CA1261581A

CA1261581A - Spin-welding apparatus

Info

Publication number: CA1261581A
Application number: CA000509870A
Authority: CA
Inventors: Keith E. Nuttall; Kenneth R. Clark
Original assignee: MB Group PLC
Current assignee: Crown Packaging UK Ltd
Priority date: 1985-05-24
Filing date: 1986-05-23
Publication date: 1989-09-26
Also published as: EP0202861B1; MY101219A; EP0203760A2; AU582852B2; BR8602330A; AU5761586A; GR861340B; FI83941B; GB2175536B; AU5761686A; JPH0232131B2; GR861341B; CA1255930A; NO862066L; FI83942C; ES8703768A1; ATE48795T1; EP0204448A2; FI862176A0; NO862067L

Abstract

SPIN-WELDING APPARATUS

ABSTRACT

Apparatus for spin-welding comprises a spin welding machine having a spin welding head, a ram assembly, and a feed mechanism, the ram assembly is driven from a shaft and the feed mechanism comprises a rotating turret mounted on a shaft which is driven from the shaft via a Geneva mechanism. The spin welding head is driven by a low inertia DC servo motor operated by a programmable logic controller and timed from a switch unit driven off the shaft.

Description

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SPIN-WELDING APPARATUS

BACKGROUND TO THE INVENTION
The invention relates to apparatus for spin-welding, which is a known technique for welding together plastics components which are assembled 5 with opposed annular surFaces, in which one of the components ls spun at high speed relative to the other to cause melting and subsequent fusion of the plastics material at the interface of the opposed surfaces.
DESCRIPTION OF THE PRIOR ART
lo In known methods of spin welding the energy for the weld is generally provided by a rotating chuck. In a first type of known method pre-assembled articles to be spin welded are mounted on a chuck which is brought into and out of engagement with a rotating drive motor and are spun thereby for a period sufficient to create a weld. In a 15 second known method one of the components of the article to be welded is rotated at high speed on a chuck and is subsequently brought into engagement with the other component. Drive to the chuck is discontinued, and the two components are welded together as the energy of rotation of the chuck is dissipated as frictional heat at the 20 component interface. In both the prior methods precise contro1 of the duration of the weld process and the amount of frictional heat generated at the weld are difficult to achieve.

SUMMARY OF THE INYENTION
According to the invention there is provided a spin welding apparatus 25 for welding together opposed surfaces of thermoplastics components which are assembled together prior to welding, comprising a spin ,~

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welding head for spinning one of the components relative to the other and a low inertia DC servo motor for driving the spin welding head, wherein the drive of the servo motor is governed by control means to prov:ide initial 810w speed spinning to ensure correct take-up of drive to the components, rapid acceleration to weld process speed, maintenance of process speed for a re~uired period, and final rapid decelera-tionand stopping of the motor.

Another aspect of the invention comprehends spin welding apparatus for welding together opposed surfaces of thermoplastics components which are assembled together prior to welding, comprising a spin welding head for spinning one of the components relative to the other and a low inertia DC servo motor operatively connected to the spin welding head, wherein the d~ive of the servo motor is governed by a programmable logic controller means programmed for consecutively providing initial slow speed spinning to ensure correct take-up of drive to one of the componénts and arrest of the other component, rapid acceleration of the one component to weld process speed, maintenance of process speed for a required period, and final rapid deceleration and stopping of -the motor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGURE 1 shows a longitudinal section through a cylindrical container body and an end component therefor FIGURE 2 is a side view of a spin-welding machine;

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FIGURE 3 is a diagrammatic sectional view of the machine of Figure 2 taken along line A - A;
FIGURE 4 is a longitudinal sectional view through the spin-welding head of the machine;
FIGURE 5 is an enlarged view of part of -the spin-welding head showing a container body and end component engaged therewith;
FIGURE 6 is a side elevational view of a device for exerting radial compressive pressure which is mounted on the spin-welding head;
FIGURE 7 is a diagrammatic sketch showing the overlap of a wire cable employed in the spin-welding head of the machine as shown with Figure 5;

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FIGURE 8 is a graph~c representation of the mach~ne cycle;
FIGURE 9 ~s a diagrammat~c time/velocity graph for the spin motor of the machine;
FIGURE lO ~s a block diagram showing the control system for the sp~n-weldlng mach~ne; and FIGURE ll is a block diagram show~ng the control system for the devlce shown ~n F~gure 6.

