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EP1660265A1 - Procede et systeme de soudage de goujons pour la fixation d'une tole sur une structure metallique - Google Patents

Procede et systeme de soudage de goujons pour la fixation d'une tole sur une structure metallique

Info

Publication number
EP1660265A1
EP1660265A1 EP04762783A EP04762783A EP1660265A1 EP 1660265 A1 EP1660265 A1 EP 1660265A1 EP 04762783 A EP04762783 A EP 04762783A EP 04762783 A EP04762783 A EP 04762783A EP 1660265 A1 EP1660265 A1 EP 1660265A1
Authority
EP
European Patent Office
Prior art keywords
stud
welding
metal
stracture
welding gun
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP04762783A
Other languages
German (de)
English (en)
Inventor
Lars Erik Hansen
Kurt Munk Pedersen
Jan THERNØE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rockwool AS
Original Assignee
Rockwool International AS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rockwool International AS filed Critical Rockwool International AS
Priority to EP04762783A priority Critical patent/EP1660265A1/fr
Publication of EP1660265A1 publication Critical patent/EP1660265A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/20—Stud welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/20—Stud welding
    • B23K9/201—Stud welding of the extremity of a small piece on a great or large basis
    • B23K9/202—Stud welding of the extremity of a small piece on a great or large basis by means of portable equipment, e.g. stud welding gun
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/20—Stud welding
    • B23K9/207—Features related to studs

