Contents Ⅰ Plastic laser welding. Ⅱ Laser soldering

Transcription

1 Contents Ⅰ Plastic laser welding 01 Plastic laser welding principle 02 Introduction of plastic laser welding 03 Welding performance of different materials 04 Effect of color on plastic laser welding 05 Effect of structure on plastic laser welding 06 Plastic laser welding methods 07 Compact laser source 08 Semi-automatic laser welding system 09 Plastic laser welding application case -- Automotive electronic brake 10 Plastic laser welding application case -- Suction bag 11 Plastic laser welding applications Ⅱ 01 principle 02 Introduction of laser soldering 03 Compact laser source 04 Multifunctional laser welding head 05 Temperature negative feedback control system 06 Intelligent wire feeding system 07 application case -- Micro switch 08 application case -- Motor 09 application cases

2 Plastic laser welding The thermal effect of laser is used to complete the melting of plastic material, and the welding of plastics to plastics is realized, which is suitable for the precision welding applications of electronic sensors and medical devices etc.

3 Plastic laser welding principle Plastic welding is one of the main methods of thermoplastic plastic secondary processing. Plastic welding can be divided into hot plate welding, laser welding, induction welding, friction welding, ultrasonic welding, high frequency welding, hot air welding etc. The main welding principle of plastic laser welding is "transmission welding". The laser (wavelengths 800 to 1950 NM) penetrates the upper layer, and is absorbed in the depth range of mm below the lower layer, and then laser radiation is converted to heat. Laser Joining pressure As the two layers of material are clamped together during the welding process, the material is heated to expand and heat is transferred from the absorbent layer to the transmissive layer. Under the synergistic effect of the internal expansion force and the external fixture pressure, the upper layer and the lower layer material are fully fused to complete the solid welding of the upper and lower parts. Absorbing laser material Weld seam Laser Transparent material Almost all of the thermoplastic can be used laser welding ---- ABS, PP, PS, PA, PVC, PBT, etc., and the welding strength can reach the base material strength. Plastic laser welding Plastic laser welding can not be used as shown below splicing welding, because the plastic melting temperature is low and mobility is poor. In this welding method, the welding strength and sealing can not be guaranteed. The following diagram shows the penetration welding, and there is a theoretical welding possible, but in the actual welding process, the compression force, laser refraction and other issues is difficult to handle. Black Black Black Transparent

4 Introduction of plastic laser welding Plastic laser welding as a new type of welding, it has begun to replace some of the traditional plastic welding. At the same time, a variety of new welding methods and new materials are suitable for laser welding have also been developed. Advantages Optical requirements Non-contact welding No vibration generated Higher welding accuracy No dust material overflow Simple welding surface shape High welding strength Easy to automate integration and mass production Convenient product switching Do not damage the welding fixture Nice welding surface The influencing factors on the quality of the laser welding Plastic laser welding requires a combination of laser transmission material and laser absorption material. In the natural conditions, the general thermoplastic material is transparent to the laser, but the absorbent effect can be achieved by an additive (e.g., carbon black). "Laser Transparency" is different from "Optical Transparency", the laser wavelength belongs to the laser spectrum that human eye is not visible. In fact, many plastic laser welding applications only need the upper layer transparent to the laser. As a result, some materials that transparent under the laser but heavy color under the human eye are developed for plastic laser welding. Material thickness, crystal properties, glass fiber content, other additives (such as flame retardants) may affect the laser transmission effect of the material. Generally need to ensure that more than 20% of the laser energy through the upper layer absorbed by the lower layer to obtain a good welding effect. Low laser transmission effect will make the upper layer first decomposition during the process of welding. UW has the professional measurement equipment to complete the material's laser transmission test. For the bottom layer absorption effect, the main way is to add carbon black, and other additives have less influence on the bottom absorption effect. 塑料焊 Material's laser transmission test Plastic laser welding