DETAILED DESCRIPTION OF THE _INVENTION
Referring to Figure l, there ~s shown a conta~ner comprising a moulded 0 plastics cyl~ndrical body l provided with an ~ntegral bottom panel 2 and a plug fit end component in the form o~ a moulded plast~cs r~ng 3 adapted to be assembled into the open end of the body. The bottom panel of the body has a plurality of external webs 4 whlch engage fixed p~ns located on the ram of-the mach~né such that they prevent the body rotat~ng during weld~ng. The r~ng 3 also has a number of external webs 5 which engage one or more drlving p~n~ ln the sp~nn~ng head of the mach~ne and thereby prov~de dr~ve for the sp~n-weld~ng process. Components such as shown ~n F~gure l ~re descr~bed ~n greater deta~l in our co-pend~ng Canadian patent application No.
507,787 filed April 28, 1986.

As shown ~n F~gure 2, the sp~n-weld~ng mach~ne fs supported on a frame 6 and has a maln AC dr~ve motor 7 driv~ng a pr~mary dr~ve shaft 8 through a geared speed reduct~on un~t 9, dr~ve belt 90, and a pneumat~c clutch lO. The clutch ~s remotely operated by a ~..

programmable control system (Figures 10,11). A hand wheel 11 may be used for manual rotation of the drive shaft during setting up. A
brake (not shown) may also be provided. The feed mechanism 12, by which pre-assembled containers are fed to the work station, is driven from a secondary drive shaft 13 which is itself driven in an indexing motion from the shaft 8 via a Geneva mechanism 14. A ram assembly 15, also driven from shaft 8, is operatlve to push the contalner at the work place into and out of engage~ent with a spin-welding head 16.
The spin-welding head is drlven by a servo motor 17 controlled by a switch unit 18 driven off the shaft 8.

The body 1 and ring 3 are pre-assembled before welding and are fed to the machine by a feed mechanism shown in Figure 3. The pre-assembled containers have already been turned on thelr sides before be~ng fed into the machine so they can roll down the infeed chute 19. A gate 20, which is shown only diagrammatically in Figures 2 and 3, stops them before they can reach a transfer turret 21 mounted for intermittent rotation on the secondary drive shaft 13. The gate is timed in sequence with the machine from the switch unit 18 and is operated when the transfer turret has stopped rotating. The gate 20 moves sideways until a container therein is lined up with turret guides. The container is then free to drop under gravity ~nto the transfer turret. The sideways movement of the gate 20 causes it to interfere with the next ~ollowlng container In feed chute 19, preventing it from dropping. After a predetermined period, the gate is returned to its original position, allowing the next container to 8~

drop into the gate. A pneumatic cylinder 200 with a solenoid valve (not shown) is used to operate the gate.

Rotation of the transfer turret 21 carries the containers from the in~eed to the work stat~on W and then to the discharge chute 25. In this example the interrupted motion o~ the trans~er turret is provided by the Geneva mechanism 14. The transfer turret comprises a pair o~
plates 23 mounted on sha~t 13 and having peripheral part-circular cut-outs therein to support the containers during their travel thereon. Outside guides and a rail prevent the containers being disturbed while the turret rotates.

The spin-welding process is carried out at the work station which is shown at W in Figure 3. At the work station, the container is held between the spin welding head shown in Figures 4 and 5~ and the ram assembly 15.

