塑料件振动摩擦焊接的理论与应用手册之四

50Abb.41518.2PresentationofpotentialapplicationsAsmentionedabove,BRANSON'sphilosophyincludestheself-reliantdevelopmentofcustomer-orientedsolu-tions,evenbeyondtherangeofassemblytechnologyproper.Thisisboundtobethebasisforefficientandsuccessfulcoopera-tionwiththecustomer'sexperts.Fig.42Theautomotiveindustry,expectingthiskindofcustomersupport,asksforactiveadvicefromthesuppliersofmajormanu-facturingequipment.ThisiswhyBRANSON,cooperatingwithanautomobiledesigner,havedevelopedanintermediateconceptcar.Fromtheangleoftheplasticsjoiningexpert,asitwere,butconversantwiththebasicsofcarmanufacturing.Theresult:SONICIII.SONICIIIprovidesabasisfordiscussionwithplannersanddesignersoftheauto-motiveindustrywhichresultsinmutualimpulses.Consequently,SONICIIIconsistsofther-moplasticcomponentswherevertheiruseisadvisable,undersuchaspectsasthecurrentstateoftheart,orcost.Theyaredesignedforwelding,andprincipallyforvibratorytechniques.Someofthecom-ponentsaremoreadvantageouslyjoinedwithultrasonics.Examplesare:-Instrumentpanelsandbumpers-Trimsandpanelsintheinterior-centreconsole-Tailgate-Illumination-ComponentsunderthehoodFurtherthoughtwasgivenbyBRANSONtomodulardesignwhereitcanbeusedtogoodpurpose:forexample,theinstru-mentpanelmoduleincombinationwiththewindscreenmodule.Thelaststepintheseconsiderationsisanoutlineofanassemblylinewithintegratedultrasonicandvibrationwelders.52Fig.43Fig.448.3AssemblycentreTheintegrationofBRANSONweldingequipmentinautomotiveproductionInconceivinganewcar,earlyconsidera-tionmustbegiventoeconomicprocess-ingandassemblinginafuture-orientedproductionline.BRANSONdesignedaworkshopforthemanufacturingofthebulkheadmodule.Themajorplasticcom-ponentsare:-Bulkheadmoduleconsistingofinjection-mouldedfibrereinforcedGMTparts,forexample.-Mainairductinthermoplasticresin-Airvents,luxuryversionaccessories,inthermoplasticresinDashboardcarrier-differentversions:-Thermoplasticfinishedpartwithgrainedsurface-Thermoplasticcarrierwithsurfacecoat-ing(foam,foil,paint,etc.)-Fibrereinforcedcarriermaterial(woodfibre/PF,GM/PU,HM/PP,GMTetc.)withcompositesurfacecoating.Fig.455354AssemblystepsThebulkheadmoduleiscompression-mouldedfromfibre–reinforcedthermoplas-ticmaterial(GMT).Alternativelymouldedintwomaterials,thedashboardcarriersaresuppliedfromstock.Suchmouldingsasmainairduct,airvents,controls,gloveboxlid,etc.,areinjection–mouldedinthreemachinesattheproduc-tionline.Abb.4655ComponentPreassemblywithBRANSONEquipmentPos.1:VibrationwelderVibrationparalleltothelengthofthethermoplasticfrontairventsisappliedtoachieveajointwiththefibre-reinforceddashboardmaterial.Asthethermoplasticresindashboardhasintegralfrontair-vents,itwillskipthisweldingcycle.Thevibrationwelderisusedfortheweld-ingofthegloveboxlid,or,resp.,thegloveboxmodule.Pos.2:VibrationwelderTransversevibrationisappliedtoweldtheleftandrightcornerairventsontothedashboardcarrierparts(madeofther-moplasticresinorfibrereinforcedcarriermaterials).Pos.3:VibrationwelderwithautomaticfeedandtakeoffAirducthavingastiffeningfunctionislongitudinallyvibrationweldedtothedash-boardcarrier,withautomaticfeedandtakeoff.Pos.4:VibrationwelderwithautomaticfeedandtakeoffSameoperationasonsystemtype3,butfordashboardmadeoffibre-reinforcedcarriermaterial.Pos.5:UltrasonicrotarytablewelderThissystemisusedtoperformtheweldingofsuchcomponentsascentreconsole,airconditioningmodule,additionalshelves.Pos.6/7:UltrasonicintegratedweldersTheseultrasonicweldersareplannedtoperformwelding,spotwelding,stakingandswagingoperations.Furthermore,ultra-sonicinsertionofmetalinsertsintocon-trolsandfunctionalmouldings,e.g.airconditioning,electricalinstallations,ash-trayetc.Pos.8/9:HeatfoilstampingequipmentOptionally,symbolsareprintedontocon-trolsandfunctionalparts.Aftertheseoperations,theswitchboardcarriercomponentiscompletelypreas-sembled,includingelectricalinstallations,airconditioningandoptionalaccessories.Pos.10:VibrationweldingsystemwithautomaticfeedandtakeoffdevicesThissystemusesvibrationweldingtojointhetwopreassembledcomponentsbulkheadanddashboardcarrier.Inthesubsequentassemblyoperations,theinstrumentcluster(screenvibrationweldedtohousing)initssymboldecoratedbezelisfittedintothebulkheadmodule,securedwithscrewsandconnectedwiththecentralelectricalinstallations.Priortoitsintegrationinthecar,thefinishedmodulepassestheteststationtoensurethequalitystandard.Aseparateassemblystationusesintegralglazingtobondthewindscreenintoitssurroundmoulding.Thewipersystemismountedonthismod-uleformingawindscreenmoduleposi-tionedandsecuredonthebulkheadmod-ule.ThiscoverstheAcolumns.Themountingofthebulkheadandwind-screenmodulesintothevehiclesiscom-pletedwiththisstep.56Wespeakyoulanguage-everywhereBRANSONwasfoundedin1946,andtheirclaimtobepioneersinplasticsjoiningtechnologyisprovenbymanypatentsforinnovatoryequipmentandtechniques.Therefore,thecustomerpurchaseswitheachproducttheknow-howofacompanywhichisaworldwideleaderinthemanu-facturingofweldingequipmentandsys-temsforindustrialuse.Theproductionofstandardisedultrasonicandvibrationweldingcomponentsiscentralizedinmanufacturingfacil