Picture 1: Air guide tube with welded on injection parts

Composition procedure

At the example of blowing formed pure air pipes we compare this with it from FKS supplementarily and after customer wish for the rise of the productivity started since rotation sweat methods known to years.

1. Tube using - air leadership with connection parts in the intake area of the air system.

Blowing form tubes as air leadership systems in the intake area. See satisfy heavy demands in the engine compartment and to the controlled burning. The pipe leadership is complex by crosscuts and out book actions gene permanently changing for disturbing contours of the engine surroundings. The pipes must take vibrations and get connected to connection parts by fast clutches and special bells. Holders and bases are welded to the connection fastening to the pipe bodies. Connection flanges have just to be welded on for the different sensors for the engine control. Clutch father plays have axially to be welded on to the pipe ends in which these connections must fulfil the highest requirement on strength and density. The blowing form process for air leadership pipes makes the rather highest demands to the production: The tubes have to adapt to the remaining place conditions in the engine compartment on the outside The tube form and the crosscut are different with that in the course of the air leadership The wall density of every place of the crosscut should be same At the sweat positions the tube must flow favourably and form passing over take the connection parts to the putting part.

Figure 2: blow molded parts before the process.

2. Assess the overall situation, together with other bonded to the blow molded air guide tube.

For pre-treatment of axial joining position is necessary in any case, the finishing of the blow-pipe with circular carbide tools. The blow quality the tube goes directly into the ends and this will then be available to the joining process. I.e. a minimum wall thickness is necessary to form sufficient melt. When sensor positions before add the necessary pipe openings are machined.

Picture 3: Circular welding, double station with options

3. Process selection and preliminary processing of blow molded for welding. There are first compared the process:

• The mirror welding (HS)

• The rotation welding (ROT)

• The circular welding (ZS)

A customer has e.g. despite extensive experience with this plate welding process due to the difficult, reproducible process safety, with frequent tool changes, discarded. The rotation welding is a very popular and repeatable process for molded parts, with the restriction only suitable for rotation symmetrically joints. Ends reprocessed blow molded forms are a special problem as regards the parallelism to the unparallel to be joined end piece - the clutch: is the ring surface can cause the "rattling" occur in the process and even the connection is not consistent. The same negative result occurs when the part-centre are added. A tongue-web connection is then not self-centred and the parts are leaking! The circular welded parts forgive greater parallelism and centre offset, because the "friction partners do not circulate. It is formed on the "body" and friction welding is plain welded. Non Parallelism, wave forms and wall thickness error over-welded be in a strong degree and form the weld expulsion of analogous to the welding depth is created. And there are two advantages to the process:

1. The same process can be asymmetric shapes like socket, bracket and flanges at other points to be welded to the tube!

2. There are two tube ends joined together with end pieces, whether same or different tubes, no matter.

The grouping of stations is useful because you can with a circular welding head welded simultaneously to two different parts to be joined. The tube location is determined by the separate shots clamping the pipe clamp directly in place fin secure form fit. Each station can also be operated individually. In one machine, multiple stations are combined to optimize the workforce and capacity.

4. Settings requirements to the welding machine in the processing of blow-molded parts with injected parts.

Settings to compensate for pre-editing tolerance is necessary to position the part to fit each other. The circular welding process is reproducible in all joining parameters, programmable. This is the basis given by untrained personnel or run through the parts handling automation. Parameters monitoring flown in the process through the machine by means of window functions. Various parts of sensors able to control the form of check before joining means of image processing is possible. Nevertheless, the best setter must for the "Tolerance trend" of the angles, blow molded, and the fitted parts to align the pipe positions. A new concept of 3D images allows for tension adjustment of the molded parts to the tube level, more can not be said! Like everywhere: The process has several stations which are already in the fit to accumulate and so is the result in time and money represented. Quality, whether the manufacturing process sequence or manufacturing floor is ideal for blowing determines the size of the series and the changing expense from product to product.

Figure 4: Circular welding center with adjust modules