The spin~welding head comprises a low inertia mechanism driven by a DC
low inertia rare earth brushless servo motor 17 as shown in Figure 4.
Drive is taken to the spin welding head shaft 26 via a toothed belt 27. The driven pulley 37 is mounted on one end of the shaft 26 which is horizontal. A disc 28 of lightweight alloy is bolted directly to the opposite end of the shaft 26, Machined in its exposed ~ace, the disc 28 has driving pins 29 wh~ch engage in the ring 3 and cooperate with the external webs 5 thereof to cause the ring to be driven in - ~2~

rotation. In order to keep friction as low as possible the shaft 26 is mounted in two bal1 races 30.

The ram movement, to push a container into the spin welding head, is actuated by a cam 38 (Fiyure 2) driven at the machine cycle speed on the shaft 8. Th1s cam action is transferred to the ram slider by a lever arm 51 pivoted at 52 and a connecting link 50. Dogs 151 located on the front face of the ram engage with the webs 4 to prevent the body 1 ~rom rotating during welding.

When the container formed by the assembled container body 1 and end component 3 is pushed by the ram assembly 15 into engagement with the spin-welding head 16 as shown in Figures 4 and 5, the end face of the end component 3 comes into contact with an ejector ring 46 (Figure 5) which yields axially under the action o~ a plurality of coil springs 47 spaced circumferentially around the ring 46. The ring 46 is held in the position shown in Figure 5 during welding and the correct end pressure for the welding process is provided by the coil springs 47 via the ejector ring.

Radial pressure is applied during the welding process by means of a tourniquet comprising a loop of steel wire cable 39 which is retained in an annular groove 42 in a cable retaining housing 45 mounted on the spin-welding head. When the tourniquet is in a relaxed condition, it forms a loop having a d-iameter slightly greater than that of the container to be welded. When no container is held in posit~on for welding, the ejector ring moves axially under the influence of the springs 47 to close oFf the annular groove 42 and to retain the wire cable 39 therein~ as shown in Figure 4.

As shown in Figure 6, one end of the cable 39 is rigidly anchored at 40 whilst the other end is attached to a pneumatic cylinder 41. A
small release area 43 is cut out of the cable retaining housing 45 to allow the cable to cross over at 44 at the cable's entry and exit points. During the operation of the machine, the assembled container body and end component are fed into the cable retaining housing and through the loop of the cable 39. The driving pins 29 are located as described below and the pneumatic cylinder 41 is operated to apply a tension to the cable such that the cable loop diameter is decreased, thereby producing the desired external pressure on the body 1 necessary for the spin-welding process. After welding, the pneumatic cylinder 41 is returned to its original position, releasing the external pressure and allowing the container to be ejected. As the ram assembly 15 moves back, the ejector ring 46 is free to move forward, thereby pushing the now welded container out of the cable retaining housing and closing the annular groove 42. The manner oF
overlap of the wire cable is shown more clearly in Figure 7.

For any given components to be spin-welded, there will be a preferred or medium interFerence fit which occurs when both components conform s~

exactly to their design dimensions. Due to the var;ations in component size, within normal plastics moulding tolerances, the Interference flt between any two components may differ significantly from the preferred value. A range of interference fits which can lead to successful welds under commercial conditions may be defined as extend~ng from a loose flt having a diametric interference substantially less than the medium fit to a tight flt having a diametric interference substant~ally greater than the medium fit. The specific values of diametric interference for "loose", "medlum" and "tight" fits will, of course, vary according to the nature of the components being welded.

In the case of the components constructed and dimensioned as described in our co-pending Canadian patent application No. 507, 787, the preferred or medium interference fit between the components is about 0.75mm (that is, the internal diameter of the body 1 when relaxed is 0.75mm less than the external diameter of the ring 3 when relaxed).
In this case, a loose fit may have a diametric interference of about 0.25mm and a tight fit may have a diametric interference of about 1.25mm. As a consequence of these variable degrees of fit between end component and s~de wall, the contact pressure between the surfaces to be welded, without appl~cationof add~tional radial pressure, can be calculated to range between 0.02 Newtons/mm2 and 0.17 Newtons/mm2.