5 Welding performance of different materials Plastic laser welding as a new type of welding, it has begun to replace some of the traditional plastic welding. At the same time, a variety of new welding methods and new materials are suitable for laser welding have also been developed. Laser transmission material PEEK TPE PSU PES PPS PA66 PA6 POM PVC PBT PET PS PC PMMA SAN ASA ABS PP PE-HD PE-LD PE-LD PE-HD PP ABS ASA SAN PMMA Laser absorbing material PC PS PET PBT PVC POM PA6 PA66 PPS PES PSU TPE PEEK Excellent welding Good welding Poor welding (need to test)

6 Effect of color on plastic laser welding Material color is also an important factor to affect the laser welding, usually transparent + black is the most simple combination, which can get the great laser welding process. Color affects material In color plastic, the pigment or dye content is very important. When the pigment content is low, the fusion depth of the laser is relatively large, but the material itself does not form thermal damage. The resulting expansion volume can extend the melt contact time and ultimately increase the welding strength. Therefore, the absorption rate and the transmittance of materials can be adjusted by adding a filler or a pigment. White + white transparent + transparent color + color color + black welding difficulty black+ black transparent+ black Black + Black laser welding Different color of welding difficulty PMMA and other non-crystalline thermoplastic plastic has a good transmission effect for the laser, on the contrary, PA, PBT, POM and other semi-crystalline thermoplastics, even in the natural conditions will absorb and reflect a part of the laser energy. The most commonly used additive for white plastic is titanium dioxide (highly reflective material). Because white will reflect most of the laser rather than absorb, so white is not ideal for laser welding material color. Titanium dioxide type, addition volume, laser wavelength and specific process control are key factors to affect the ability of white materials welding. Plastic laser welding requires a combination of "laser-transparent" and laser-absorbing materials, but all black standard materials can absorb certain lasers. In order to achieve the black and black materials. The lower black layer shall adopt PA66. BASF's Ultramid A3WG6 LT (PA66) material has a black appearance and laser penetration, with the addition of carbon black PA66 material can achieve good laser welding. Plastic laser welding

7 Effect of structure on plastic laser welding Plastic laser welding in the structure is different from the traditional ultrasonic welding, because the different heat source and conduction mode, the laser welding requires flat and flat contact to complete the welding process. T-type convex structure Similar to ultrasonic welding, plastic laser welding generally use T-type connector, but the welding position to be used in flat and flat contact. A: Light transmission material B: Light absorbing material C: Inside fixture D: Outside fixture E: Welding convex platform with the allowable collapse space F: Material overflow area G: Cover to avoid laser angle H: The thickness of the light transmission layer For high hardness, small product deformation parts, usually use the inside fixture (C) or the outside fixture (D), conversely need both to press fit. In the quasi-simultaneous welding process, welding convex platform melted would collapse because of fixture pressure. The welding collapse can achieve better welding strength and overcome certain deformation error of the material. Circle structure For the circle structure shown below, don t need the welding convex platform structure, but should ensure the material with the interference fit. During the welding process, the internal expansion of the material could complete the required compression process. Plastic laser welding Because the laser beam is tapered, laser transmission material should avoid the laser path. Semi-crystalline plastic can absorb the laser, with this material to do the cover should consider the thickness of the laser layer ( the larger the thickness, the smaller laser penetration energy).

8 Plastic laser welding methods Plastic laser welding is suitable for various industrial applications, according to different sizes and shapes of products, UW laser can provide two methods : contour welding and quasi-simultaneous welding. Contour welding Quasi-simultaneous welding During the contour welding process, the laser welding head or product driven by the XYZ axis, the laser running along the welding trajectory. In whole process, partial materials melted, and have no overflow materials. As the material welding surface without the overall melting process, the welding product height change small at the end. The quasi-simultaneous welding is a more efficient welding method. When welding scanner lens guide laser beam at a speed of more than 5 m/s along the welding path high-speed movement, which make the whole welding surface heat melting gradually. Under the action of the fixture pressure, the entire welding convex platform have a certain collapse. The contour welding requires that the welding position of the upper and lower materials be fully fit, and the lager deformation will increase the design difficulty of the welding fixture. The contour welding can be adapted to larger product sizes and complex 3D structures, and can be quickly switched between different products. The quasi-simultaneous welding is similar to the traditional plastic welding, the weld seam position has molten outflow and the height of the product decreases.due to the material collapse, so can overcome the material deformation. The quasi-simultaneous welding can be adapted to product sizes is generally not more than 200mm * 200mm, and is usually used for planar welding. As a result of the overall heating, the efficiency is higher than the contour welding. Plastic laser welding

