-- the diode laser of high power solders the advantage that plastic place has accords with auto industry demand to be in auto industry especially, plastic use increases increasingly. Same, material is mixed the conformity of yuan of component is meant solder plasticly the technology that the method makes a key with each passing day. Already some technologies solder like ultrasonic, heat up board solder, and agglutinate technology each has his strong point, but these technologies are put in many limitation, if machining a process, can solder data side has restriction, cost is high, or it is to need to use special tool. However, be aimed at the limitation of these technologies, appeared a kind of new-style technology. Commercialize and transmit of laser of high power diode solder technical development from go up at all improvement is plastic soldering ability, it already developed to make laser beam welding receive the crucial processing technique that makes plastic treatment likely. Graph 1: Electronic-controlled laser of diode of high power of laser of diode of high power of footplate of solar term door is be based on solid state technology and development rises, accordingly, their dependability is good, typical least design service life is in 10, the left and right sides when 000 jobs. They are right also already some laser types brought further marked improvement, in the structure compact sex, dimension of beam of light, efficiency of light produced by electricity and capital and moving charge respect. For example, the measure of laser head unit of 250W only 260 × 125 X 125mm, weigh 5 Kg. Auxiliary facility is only a small Control Panel and a cooling device. The system that sets control system and cooling plant is usable also. The structure with laser compact head makes it can be gone to by direct installation on manipulator, have much axis thereby process capability. If need, beam of light also can be transmitted through cable. The efficiency of light produced by electricity of diode laser is more than 30% , photograph comparing is mixed at CO2 Nd:YAG laser, respective efficiency value is respectively 10% with 4% . At present laser of existing high power diode outputs power to be more than 6KW, such intensity enough satisfies frit Fu, solder, and exterior heat treatment of the metal. However, in auto industry respect, laser beam welding receives initiative applying is in join polymer respect. Although thermoplastic plastic the radiant energy of the wave band outside absorbing Yuan Gong easily, but the close infra-red light that produces to diode laser is pervious to light however. Major energy is not absorbed by polymer. However, can pass those who have a choice to join additive to be like pigment, filler, aggrandizement agent will make plastic draw laser energy. Graph 2: ETC laser beam welding receives unit to transmit solder transmit solder what the technology used polymer and additive is different absorb and transmit character, used the pattern that has some kind of jackknife to come true solder. Pass careful choice material and additive, make the on half part of contact OK transmission laser and below half part is become by the design can draw enough laser energy, such making interfacial melt, come true thereby solder purpose. In the application of this respect, carbon is very ideal additive, because it draws the energy of diode laser easily. Laser is transmitted solder as plastic as what have solder technical photograph is compared have a lot of advantages. With vibration / supersonic solder different, laser is transmitted solder dispute contacts treatment, be opposite not easily quite so sensing element, contain the element of electronic circuitry for instance, cause damage. In addition, what does it need scarcely special tool, and major vibration / supersonic, heat board solders the system needs a lot of special tools to undertake machining to component. The crucial factor in process of laser beam machining includes: The choice adds the additive of polymer, (namely assistant of pigment, intensifier, treatment) , juncture design, treatment access design. Company of British Warwick Laser Systems (one's deceased father civil hang down city) already developed gave a kind of plastic laser to transmit solder device and realized commercialization. Right a series of thermoplastic plastic applicability evaluates what had defined a lot of material to solder condition, these material included chromatic material, polypropylene, polyethylene, acrylic colophony, polycarbonate, vitreous filling and filmy material. Graph 3: Filter solders sectional sketch map of the position regards blame contact as the technology, laser beam welding receives the issue that the tool pollution that avoided to be concerned with other and traditional technique and product place. Height can accuse the beam of light that shoots from diode laser system, and output is stable and but beforehand set, allow to undertake soldering continuously. Laser power is high, beam of light is wide, can undertake bedding face is accumulated accordingly solder, do not have any limitation to component dimension and structure in fact. And if need, the can accuse gender and beam of light to transmit highly accuracy of beam of light also can ensure very accurate solder operation. Car application is packed in food, medical treatment equipment, in waiting for a domain with scientific research equipment very good already used laser to transmit solder technology, and auto industry still is the adoption with this the mainest technique domain. Recently, company of British Birkbys Plastics (on the west York county, lifuxiji) use laser to transmit solder the technology will make