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g For one set of welding conditions, for example, derived from experiments using polypropylene rings and bodies, the ideal contact pressure between the surfaces during welding has been found to be about 0.23 Newtons/mm2. It has been shown that for the example quoted, the radlal pressure required to maintain the contact pressure between the welding surfaces at about 0.23 Newtons/mm2 needs to be about 0.25 Newtons/mm2 for the loose fit situation of 0.25mm diametric interference, and about 0.07 Newtons/mm2 for the tight fit situation of 1.25mm diametric interference. Such pressures enable both extremes of fit to be satisfactorily spin-welded to give a fully-fused integral joint in a total time of about 0.21 seconds at lOOOrpm, wherein 0.05 seconds is required to accelerate the end component to the required speed, and 0.08 seconds is required to electromagnetically brake the system to the stat~onary pos;tion. This total time can be reduced by choosing a greater contact presssure or by increasing the motor speed, or both.

In order for the correct radial pressure to be applied by the tourniquet during welding, it is necessary for the interference fit between the conta~ner body and the end component to be measured. Two methods have been shown to be useful and are explained below as examples.

The first is based on the force requlred to fully assemble the end component into the side wall of the container prior to spin-welding.

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It has been found that a substantially linear relationship exists between the interference fit and maximum force of assembly, during which the side wall is caused to deform in an elastic fashion because of the d~ametric interference between the end component and the side wall, although the general shape of the insertion force profile can be ~nfluenced by the design of the container and the end component. The measurement of the insertion force may be made on a preliminary assembly machine which fits rings 3 to bodies l or at an assembly station that forms an integral part of the spin welding apparatus.

The second method is based on the measurement, on the spin-welding machine itself, of the current required by the spin-welding servo motor to produce a torque sufficient to spin, at a low speed such as 70rpm, the end component within the side wall when fully assembled.
This is a particularly appropriate method since it is convenient to programme the servo motor to spin at such low speed for say O.lO
seconds at the very beginning of the welding cycle to facilitate engagement of the drive webs 5 on the plug by the corresponding drive pins 29 on the spin-welding head before accelerating to the much higher welding speed. The engagement time can be extended for a short period such as O.l second dur~ng which time the torque requ~red for slowly spinning the end component within the side wall can be measured and related to a diametric interference between end component and side wall by means of a prev~ously establ~shed correlation relat~onship.

For the components shown in Figure 1, which relate closely to those descr~bed in Canadian paten-t application No. 507,787, the current required to slow-sp~n the end components within the side wall has been shown to vary in an essentially linear fashion with diametr~c S ~nterference between end component and side wall. This relationship can be made even more pronounced ~f a radial pressure is appl~ed to the side wall during measurement. Thus the degree of fit existing between a container body and an end component therefor to be welded can be measured since different fits will require different currents to driYe the servo motor at the chosen fixed low speed.

A voltage is generated by a servoamplifier which is an analogue of the motor current. This measwred voltage is received in a control system where it is compared with the voltages predetermined to represent various fit types e.g. loose, medium and tight. Each of the various fit types will in pract~ce represent a band of the full range of possible fits extending from~the very .loose fit to the very tight fit. The sensitivity of the system will depend on the number of such bands which are distinguished.

The conkrol system will also identify and lead to the ejection of assembled components whereln the interference f~t is either so loose or so ~ight that a satisfactory weld will not be possible under the prevailing operat~ng conditions.

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When the type of fit has been identified by the control system, a signal is sent to the machine's pneumatic system, choosing one of a series of solenoid valves that each have had their pressure pre-set to suit one of the fit types. Therefore, in this way, the correct external pressure can be app1~ed by the pneumatic cyl~nder 41 to the cab1e 39 for any range of fits between the end components and the container bodies. There is, of course, no limit to the fit types whlch may be identified in this way and the system can provide a d~rect correlation between the interference fit of the components and the appropriate corresponding radial pressure to be appliedO

Although a measurement of voltage has been used in this example as a means for comparing the torque applied by the motor to spin the end component relative to the container body against the frictional force of the interference fit, other parameters relating to this torque could be measured as an alternative according, for example, to the type of motor employed. Thus a predetermined constant torque may be applied by the motor and the resulting speed of rotation measured.