Definitions

  • the present invention relates to a method of attaching a sheet panel onto a metal structure by placing a number of studs through the sheet material and welding said studs onto the metal structure by using a stud-welding system, a stud for use by attaching a sheet panel onto a metal structure comprising a head with a protruding pin member and a stud welding gun for welding on studs comprising spring-loaded stud holding means for receiving a stud and pinching this stud through a sheet panel and forcing the stud towards an underlying metal structure.
  • steel structures covering panels of fibrous insulation material may often be fitted in order to provide fire, thermal and/or noise insulation, e.g. of steel structures in building constructions, metallic ventilation ducts, steel chimneys/stacks, pipes or metal structures for maritime purposes. This insulation is often required in order to provide an effective fire protection.
  • an insulating layer In order to fit an insulating layer to a metal structure, typically a steel structure, it is known to weld a number of needle pins onto the steel surface. On these needles, panels of fibrous insulation material are mounted. When the panels are mounted, the needles are pinched through the panel and a locking disc is secured to the ends of the pins, which protrude through the fibrous insulation panels. In order to ensure that the insulation panels are properly secured, the needle pins must be positioned relatively close.
  • Another method of attaching fire insulation to a steel structure is to use welding studs pinched through an insulation panel, which are fitted to the surface of the structure, and then welded to the structure by use of a welding gun.
  • This method it is possible to position the attachments in relation to the assembling joints of the fibrous insulation panels.
  • the mounting of the insulating panels is also easier and the danger of being injured on the needles is eliminated.
  • the studs are pinched through the insulation panels or layers and into contact with the underlying steel surface at desired positions, i.e. away from the joining lines between the panels. Thereby, the amount of attachment points may be reduced and the mounting is easier and less time-consuming. This method is also applicable to rolls of insulation material.
  • this method is significantly less applicable to non-conducting, corrosion protected surfaces, such as painted surfaces, since the welding must bum away the paint before a metallic contact between the steel and the stud can be established.
  • the welding attachment may be of a poor quality due to residues in the welding areas, since the worker needs to remove the paint prior to performing the welding operation.
  • the corrosion protective layer cannot be re-established if it is damaged. The method demands a great power from the worker in order to shoot the studs into the panel and they may fall out or become damaged during the penetration due to the high resistance.
  • any paint or rust scales must initially be removed, e.g. by grinding, before the welding can take place. This results in inaccuracies since many areas are left exposed without any protection against corrosion.
  • the object is achieved by a method of attaching one or more sheet panel onto a metal structure by placing a number of studs through the sheet material and welding said studs onto the metal structure by using a stud-welding system in which the stud is positioned in a stud- welding gun, said method comprising the steps of penetrating a stud through the sheet material and positioning a stud-welding gun of the stud- welding system on the stud, providing an electrical contact between a stud and the underlying metal structure. A welding current is applied, and the stud is retracted providing a gap between the stud and the metal structure and establishing a welding arc, and forcing the stud against the metal structure after a predetermined duration of time.
  • the electrical contact may be provided by positioning a distal end of the stud immediately above the metal structure, whereby a high frequency voltage is applied to the stud, preferably between 6 kV to 14 kV with a frequency of 100 kHz to 200 kHz.
  • the high frequency high voltage power supply is similar to the one known from a TIG (Tungsten Inert Gas) welding system.
  • the gap is preferably between the distal end of the stud and the metal structure between 0.1 mm to 1 mm, preferably approx. 0.5 mm, and the high frequency voltage is applied for a sufficient amount of time to establish a welding arc whereafter the welding current is applied, preferably within the interval of 0.25 to 1 second.
  • a cleaning of the surface to which the stud is to be welded can be obtained. Any coating or other impurities may be burned off and a small drawn arc may be created between the distal end of the pin of the stud and the surface of the metal structure. Subsequently, the stud welding process may be performed.
  • the attachment of panels may be carried out in a single operation and with a better precision, since the panels may be placed in position before the attachment points are established.
  • the spikes must be welded onto the exposed surface before the panels are pressed into position.
  • This method is particular advantageous for attachment of fibrous insulation to steel constructions in maritime insulation and fire insulation of steel columns and girders.
  • the method is also advantageous in that insulation panels in certain occasions may be attached to confined spaces of a steel structure since a considerably smaller amount of space is required for performing the attachment.
  • the electrical conductivity is measured by measuring means and when the electrical conductivity exceeds a predetermined value the surface coating is sufficiently broken or removed and the surface is sufficiently clean so that a good electrical contact between the stud and the metal structure may be established.
  • the welding current is established and right after, almost simultaneously, the stud is moved backwards creating a second gap and draw the welding arc.
  • the second gap which is provided is preferably between 0.5 mm to 4 mm, more preferably between 0.75 mm to 2.25 mm.
  • the welding current is applied as, or after, the electrical contact is being provided.
  • the welding arc forms a melting pool between the stud and the metal construction.
  • the welding current has a magnitude of 50 A to 850 A, preferably 100 A to 500 A, and duration between 0.5 ms to 500 ms, preferably 10 ms to 200 ms.
  • the welding current may be replaced by a current sequence comprising at least two different current levels where a first period with a current of approximately 10 A to 100 A, is used for preheating the metal in the welding zone.
