Systems and methods for induction welding

Patent metadata

Field	Value
Publication number	US-11760036-B2
Application number	US-202117554908-A
Country	US
Kind code	B2
Filing date	Dec 17, 2021
Priority date	Dec 17, 2021
Publication date	Sep 19, 2023
Grant date	Sep 19, 2023

Abstract

An induction welding system includes a first gantry, a second gantry, and a support structure. The first gantry includes a first frame and a first plurality of trunks. The first plurality of trunks defines a first curved inner support surface of the first gantry. The first curved inner support surface has a first curvature geometry. The second gantry includes a second frame and a second plurality of trunks. The second plurality of trunks defines a second curved inner support surface of the second gantry. The second curved inner support surface has a second curvature geometry which is different than the first curvature geometry. The support structure includes at least one tooling member defining a curved outer support surface of the support structure. The support structure is longitudinally moveable relative to the first gantry and the second gantry.

First claim

The invention claimed is:

1. An induction welding system comprising:
a first gantry including a first frame and a first plurality of trunks, the first plurality of trunks defining a first curved inner support surface of the first gantry, the first curved inner support surface having a first curvature geometry;
a second gantry including a second frame and a second plurality of trunks, the second plurality of trunks defining a second curved inner support surface of the second gantry, the second curved inner support surface having a second curvature geometry which is different than the first curvature geometry; and
a support structure including at least one tooling member defining a curved outer support surface of the support structure, the support structure longitudinally moveable relative to the first gantry and the second gantry between a first longitudinal position, in which the support structure and the first gantry are configured to secure a first portion of a workpiece vertically between the curved outer support surface and the first curved inner support surface during induction welding of the workpiece, and a second longitudinal position, in which the support structure and the second gantry are configured to secure a second portion of a workpiece vertically between the curved outer support surface and the second curved inner support surface during induction welding of the workpiece.

2. The induction welding system of claim 1 , further comprising at least one rail extending through the first gantry and the second gantry, the support structure coupled to the rail and configured to move along the rail relative to the first gantry and the second gantry.

3. The induction welding system of claim 1 , further comprising:
a first induction welder track at least partially surrounding the first gantry; and
a first end effector moveably mounted to the first induction welder track, the first end effector comprising a first induction coil assembly including a first induction welding coil configured for induction welding of the workpiece, the first end effector configured to move along the first induction welder track in a first circumferential direction to induction weld the workpiece with the first induction welding coil along the first curvature geometry.

4. The induction welding system of claim 3 , further comprising:
a second induction welder track at least partially surrounding the second gantry; and
a second end effector moveably mounted to the second induction welder track, the second end effector comprising a second induction coil assembly including a second induction welding coil configured for induction welding of the workpiece, the second end effector configured to move along the second induction welder track in a second circumferential direction to induction weld the workpiece with the second induction welding coil along the second curvature geometry.

5. An induction welding method comprising:
arranging a support structure and a workpiece together, the support structure including at least one tooling member defining a curved outer support surface of the support structure in contact with the workpiece;
securing a first longitudinal portion of the workpiece vertically between the support structure and a first gantry including a first frame and a first plurality of trunks connected to and repositionable on the first frame, the first plurality of trunks defining a first curved inner support surface of the first gantry, the first curved inner support surface having a first curvature geometry;
induction welding a primary member of the workpiece to a first secondary member of the workpiece using an induction welding coil while the workpiece is vertically secured between the curved outer support surface and the first curved inner support surface; and
securing a second longitudinal portion of the workpiece vertically between the support structure and a second gantry including a second frame and a second plurality of trunks connected to and repositionable on the second frame, the second plurality of trunks defining a second curved inner support surface of the second gantry, the second curved inner support surface having a second curvature geometry which is different than the first curvature geometry.

6. The method of claim 5 , further comprising induction welding the primary member of the workpiece to the first secondary member of the workpiece, subsequent to securing the second longitudinal portion of the workpiece, using the induction welding coil while the workpiece is vertically secured between the curved outer support surface and the second curved inner support surface.

7. The method of claim 5 , further comprising induction welding the primary member of the workpiece to a second secondary member of the workpiece, subsequent to securing the second longitudinal portion of the workpiece, using the induction welding coil while the workpiece is vertically secured between the curved outer support surface and the second curved inner support surface.

8. The method of claim 5 , further comprising moving the arranged support structure and workpiece from the first gantry to the second gantry.

9. The method of claim 5 , wherein securing the first longitudinal portion of the workpiece vertically between the support structure and the first gantry includes vertically moving the first gantry relative to the support structure.

10. The method of claim 5 , wherein induction welding the primary member of the workpiece to the first secondary member of the workpiece includes positioning the induction welding coil in a gap defined longitudinally between a first trunk of the plurality of trunks and a second trunk of the plurality of trunks.

Assignees

• Rohr Inc

Inventors

• Huang Jonathan S
• Woods Jeffrey D
• Adan Andrew
• Lechner Robert

Classifications

• B29C65/3668 Primary

  characterised by the means for supplying heat to said heated elements which remain in the join, e.g. special induction coils · CPC title

• B29C66/83 Primary

  characterised by the movement of the joining or pressing tools · CPC title

• B29C65/7838

  from the inside, e.g. of tubular or hollow articles (B29C66/3242 takes precedence) · CPC title

• B29C66/301

  Three-dimensional joints, i.e. the joined area being substantially non-flat (B29C66/5223, B29C66/5224, B29C66/5225 take precedence) · CPC title

• B29C66/131

  Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area · CPC title