The drive of the servo motor is governed by an amplifier which can be controlled through a programmable logic controller to provide the required time velocity profile for the motor during the welding process. Operation of the motor 17 ls timed to the machine cycle from the switch un~t 18. On initiation of the weld process the amplifier is energised and the motor is run at a slow speed for a short time to ~Z~58~

enable the driving pins 29 of disc 28 to engage the external webs 5 of ring 3 and fixed dogs 151 of the ram to engage the webs ~ on the base of the container. After the webs have been engaged, the current required to run the servo-motor at the predetermined slow speed is measured, to classify the interference fit, and the appropriate radial pressure to be applied by the tourniquet is selected. After this the output of the amplifier is ramped such that the motor is rapidly accelerated to its welding process speed and retained at this speed for a period decided by the nature of the particular container type being welded. At the end of the weld time the amplifier is de-energised and the motor is stopped by the friction generated at the weld. Stopping of the motor can also be assisted by braking or by powered ramping down of the speed.

Figure 8 is a graphic representation of the machine cycle over one rotation of the primary shaft 8. Lines AB and HJ represent the movement of the turret through one indexed motion (i.e. 90 of the secondary shaft 13). The curves CD and FG represent the forward and return movements of the ram. As can be seen, there is a slight overlap of the ram motion with the movement of the turret~ In the period defined between points D and F the ram is stationary in its forward pos~tion and during this period the welding takes place.
During the period D to E the motor 17 is driven at slow speed to enable the fixed pins 29 on the spin welding disc 28 to locate on the webs 5 of the ring and the dogs 151 on the ram to locate on the webs ~z~

on the base of the container and to allow the appropriate radial pressure PW to be selected. Between the points E and F the motor 17 is accelerated up to weld speed, retained at weld speed for the required period for welding to occur, and stopped either through fr~ction at the weld or through braking means referred to earlier.
Figure 9 is a diagrammat1c timelt)/velocity(v) curve for the motor 17 during the peri~d between the points D and F. From Figure 9 it will be seen that the motor 17 is stopped before the po;nt F. The period XY during which welding takes place can be altered according to the nature of containers being formed.

The current taken by the motor 17 over the welding period XY may be monitored and compared with a previously established datum. If the load on the motsr applied by the weld is below a predetermined level, a satisfactory weld will not be formed. By monitoring the cur~ent taken by the motor during the weld period, unsatisfactory welds can be identi~ied and the container rejected.

Suitably, the period defined between the points D and F may be of the order of 0.4 seconds.

Whilst a pneumatic cylinder 41 has been described for applying tension to the cable 39 in order to apply an inwardly directed radial pressure to the wall 1 the cylinder 4 may if desired be replaced by a solenoid or a servo motor system connected directly to the cable.

Whilst the cable 39 is able to apply a narrow hoop of radial pressure to the end wall 1 it may be replaced, if desired by a ring of segments each urged against the wall 1 by, for example, pneumatic or hydraulic means.

Figure 10 shows diagrammatically the functional interrelationship between the di~ferent parts of the apparatus, and in particular, the control connections between the spin-welding machine and the programmable logic controller.

Figure 11 is a diagrammatic representation of the system for controlling the application of radial pressure, and shows ~n particular the control connections between the electronic system for measuring the parameter which represents the interference fit, the programmable logic controller and the tourniquet adjusting system which adjusts the radial pressure applied during welding.