  • This preheating current has duration of approximately the same order of magnitude as the welding current.
  • the welding current is applied after the preheating current. If using a sequence of currents, the gap is created as the welding current is initiated.
  • the stud After the welding arc has created a molten pool, the stud is forced into the pool by releasing the spring-loaded receiving means holding the stud in the stud- welding gun.
  • the time delay before this release and the welding current to be applied are determined according to the type of stud, e.g. stud pin diameter and the material of the metal structure.
  • the sheet material is preferably a fibrous insulation sheet material.
  • the method may also be applied in relation to the attachment of other types of panels, such as for instance calcium silicate boards, gypsum boards or cementious boards.
  • the panels are usually stiff, but soft materials may also be used as panels, e.g. rolls, batts, foam panels or other sound or vibration absorption panels.
  • the metal structure is a steel structure.
  • the method may also be applied in connection with other metal structures such as e.g. aluminium structures.
  • the method is preferably applied in connection with a coated steel structure, e.g. with a corrosion resistant coating in order to remove the coating.
  • the method according to the invention may also be advantageously used for uncoated structures for removing impurities on the surface at the point of welding. Otherwise, impurities, such as scaling, heat residues etc., must be removed before the welding process, which is very time consuming.
  • the structures may be coated with plastic coatings, paint or any other suitable protective coating.
  • the invention also relates to a stud welding system comprising a stud for use by attaching a sheet panel onto a metal structure comprising a head, preferably a discshaped head, with a protruding pin member, wherein said pin member is provided with top layer removing means at its free end.
  • the top layer corresponds to the corrosion protective layer or coating, e.g. paint.
  • the stud according to this aspect of the invention is thus adapted for use by a method according to the above-described first aspect of the invention.
  • the head may be provided with a non-rotary symmetric shape.
  • magnetic holding means may be provided and/or the disk-shaped head may be provided with indexing means, such as one or more indentations on the outer rim of the head. The indentations may also be provided in the interior of the head.
  • the pin and/or the underside of the head is provided with an electrically insulating sleeve. This is advantageous if the insulating panels are provided with a top layer of aluminium foil in order to isolate the aluminium foil from the welding process.
  • the invention comprises a stud- welding gun for welding studs onto an underlying metal surface for attaching an insulation panel to said metal surface, said stud-welding gun comprising first spring-loaded stud holding means for receiving a stud, which is pinched through a sheet panel, and biasing the stud towards an underlying metal structure, welding current application means capable of applying a high frequency voltage and applying a welding current to the stud, wherein said stud receiving means are provided with lifting means for retracting the stud along its pin axis, said lifting means being capable of positioning the stud immediately above the metal structure surface at at least two different levels.
  • the stud-welding gun is adapted for use in performing a method according to the first aspect of the invention.
  • the receiving means are preferably provided with magnetic means for retaining the stud in a predetermined position relative to the metal structure.
  • the stud can be placed in a predetermined position in the receiving means of the stud- welding gun and kept in this position before the action of attachment commences.
  • the stud-welding gun is preferably provided with support members, such as support levers, said legs preferably being adjustable, for providing a predetermined distance and pressure during the welding process.
  • the support legs are designed in such a manner, that the distal end of the stud when positioned in the spring-loaded receiving means protrude a certain protrusion distance in front of the legs.
  • Three or more supporting members offer a good adjustment of the stud, always holding it perpendicular to the surface of the metal construction.
  • three or more supporting members complicate application of the method in e.g. comers due to limited space. This problem is reduced by only having two legs. With two legs, however, there is a risk of installing the stud not perpendicular to the underlying metal construction surface. With only one supporting member, the application in limited spaces is easier, but also the risk of installing the stud not perpendicular to the underlying metal construction surface is higher. However, one supporting member should be enough for ensuring the correct distance during the welding process.
  • fig. 1 is an illustration of a steel structure with a fibrous insulation mounted thereon
  • fig. 2 is a principal cross-section view of a steel girder with an insulation fitted around it
  • fig. 3 is a schematic illustration of the method of attaching a fibrous insulation panel according to the invention
  • fig. 4 is a perspective drawing of a stud according to the invention
  • fig. 5 is a top view of a stud according to another embodiment
  • fig. 6 is a schematic detailed view of the stud as it engages the steel structure
  • fig. 7 is a schematic illustration of another use of the invention for assembly of panels of a plurality of layers
  • fig. 8 is a diagram of the welding current as a function of time during the welding process
  • figs. 9 and 10 are detailed views of a stud-welding gun according to the preferred embodiment of the invention.
  • FIG 1 a steel structure 2 with fire insulation 1.
  • the insulation is typically made up of fibrous insulation panels 1, which are mounted on the steel girder structure side by side covering the entire surface of the steel structure.
  • the fibrous insulation panels 1 are secured to the steel structure by studs 3, which are pinched through the insulation panel and brought in contact with the steel surface underneath, as shown in fig. 2 and welded onto the steel structure 2 by use of a stud welding gun 4 by an electric welding process (see fig. 3).
  • the welding gun 4 has a capacitor unit or a transformer unit (not shown).
  • the capacitor unit is charged by a main voltage-supplied transformer (not shown).
  • a sufficient high amount of energy may be applied to the stud in a short time (a fraction of a second) so that the stud is welded onto the metallic surface.
