Welding apparatus and welding method

• US 10,449,620 B2
• Filed: 03/31/2015
• Issued: 10/22/2019
• Est. Priority Date: 03/31/2014
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Nakamura, Masaya
• Primary Examiner(s): Ross, Dana
• Assistant Examiner(s): Baillargeon, Joseph M
• Application Number:
  US14/674,505
• Publication Number:
  US 20150273619A1
• Time in Patent Office: 1,666 Days
• Field of Search: 219 8641, 219110, 219 911, 219108, 313118, 29746, 228 8, 228 9, 445 7, 445 4, 445 64, 445 67, 374101, 374102, 374107, 374141, 374100, 374163
• CPC Class Codes: B23K 11/002 specially adapted for particular articles or work
• CPC Class Codes: B23K 11/0033 Welding locally a thin plate to a large piece
• CPC Class Codes: B23K 11/004 Welding of a small piece to a great or broad piece
• CPC Class Codes: B23K 11/0046 the extremity of a small piece being welded to a base, e.g. cooling studs or fins to tubes or plates
• CPC Class Codes: B23K 11/241 Electric supplies B23K11/248 takes precedence
• CPC Class Codes: B23K 11/252 using digital means
• CPC Class Codes: B23K 11/253 the measured parameter being a displacement or a position

Abstract

A welding apparatus for resistance-welding a tubular member and a bar member includes: a positioning jig configured to make contact with the bar member from one side of the bar member in a direction perpendicular to an extending direction of the bar member; a first power supply jig configured to press the bar member from the other side of the bar member in the direction; a second power supply jig provided on an anti-bar member side of the tubular member and configured to apply pressure to contact surfaces of the bar member and the tubular member; and means for supplying, with the bar member pressed between the positioning jig and the first power supply jig and the second power supply jig applying pressure to the contact surfaces, electric current to the first power supply jig, the bar member, the contact surfaces, the tubular member and the second power supply jig.

Claims

1. A welding apparatus for resistance-welding a tubular member and a bar member arranged in contact with one axial end surface of the tubular member, the welding apparatus comprising:

a positioning jig configured to contact the bar member from a first side of the bar member in a direction perpendicular to an extending direction of the bar member;

a first power supply jig configured to actively press the bar member from a second side of the bar member opposite the first side of the bar member, the first power supply jig actively pressing the bar member against the positioning jig in the direction perpendicular to the extending direction of the bar member;

a second power supply jig located on an anti-bar member side of the tubular member, the second power supply jig being configured to actively press against respective contact surfaces of the bar member and the tubular member in the extending direction of the bar member, the bar member being actively pressed between the positioning jig and the first power supply jig, the second power supply jig actively applying pressure to the contact surfaces of the bar member and the tubular member;

an electric current supplier supplying electric current to the first power supply jig, the bar member, the contact surfaces, the tubular member, and the second power supply jig, the bar member having a smaller heat capacity than the tubular member; and

a controller configured to;

receive a temperature of the tubular member measured by a temperature sensor;

calculate a temperature of the bar member based on a rate of change of the measured temperature of the tubular member; and

control the electric current supplied by the electric current supplier so as to;

(i) maintain the temperature of the bar member, as calculated based on the measured temperature of the tubular member by the temperature sensor, at a constant value at a temperature that suppresses melting of the bar member for a predetermined period of time, which is after a start of the electric current supply and after the temperature of the bar member is increased to reach the temperature that suppresses melting of the bar member, and then (ii) increase the temperature of the bar member and the temperature of the tubular member to temperatures that melt the bar member and the tubular member.

2. The welding apparatus as set forth in claim 1, further comprising a pressure application jig that is provided on an anti-housing side of the bar member to apply, together with the second power supply jig, pressure to the contact surfaces of the bar member and the tubular member.

3. The welding apparatus as set forth in claim 1, wherein the first power supply jig has a contacting portion that surface contacts or line contacts the bar member.

4. The welding apparatus as set forth in claim 1, wherein the first power supply jig is configured to press the bar member at a position slightly away from the contact surfaces of the bar member and the tubular member so as to suppress buckling of the bar member due to Joule heat on a housing side of a contact region between the first power supply jig and the bar member.

5. The welding apparatus as set forth in claim 1, further comprising a displacement sensor that detects a displacement magnitude caused by a welding deformation of the tubular member and the bar member, wherein

the controller controls, based on the displacement magnitude detected by the displacement sensor, a pressure-applying force of the second power supply jig as well as the electric current supplied by the electric current supplier.

6. The welding apparatus as set forth in claim 1, wherein the electric current supplier supplies, as the electric current, DC electric current through an inverter control.

7. A method of resistance-welding a tubular member and a bar member arranged in contact with one axial end surface of the tubular member, the method comprising the steps of:

actively pressing the bar member by a first power supply jig;

actively pressing contact surfaces of the bar member and the tubular member by a second power supply jig;

receiving a temperature of the tubular member measured by a temperature sensor;

calculating a temperature of the bar member based on a rate of change of the measured temperature of the tubular member; and

supplying electric current, after the pressing step and the pressure applying step, to the first power supply jig, the bar member, the contact surfaces, the tubular member, and the second power supply jig, the electric current is supplied so as to;

(i) maintain the temperature of the bar member, as calculated based on the measured temperature of the tubular member by the temperature sensor, at a constant value at a temperature that suppresses melting of the bar member for a predetermined period of time, which is after a start of the electric current supply and after the temperature of the bar member is increased to reach the temperature that suppresses melting of the bar member, and then (ii) increase the temperatures of the bar member and the tubular member to temperatures that melt the bar member and the tubular member, the bar member having a smaller heat capacity than the tubular member.

8. The method as set forth in claim 7, further comprising, before the pressing step and the pressure applying step, a step of forming a protrusion at a tubular member-side end of the bar member.

9. The method as set forth in claim 7, further comprising, before the pressing step and the pressure applying step, a step of forming a recess, which is smaller than a cross section of the bar member, in the axial end surface of the tubular member facing the bar member.

10. The method as set forth in claim 7, further comprising, before the pressing step and the pressure applying step, a step of forming a protrusion on the axial end surface of the tubular member facing the bar member.