9 Compact laser source Plastic laser welding general use of diode lasers for the heating laser source, diode laser power density is very uniform, and can achieve uniform heating of the weld seam. Technology data Machine type Laser power Laser wavelength Diode laser 50/100/200/400W 915nm Technology advantages Operation mode CW Fiber output number 1 Laser guide <3mW Fiber diameter 200/400um Fiber length 5/10m Miniaturized structure Long service life High electro-optical conversion efficiency No wearing parts Can set the laser power output Electro-optical >25% efficiency Power output AC220V±10%50/60Hz 50W&100W-430w 450d 165h(mm) Machine size 200W&400W-430w 655d 215h(mm) Cooling type 50W&100W&200W-Air cooling 400W-Water cooling Working temperature Working humidity 30%-75% 50/100W diode laser 200/400W diode laser Plastic laser welding

10 Semi-automatic laser welding system UW-PW-S is a standard plastic welding semi-automatic system, in addition to the standard welding function, and also can increase the rotary table and conveyor belt to achieve fully automatic production. Technology data Welding type Laser power Spot shape Weld width Welding method Position method Plastic welding 50/100/200/400W Round mm Contour welding / Quasi-simultaneous welding CCD & red, optional vision Contour welding 0 ~ 200mm / s Welding speed Welding range Control method User interface Power input Machine size Weight Working temperature Working humidity Quasi-simultaneous welding 0~3000 (multiple welding) mm / s 200 * 200mm can be customized to a wider range Industry PC UW welding software AC220V±10%50/60Hz 960w 1000d 2005h (mm) About 300Kg determined by design %-75% Equipment feature Allow the contour welding or the quasi-simultaneous welding. Some materials can increase real-time welding temperature monitoring Modular parts Can increase the two position or four position rotary table Plastic laser welding

11 Plastic laser welding application case -- Automotive electronic brake The program uses XYZ three-axis workbench, with the rotating table, to achieve loading and welding at the same time. Suitable for mass production of plastic welding of automotive electronic brake actuators. Technology data Welding type Laser power Spot shape Weld width Welding method Position method Welding speed Welding range Control method User interface Power input Plastic welding 100W Round 2.5mm Contour welding CCD & red mm/s 400(X)*150(Y)*300(Z)(mm) Industry PC UW welding software AC220V±10%50/60Hz Equipment feature Rotary table, loading& unloading & welding at the same time Special pneumatic fixture to complete the welding pressure Manually start and screen protection, protect the security of the operating staff. Intelligent control, double position independent program control. Machine size 1774w 1297d 1707h(mm) Weight Determined by design(kg) Cooling type Air cooling Working temperature Working humidity 30%-75% Application areas Auto sensors Plastic laser welding Sample Sample Welding position

12 Plastic laser welding application case -- Suction bag The program uses XYZ three-axis workbench, with double Y-axis and double-w axis, to achieve loading and welding at the same time. Suitable for mass production of round plastic welding of suction bag. Technology data Welding type Laser power Spot shape Weld width Welding method Position method Welding speed Welding range (X*Y1*Y2*Z*R1*R2) mm Control method User interface Power input Machine size Plastic welding 120W Round 1.5mm Contour welding CCD & red mm/s 200*400*400*400*R1*R2 Industry PC UW welding software AC220V±10%50/60Hz 1600w 1819d 2259h(mm) Equipment feature Double Y-axis sports platform, loading and unloading and welding at the same time. Double W-axis to complete the rotation function. Separate button control, protect the security of the operating staff. Intelligent control, double position independent program control. Weight Determined by design(kg) Cooling type Water cooling Working temperature Working humidity 30%-75% Application areas Round light plastic Welding principle Sample 焊接位置 Plastic laser welding