  • the welding gun 4 is pressed against a stud 3, which is pressed through the insulation panel 1, as shown in fig. 3.
  • the stud 3 is accommodated in a receiving head 5 of the welding gun 4.
  • the welding gun 4 is placed over the stud 3 so that the receiving head 5 is fitted over the head 31 of the stud 3 (see fig. 4).
  • the stud 3 is positioned with a small first gap above the metal structure 2 and a high-frequency high-voltage is applied for establishing an electrical contact.
  • the stud is moved back slightly to a position leaving a second gap between the distal end of the stud pin and the metal structure and a welding current is applied. This establishes a welding arc creating a molten pool. After a predetermined time the stud is forced into this molten pool and the insulation panel 1 is retained between the metal structure and the head of the stud 3.
  • the stud 3 consists of a preferably disc-shaped head 31 from which an elongated protruding pin member or stud pin 32 extends.
  • the head 31 may additionally be provided with indentations and the contour of the head 31 is designed to co-operate with the inner shape (non shown) of the receiving means 5 of the welding gun 4 to ensure a firm grip of the receiving means 5 is transferred to the head 31 and thereby the stud 3.
  • a top layer penetration means 35 is provided, preferably as a cone or pyramid shaped end of the pin 32. Adjacent the penetration means 35, a small deposit of zinc or similar corrosion protective material may be provided or the entire stud pin may be galvanised or provided with a similar coating. The zinc or similar corrosion resistant protective material gives good protection against galvanic corrosion.
  • a magnetic grip by the receiving means 5 on the stud may prove sufficient in some circumstances in order to provide the necessary grip of the stud 3 (see figs. 9 and 10).
  • the pin 32 is provided with a sleeve 36 of plastic or similar non-conductive material extending substantially along the length of the pin between the tip 35 and the head 31.
  • an isolating coating 38 of non-conductive material may be provided on the underside of the head 31. This prevents damaging an aluminium foil coated insulation panel from the electrical current of the welding gun as the welding energy is released during the welding process.
  • the insulation 1 which has to be fastened to the metal structure is covered by a metal foil, e.g. aluminium, on the surface opposite the metal structure.
  • the first welding pin 3 may therefore make up an electrical connection or short- circuit between the foil and the metal stmcture 2. This will make it more difficult to perform the welding of the second and following pins, as the pin holding means 5 on the welding gun 4 or the pin 3 itself will be in electrical contact with the foil. This will make it impossible to establish a welding arc.
  • the electrically insulating surfaces on the pin holding means 5 could be ceramic materials applied by e.g. thermal spraying, or some other temperature resistant material.
  • the electrically insulating surface on parts of the pin 3 may be applied by any substantially electrically insulating paint or other substantially electrically insulating surface layer.
  • the tip 35 of the pin 32 is provided with a pointed distal end, e.g. a conical or a pyramid shape for facilitating a penetration into the molten pool of the steel surface of the steel stmcture 2 when the stud is pressed into the pool.
  • a pointed distal end e.g. a conical or a pyramid shape for facilitating a penetration into the molten pool of the steel surface of the steel stmcture 2 when the stud is pressed into the pool.
  • the stud pin 3 may be without a stud head.
  • the disc shaped head may be subsequently attached to the pin after the pin has been welded onto the metal stmcture by the welding gun.
  • FIG. 7 Another utility of the invention is shown in fig. 7 where several layers la, lb of panels 1 are attached to a steel stmcture 2 by one or more studs 3.
  • the stud 3 is retained in magnetic receiving means 5 in the stud- welding gun 4.
  • the magnetic receiving means retains the stud 3 at its head 31 or at its head end so that the stud pin 32 points towards the surface to which it is to be attached.
  • the stud 3 is penetrated through the insulation layer (not shown in figs. 9 and 10) and positioned so its distal end tip abuts the metal structure 2.
  • the distal end of the stud 3 protrade beyond the support members, e.g. support legs, 40 of the welding gun 4 when the spring-loaded receiving means 5 are in the spring means are unloaded.
  • the support member 40 also penetrate the insulation and makes contact with the coated metal surface 2, as the spring-loaded receiving means 5 are compressed by a distance D, whereby the distal end of the support members 40 also makes contact with the underlying surface.
  • the stud-welding gun is kept in a predetermined position by the support members 40, e.g. support legs, so that the correct distance D is maintained and controlled during the securing action of the stud pin 3.
  • the spring-loaded receiving means 5 may comprise a compression spring means 41 which in an advantageous embodiment may be provided with adjustment means for regulating the spring force and the protmsion distance D.
  • the receiving means 5 may preferably be provided with reciprocating means which may be activated for repetitively knocking or tapping the stud against the surface of the metal stmcture for establishing a sufficiently good electrical contact.
  • Measurement means (not shown) may preferably be provided for measuring the electrical resistance between the stud and the metal surface in order to automatically determine when a sufficiently good electrical contact is established.
  • a measurement means is applied for determining when the electrical resistance has fallen below a predetermined level.
  • the welding current is applied and almost simultaneously the stud 3 is lifted slightly and the second gap L appears as indicated in fig. 10.
  • the welding arc is now established.
  • the second welding current is applied.
  • the melting pool is created by the welding arc and after a predetermined amount of time (the welding time), the welding current is cut off and the stud is pressed into the molten pool and the stud is attached to the metal stmcture.
  • the results may vary depending on the stud pin diameter and other parameters, such as material, etc.
  • the welding time may be longer than 10 ms.
  • the result of the welding process may be enhanced by using a longer welding time.
  • the pin size limits the duration of welding time. It is realised that a significant improvement in the welding quality may be achieved making the insulation panel attachment considerably better and less labour intensive.

