible abrasive material that is resilient to accommodate the curvature of the electrode side.
    [11]
    The method of claim 1 further comprising, if the number of aluminum to aluminum welds is determined to cause excessive pitting or buildup of aluminum on the electrodes, then a temporary stop of aluminum to the aluminum weld is made to perform an intermediate cleaning and texturing of the electrode sides prior to completion. of aluminum for the aluminum welds and continuation of steel for the steel welds.
    [12]
    A method of welding a plurality of aluminum to aluminum and a plurality of steel to steel welds, by electrical resistance welding, using the same welding equipment comprising: providing a resistance spot welding device with a pair of welding electrodes which has a radius of curvature of the electrode side in the range between 20 mm and 40 mm, said electrode side is textured with a roughness in the range of 2-50 μm, the yield strength of the copper wire is at least 400 MPa, the electrodes are of a copper alloy which does not soften at a temperature of 400 ° C, the electrodes have an electrical conductivity higher than 80% IACS conductivity and preferably higher than 90% IACS; first making a series of aluminum to aluminum welds; then performing a series of steels for steel welds, after the completion of the aluminum for the aluminum welds; then cleaning the welding electrodes, after completing the steel for the steel welds, to remove the buildup of aluminum on the electrodes and re-texturing the electrode side to the roughness of 2-50 μm before starting a new series of aluminum for aluminum welds.
    [13]
    The method of welding according to claim 12 further comprising machining the electrodes thereafter, in the event that the electrodes have been flattened.
    [14]
    The method of claim 12 further comprising measuring the electrodes, after completing steel to the steel welds, to determine the extent of the flattening of the electrodes, and if the flattening is determined, then processing of the electrodes takes place before re-texturing the electrodes.
    [15]
    The method of claim 12 further comprising that the cleaning and re-texturing is performed by a rotating grinding wheel.
    [16]
    The method of claim 15 further comprising the rotating wheel being a fixed grinding wheel having a groove therein, having a radius of curvature in the range between 20 mm and 40 mm. 10 15
    [17]
    The method of claim 16 further comprising that the rotating wheel is of a flexible abrasive material that is resilient to accommodate the curvature of the electrode side.
    [18]
    The method of claim 12 further comprising, if the number of aluminum to aluminum welds is determined to cause excessive pitting or buildup of aluminum on the electrodes, then temporary cessation of aluminum to the aluminum weld occurs to perform an intermediate cleaning and texturing of the electrode sides prior to completion of aluminum for the aluminum welds and continuation of steel for the steel welds.
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    法律状态:
    2019-01-29| NUG| Patent has lapsed|
    优先权:
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    US12/768,928|US8274010B2|2010-04-28|2010-04-28|Welding electrode with contoured face|
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