Apparatus for welding a plastic component to the aperture of a plastic body

Abstract

An apparatus for welding a plastic component to a body's aperture comprises a frame element, a first heating head mounted to the frame element for heating the component, a gripper for gripping the component and for mounting the component to the body's aperture, a heater arm having a second heating head mounted thereto for heating the body's aperture, and an actuator for mounting both the heater arm and the gripper to the frame element for alternating between a heating position wherein i) ia) the gripper is generally aligned with the first heating head for abutment therewith following relative movement towards each other, while ib) the second heating head is positioned for heating the body's aperture, and a work position wherein ii) the gripper is generally aligned with the body's aperture for mounting the component to the body's aperture for welding therewith. The gripper is mounted to the actuator via a cylinder arm provided with a collision monitor in the form of a linear encoder to detect inadvertent collision between the component and the heating head or the body. The collision monitor is configured to trigger an alarm when the linear encoder detects an inadvertent collision.

1 . An apparatus for welding a plastic component to a plastic body's aperture comprising: 
 a frame element;    a first heating head mounted to said frame element for heating the component;    a gripper for gripping the component and for mounting the component to the body's aperture;    a heater arm having a second heating head mounted thereto for heating the body's aperture; and    an actuator for mounting both said heater arm and said gripper to said frame element for alternating between a heating position wherein i) ia) said gripper is generally aligned with said first heating head for abutting the component therewith following relative movement towards each other, while ib) said second heating head is positioned for heating the body's aperture, and a work position wherein ii) said gripper is generally aligned with said body's aperture for mounting the component to the body's aperture for welding therewith.    
     
     
         2 . An apparatus as recited in  claim 1 , wherein said gripper further includes a collision monitor to detect inadvertent collision between the component and at least one of said first heating head and the body.  
     
     
         3 . An apparatus as recited in  claim 2 , wherein said gripper is mounted to said actuator via an arm cylinder.  
     
     
         4 . An apparatus as recited in  claim 3 , wherein said collision monitor is in the form of a linear encoder mounted to said arm cylinder.  
     
     
         5 . An apparatus as recited in  claim 3 , wherein said arm cylinder is further configured for applying a predetermined force between said first heating head and said component during heating thereof by said heating head and between said component and said body's aperture during welding thereof.  
     
     
         6 . An apparatus as recited in  claim 5 , wherein applying a predetermined force between said first heating head and said component during heating thereof includes applying a matching force for a first predetermined period and then applying a heating force for a second predetermined period.  
     
     
         7 . An apparatus as recited in  claim 5 , wherein applying a predetermined force between said component and said body's aperture during welding thereof includes applying a matching force for a first predetermined period and then applying a heating force for a second predetermined period.  
     
     
         8 . An apparatus as recited in  claim 2 , wherein said collision monitor is configured to trigger an alarm when said collision monitor detects said inadvertent collision.  
     
     
         9 . An apparatus as recited in  claim 1 , wherein said actuator includes an output shaft and a slanted block secured to said output shaft for rotation in unison therewith; said slanted block having two perpendicular surfaces, each defining a 45 degree angle with said output shaft and receiving a respective one of said gripper and said heater arm; 
 whereby a 180 degree rotation of said output shaft causes the actuator to alternate between said heating position and said work position.    
     
     
         10 . An apparatus as recited in  claim 1 , wherein said gripper is mounted to said actuator via an arm cylinder.  
     
     
         11 . An apparatus as recited in  claim 10 , wherein said gripper further includes a collision monitor to detect inadvertent collision between the component and at least one of said first heating head and the body.  
     
     
         12 . An apparatus as recited in  claim 11 , wherein said collision monitor is in the form of a linear encoder mounted to said arm cylinder.  
     
     
         13 . An apparatus as recited in  claim 12 , wherein said linear encoder further allows measuring at least one of a melt depth and a weld depth of the component.  
     
     
         14 . An apparatus as recited in  claim 1 , wherein said heater arm is mounted to said actuator via an arm cylinder.  
     
     
         15 . An apparatus as recited in  claim 14 , wherein said arm cylinder includes a linear encoder for at least one of monitoring a tank melt and applying a predetermined force during said heating the body's aperture.  
     
     
         16 . An apparatus as recited in  claim 1 , wherein said body is a tank and said plastic component is a tank inlet.  
     
     
         17 . An apparatus as recited in  claim 16 , wherein said tank inlet is defined by an elongated cylindrical body having two longitudinal ends and a peripheral collar therebetween.  
     
     
         18 . An apparatus as recited in  claim 17 , wherein said heating head is ring-shaped for receiving said cylindrical body and for abutment of said peripheral collar therewith.  
     
     
         19 . An apparatus as recited in  claim 1 , wherein said frame element includes a rigid post.  
     
     
         20 . An apparatus as recited in  claim 19 , wherein said first heating head is slidably mounted to said post for reciprocal movement therealong.  
     
     
         21 . An apparatus as recited in  claim 20 , wherein said first heating head is suspended near a distal end of an arm; said arm being slidably secured to said post near a proximate end thereof.  
     
     
         22 . An apparatus as recited in  claim 21 , further comprising a cylinder operatively coupling said arm to said post for selectively translating said arm along said post.  
     
     
         23 . An apparatus as recited in  claim 1  mounted to a robot through said frame member; said robot being for providing displacement of said apparatus.  
     
     
         24 . An apparatus for welding a plastic component to a body's aperture comprising: 
 a frame element;    a heater mounted to said frame element for heating at least one of the body's aperture and the component; and    a gripper mounted to said frame element for gripping the component and for mounting the component to the body's aperture; said gripper including a collision monitor to detect an inadvertent collision of the component with the body while the component is mounted to said body's aperture.    
     
     
         25 . An apparatus as recited in  claim 24 , wherein said gripper is mounted to said frame element via an arm cylinder.  
     
     
         26 . An apparatus as recited in  claim 25 , wherein said gripper includes a collision monitor to detect inadvertent collision between the component and the body.  
     
     
         27 . An apparatus as recited in  claim 26 , wherein said collision monitor is in the form of a linear encoder mounted to said arm cylinder.  
     
     
         28 . An apparatus as recited in  claim 27 , wherein said linear encoder further allows measuring at least one of a melt depth of the component and a weld depth of the component.  
     
     
         29 . An apparatus as recited in  claim 24 , wherein said body is a tank and said plastic component is a tank inlet.  
     
     
         30 . An apparatus as recited in  claim 29 , wherein said tank inlet is defined by an elongated cylindrical body having two longitudinal ends and a peripheral collar therebetween.  
     
     
         31 . An apparatus as recited in  claim 30 , wherein said heater includes a ring-shaped element for receiving said cylindrical body and for abutment of said peripheral collar therewith.  
     
     
         32 . An apparatus as recited in  claim 24  mounted to a robot through said frame member; said robot providing displacement of said apparatus.  
     
     
         33 . A gripper tool for a robot for mounting a plastic component to a plastic body's aperture, the tool comprising: 
 a gripper hand for receiving the component and for selectively releasing the component in the body's aperture;    a gripper arm cylinder for mounting the gripper hand to the robot; said gripper arm cylinder having a collision monitor for detecting inadvertent collision of the component in said gripper hand with the body; and    a controller coupled to said collision monitor; said controller being configured to trigger an alarm upon detecting said inadvertent collision.    
     
     
         34 . A gripper tool as recited in  claim 33 , wherein said collision monitor is in the form of a linear encoder.