13 Plastic laser welding applications Plastic is easy to mold into a complex shape structure, which widely used in industrial applications, such as auto parts, medical equipment, electronic sensors etc. Sample show Auto parts(contour welding ) Auto meter(quasi-simultaneous welding) Auto sensor(contour welding ) Electronic brake(contour welding ) Packing tape(contour welding ) Suction bag(contour welding ) Application Plastic laser welding Auto: Electronic sensors: Medical equipment: Repeat reliable welding No vibration welding Clean and no pollution

14 激光锡焊篇 Using the thermal effect of laser to complete the melting of tin, and realize fine soldering process of electronic devices, PCB / FPCB board etc.

15 principle is an important part in electronic components assembly process, the welding methods including wave soldering, reflow soldering, automatic soldering robot, laser soldering and hot pressure soldering etc. principle Welding step uses laser as a heating source, in conjunction with optical fiber and laser head, to make the laser focused on the welding area, and the laser radiation energy converted into heat to melt the tin, then the welding complete. source mainly is diode laser source ( nm). The diode laser source belong to near infrared band and has good thermal effect. Due to its unique beam uniformity and laser energy persistence, the welding plate is heated uniform and rapid, which can have high welding efficiency. Preheat: The laser heats the welding plate and pin so that the temperature rise to melt tin. The laser spot needs to be smaller than the welding plate size, however the laser outside the welding plate may cause PCB damage. Wire feeding: The wire through the automatic wire feeding device to the welding position, which melts under the synergistic effect of laser heating and welding position heating. Soldering: The molten solder spreads between the terminals and the welding plates to form a mountain-like welding shape. Cooling: The wire is withdrawn from the solder spot, at the same time the laser power is reduced and the solder spot are cooled. Wire feeder PCB board Pin Soldering Laser

16 Introduction of laser soldering As a new type of laser soldering method, laser soldering has a great advantage over traditional welding in high heat dissipation element, space limiting area and precision stable welding. Welding type Automatic iron soldering Heating method Surface heating Heat conduction Heating speed Fast Slow Temperature increase Continuous temperature rise Temperature limited Advantages Disadvantages Suitable for precision devices, can weld narrow and complex areas Spot welding only, can not drag soldering and repair short circuit Spot welding and drag soldering allow, small footprint and small power Iron head is easy to wear out, and large radiator parts is easy cause pseudo soldering Advantages Non-contact welding District heating Short welding time High welding flexibility Space unlimited Low maintenance (no iron damage) Meet the 3D heating needs Easy to automate integration Higher welding accuracy

17 Compact laser source usually used diode laser as the heating source, so the power density is very uniform and the welding plate heated uniform. And the diode laser have the highest electro-optical conversion efficiency, and energy consumption is lower than other lasers. Technology data Machine type Laser power Diode laser 50/100/200/400W Technology advantages Miniaturized structure Laser 915nm wavelength Operation CW mode Fiber output 1 number Laser guide <3mW Fiber diameter 200/400um Fiber length 5/10m Long service life High electro-optical conversion efficiency No wearing parts Can set the laser power output waveform Electro-optical efficiency Power output Machine size Cooling type Working temperature Working humidity >25% AC220V±10%50/60Hz 50W&100W-430w 450d 165h(mm) 200W&400W-430w 655d 215h(mm) 50W&100W&200W-Air cooling 400W-Water cooling %-75% 50/100W diode laser 200/400W diode laser

18 Multifunctional laser welding head The laser welding head focuses the laser on the welding position to achieve the spot size and shape. With the temperature detection and beam shaping, which can complete more sophisticated, more diversified welding technology. Compared to the circular spot, the elliptical spot can be faster to achieve rectangular welding plate, oval-shaped welding plate's uniform heating, which can enhance the welding efficiency and can prevent district overheating. Standard Adjustable circular spot Rectangular optical path Three directions (wire feeding position ) optional Coaxial CCD monitoring The CCD double cross line matches the spot size Extensible and adjustable elliptical spot shape Elliptical spot Coaxial temperature measurement Elliptical spot Coaxial temperature measurement Adjustable circular spot Rectangular optical path Three directions (wire feeding position ) optional Coaxial CCD monitoring The CCD double cross line matches the spot size Extensible and adjustable elliptical spot shape Can be integrated mini wire feeding device Elliptical spot