The method and apparatus described are particularly suitable for welding container components made from thermo plastics materials such as polyethylene, polypropylene, copolymers thereof, or polyamldes when in a form flexible enough to yield under the imposed inwardly directed radlal force to achieve the Inkerference fit necessary Por spin welding. Whilst the invention has been described in terms oP radially contracting a cylindrical wall against a plug therein, the same controls of inter-component ~nterference may be achieved in principle by spreading the plug against the interior of the cyllndrical wall.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:-

1. Spin welding apparatus for welding together opposed surfaces of thermoplastics components which are assembled together prior to welding, comprising a spin welding head for spinning one of the components relative to the other and a low inertia DC servo motor for driving the spin welding head, wherein the drive of the servo motor is governed by control means to provide initial slow speed spinning to ensure correct take-up of drive to the components, rapid acceleration to weld process speed, maintenance of process speed for a required period, and final rapid deceleration and stopping of the motor.

2. Apparatus as claimed in Claim 1, comprising pressure means for selectively applying a radial pressure to the components in the region of the opposed surfaces whilst the weld process speed of the servo motor is maintained, wherein the control means includes means for measuring, during initial slow speed spinning, a parameter which is a function of the interference fit between the two components to be welded, for comparing the measured value of the parameter with predetermined values, and for selecting the radial pressure applied by the pressure means.

3. Apparatus as claimed in Claim 2, in which the measured parameter is a voltage generated by a servo amplifier as an analogue of the current taken by the servo motor during initial slow speed spinning.

4. Apparatus as claimed in claim 1 wherein the control means includes a programmable logic controller programmed to govern drive to the servo motor.

5. Apparatus as claimed in claim 4, wherein the programmable logic controller is connected to the servo motor via an amplifier.

6. Apparatus as claimed in claim 5, wherein the programmable logic controller is programmed to de-energise the amplifier at the end of the said required period such that the servo motor is decelerated and stopped by the frictional forces generated at the weld.

7. Apparatus as claimed in claim 1, 4 and 6, further comprising a feed mechanism for successively feeding pre-assembled components to a work station on the apparatus, and a ram assembly for moving components at the work station into engagement with the spin welding head, wherein the feed mechanism and the ram assembly are driven in timed relation from a first motor driven shaft and wherein the drive to the servo motor is timed by a switch unit driven from the first shaft.

8. Spin welding apparatus for welding together opposed surfaces of thermoplastics components which are assembled together prior to welding, comprising a spin welding head for spinning one of the components relative to the other and a low inertia DC servo motor operatively connected to the spin welding head, wherein the drive of the servo motor is governed by a programmable logic controller means programmed for consecutively providing (a) initial slow speed spinning to ensure correct take-up of drive to one of the components and arrest of the other component, (b) rapid acceleration of said one component to weld process speed, (c) maintenance of process speed for a required period, and (d) final rapid deceleration and stopping of the motor.

9. Apparatus as claimed in claim 8, comprising pressure means for selectively applying a radial pressure to the exterior of a first component in the region of the opposed surfaces of said first component and a plug member therein whilst the weld process speed of the servo motor is maintained and control means for measuring, during initial slow speed spinning before radial pressure is applied, a parameter which is a function of the interference fit between the two components to be welded, for comparing the measured value of the parameter with predetermined values, and for selecting the radial pressure to be applied by the pressure means during welding as a result of comparison between the measured value and the predetermined values.

10. Apparatus as claimed in claim 9, in which the measured parameter is a voltage generated by a servo amplifier as an analogue of the current taken by the servo motor during initial slow speed spinning.

11. Apparatus as claimed in claim 8, wherein the progammable logic controller means is connected to the servo motor via an amplifier.

12. Apparatus as claimed in claim 11, wherein the progammable logic controller means is programmed to de-energize the amplifier at the end of the said required period such that the servo motor is decelerated and stopped by the frictional forces generated at the weld.

13. Apparatus as claimed in claim 8, 9 or 11, further comprising a feed mechanism for successively feeding pre-assembled components to a transfer turrent defining a work station on the apparatus between said spin welding head, and a ram assembly for moving components at the work station into engagement with the spin welding head, wherein the feed mechanism and the ram assembly are driven in timed relation from a first shaft driven by a motor and wherein operation of the servo motor is timed by a switch unit driven from the first shaft.