a kind new-style and electronic-controlled solar term door (ETC) footplate is used at motor-driven car. If footplate pursues 1, it is made mould of vitreous fill nylon, the use in auto industry is very extensive. New ETC footplate characteristic is the sensor that uses bolt of integrated and rather than to receive, this makes it and other footplate photograph are compared, have compositive, economy, and not easy attaint is characteristic. When driver pedal, demand signal is conveyed to control a system to engine, compare it and ignition graph photograph, can make fuel is added accurately in engine, carry tall combustion efficiency, achieve economy thereby, of function optimize, with the purpose with little exhaust emission. Should be sensor conformity in footplate is the most important is will " potentiometer " solder accurately in proper place. Because potentiometer needs by accurate placement and zero, if use vibration,solder so it is not actual that the technology undertakes soldering between two different plastic element. In addition, used the vitreous fill nylon of two kinds of different level because of use potentiometer and footplate, their melting point is different, also cannot use hot technology so supersonic perhaps solder the technology will join these two component. Graph 4: Filter is in 34 cling to below intensity of pressure, after the development center of the company of circumstance Warwick Laser Systems after blowout is having a test successfully for many times, transmit diode laser solder to be assembled automatically what the system closes to go to Birkby company to be built designedly directly, solder and test product line, will solder electronic-controlled the component of nylon of two glass fill in component of footplate of solar term door (graph 2) . The juncture with wide 3mm of this system generation and potentiometer sealed in footplate. Below this kind of circumstance, laser is by installation on the manipulator of German Kuka, need not any special tools. The profit that uses manipulator operation to this component depends on realizing systematic flexibility. Because ask to solder to undertake in the both sides of component, below this kind of circumstance, manipulator is the most efficient choice. The word that has reduplicative element uses clamping apparatus with respect to need, and undertake to the program alter. The program of manipulator can be risen by memory, reduced shutdown time thereby. The output power of laser can use powermeter to monitor regularly. Because the work area of manipulator is very large, because this is OK,install powermeter at any convenient places. With simple procedure can be being produced a certain number of undertake metrical after the spare parts of several. The plan that establishs material to check platform inside this job unit is undertaking in, this platform can find a place for outside working area 90 ° arrive any area between 180 ° . The advantage depends on, laser, manipulator and safe charge already business accounting passed. Such, need to consider stationary fixture and manipulator program only. Graph 5: Filter laser beam welding receives unit the another application example of this technology is to be company of British Pall Automotive Division (Chinese hackberrya second Mao Si) solder permanent and sealed fuel filter crust. The data that this crust uses is acetyl colophony, mural thick 2mm. In fact, crust is cirque canister form, accordingly it needs from outside the predestined relationship is mixed inside the brim undertakes butt welding is received (pursue 3) . Soldering previously, inside housing filter medium is compressed to be in casing, as a result of damp effect, cannot use vibration to solder technology. The dissilient intensity of pressure with the least crust is 12 cling to, secure job intensity of pressure is 6 cling to. Although had succeeded passed auto industry to test a standard, but the dissilient intensity of pressure of filter is considered as to solder the critical test of intensity, the mode that because this is welding line,damages finally. Use crock of hydraulic pressure of a manual to use pressurization, pressure sensor is used measure intensity of pressure. Filter by replete oily, and by sealed. Give pressurization of hydraulic pressure crock ceaselessly the working intensity of pressure till filter 12 cling to. Maintain this intensity of pressure a few seconds, the fall that has any intensity of pressure shows generation is interstitial possibly. Continue next pressurization till filter is final burst. The standard of burst intensity of pressure is worth > 30 cling to. Graph 4 gave out the case after burst. Noticing material is to be in the place that becomes ~60 ° with welding line to produce burst, is not along welding line. Include to have two fixed platform in the manufacturing machine of Pall, have the diode laser of a 250W severally, with will undertake from inside and from outside solder, every platform is useful be installed at taking put manipulator to come and deferent filter, in addition still an online pressure measures a station. Whole apparatus is shown 5 times like the graph. Conclusion serves as use agglutination and solder plastic method, laser of high power diode is transmitted solder the feasible replacement scheme that the technology is becoming traditional technique quickly. Its advantage very the need that accords with auto industry, on certain agglutination application, this kind of technology often is only alternative. Brian Bryden, (B. G.
Bryden@warwick.
Ac.
Uk) , it is Warwick university, warwick makes a group, the senior researcher of company of Warwick laser system. CNC Milling
CNC Machining