Landscapes

  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding Control (AREA)
  • Connection Of Plates (AREA)

Abstract

L'invention concerne un procédé pour fixer un panneau de tôle sur une structure métallique, par positionnement d'un certain nombre de goujons à travers le matériau de tôle, et par soudage des goujons sur la structure métallique, au moyen d'un système de soudage par goujons dans lequel le goujon est placé dans un pistolet de soudage par goujons. Le procédé selon l'invention comprend les étapes consistant: à introduire le goujon dans le matériau de tôle et à positionner un pistolet de soudage par goujons du système de soudage par goujons, sur le goujon; à établir un contact électrique entre le goujon et la structure métallique sous-jacente; à appliquer un courant de soudage au goujon; à retirer le goujon, de façon à ménager un interstice entre le goujon et la structure métallique; à former un arc de soudage; puis à forcer le goujon contre la structure métallique après un laps de temps prédéterminé.
EP04762783A 2003-08-27 2004-08-24 Procede et systeme de soudage de goujons pour la fixation d'une tole sur une structure metallique Withdrawn EP1660265A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP04762783A EP1660265A1 (fr) 2003-08-27 2004-08-24 Procede et systeme de soudage de goujons pour la fixation d'une tole sur une structure metallique

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP03077672 2003-08-27
EP04762783A EP1660265A1 (fr) 2003-08-27 2004-08-24 Procede et systeme de soudage de goujons pour la fixation d'une tole sur une structure metallique
PCT/DK2004/000562 WO2005021200A1 (fr) 2003-08-27 2004-08-24 Procede pour fixer un panneau de tole sur une structure metallique, et systeme de soudage par goujons correspondant

Publications (1)

Publication Number Publication Date
EP1660265A1 true EP1660265A1 (fr) 2006-05-31

Family

ID=34259173

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04762783A Withdrawn EP1660265A1 (fr) 2003-08-27 2004-08-24 Procede et systeme de soudage de goujons pour la fixation d'une tole sur une structure metallique

Country Status (3)

Country Link
EP (1) EP1660265A1 (fr)
NO (1) NO20061098L (fr)
WO (1) WO2005021200A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102016125600A1 (de) * 2016-12-23 2018-06-28 Newfrey Llc Fügeverfahren und Fügevorrichtung
CN114606456B (zh) * 2022-03-13 2023-12-22 兰州交通大学 一种基于螺柱焊的钛合金板材表面喷涂铝金属层的方法

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US2435815A (en) * 1945-08-31 1948-02-10 Merrill W Ambrose Welding apparatus
US2467723A (en) * 1946-05-17 1949-04-19 English Electric Co Ltd Stud welding apparatus
DE2348174A1 (de) * 1973-09-25 1975-04-03 Hilti Ag Bolzenschweisspistole
US4178495A (en) * 1976-01-12 1979-12-11 Trw, Inc. Apparatus for welding studs to workpieces
DE4312181C5 (de) * 1993-04-14 2007-05-03 HBS Bolzenschweißsysteme GmbH & Co. KG Schweißverfahren, -vorrichtung und -bolzen zum Befestigen eines an der Oberfläche leitenden elastischen Materials
US6215085B1 (en) * 1994-10-18 2001-04-10 Emhart Inc. Stud welding device
JPH1049886A (ja) * 1996-07-29 1998-02-20 Nippon Conlux Co Ltd 光メモリカードのトラッキング制御方法および装置
DE19925628A1 (de) * 1999-06-05 2000-12-07 Emhart Inc Hubzündungsschweißverfahren mit Reinigungsstufe
DE19927371C2 (de) * 1999-06-16 2001-05-03 Udo Franz Verfahren zum Anschweißen von Schweißelementen an ein Werkstück
DE10001344A1 (de) * 2000-01-14 2001-07-19 Emhart Inc Verfahren und Vorrichtung zum mehrstufigen Lichtbogenschweißen
JP2003019563A (ja) * 2001-07-04 2003-01-21 Nippon Pop Rivets & Fasteners Ltd アルミニウム系スタッドの溶接方法及び装置
EP1352699A1 (fr) * 2002-04-09 2003-10-15 Rockwool International A/S Procédé et système de soudage de goujons pour la fixation d'une tôle sur une structure métallique

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Title
See references of WO2005021200A1 *

Also Published As

Publication number Publication date
NO20061098L (no) 2006-03-07
WO2005021200A1 (fr) 2005-03-10

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