19 Temperature negative feedback control system The temperature sensor based on infrared heat radiation can detect the temperature of solder spot in real time. Meanwhile, the temperature negative feedback technology can adjust the welding power in real time to ensure the welding temperature controllable. Temperature control principle During laser soldering, the laser can continue to heat the welding area, so the temperature control is particularly important. The traditional way of controlling the welding temperature by changing the laser power, but it easy affected by the difference of the welding plate, such as absorption rate, heat dissipation rate, which would resulting in welding failure. Through the non-contact infrared temperature sensor, welding position temperature can be detected in real time. And in according with the welding changes, adjusting the welding power to ensure the welding process is always within the controllable temperature range. No temperature control Temperature control (300 ) Infrared and non - contact temperature measurement The mini measuring range is 0.5mm Temperature range Note: (Green)Temperature setting (Red)Actual temperature (Black)Power output Response time is 0.2ms Temperature control comparison In the case of temperature control, the welding temperature is always controlled within the setting range so does not cause the welding plate damage. At the same time through the No temperature control Temperature control temperature feedback can achieve rapid heating process.

20 Intelligent wire feeding system The wire feeding system ensures the stable supply of welding wire, control the accurate tin time and suitable soldering amount. Wire feeding control During the laser soldering process, the stepper motor drives the tin roller, sends the wire to the welding position through the wire feed pipe, and separates the soldering wire from the soldering joint before welding is completed. The precision blade would punch the side wire during the wire feeding process, so that the flux flow out, which can prevent tin boiling phenomenon and reduce the probability of solder ball. Wire Flux No explosion-proof tin treatment Wire diameter mm Wire hole use explosion-proof tin treatment Lack of tin detection Different wire diameter fast switching Explosion-proof tin treatment Welding effect of no explosion - proof tin treatment In case of no explosion-proof tin treatment, flux splash serious and produce more solder balls.

21 application case -- Micro switch The solution uses XYZ three-axis workbench, with the rotary table to achieve simultaneous loading and unloading. Suitable for soldering mass production of small electronic devices such as micro switch. Technology data Welding type Laser power Spot shape Spot size Weld method Position method Welding speed Welding range Control method User interface Power input 100W Round 3mm Wire feeding welding CCD & red mm/s 100(X)*110(Y)*100(Z)(mm) Industry PC UW welding software AC220V±10%50/60Hz Equipment feature The rotary table can achieve loading and unloading & welding at the same time. Special fixture to complete the product wire positioning compression. Laser screen and door protection to protect operator's safety. Before and after welding inspection to ensure product quality Temperature feedback to ensure the welding process Machine size 900w 1100d 1555h(mm) Weight Determined by design(kg) Cooling type Air cooling Working temperature Working humidity 30%-75% Application areas Auto sensors Internal position Sample

22 application case -- Motor The solution uses XYZ three-axis workbench, manual loading, unloading and visual positioning. Suitable for soldering small production of motor coil and other components. Technology data Welding type Laser power Spot shape Spot size Weld method Position method Welding speed Welding range Control method User interface Power input Machine size Weight Cooling type Working temperature 100W Oval 2*4mm Wire feeding welding CCD & red and visual positioning mm/s 200(X)*100(Y)*200(Z)(mm) Industry PC UW welding software AC220V±10%50/60Hz 700w 1000d 1703h(mm) Determined by design(kg) Air cooling Working humidity 30%-75% Application areas Motor Equipment feature Elliptical spot heating Visual positioning to ensure the welding position Fast fixture switching The workbench is compact and flexible Sample

23 application cases as a precision welding method, which is mainly used in high welding requirement industries, such as auto electronics, communications electronics and mobile devices etc. Auto sensor Wave filter Pressure sensor Wave filter accessories Communication components Micro switch Motor coil Diode Buzzer