Vehicle-mounted charger shell friction welding device and welding method thereof

Abstract

The invention discloses a vehicle-mounted charger shell friction welding device and a welding method thereof, and relates to the technical field of resistance substrate detection.The vehicle-mounted charger shell friction welding device comprises a base, Y-axis displacement mechanisms are fixedly installed on the two sides of the upper end face of the base, and an X-axis displacement mechanism is installed between the two Y-axis displacement mechanisms; an X-axis displacement mechanism is installed on the upper portion of the base, a vertical displacement mechanism is installed below the X-axis displacement mechanism, a friction welding mechanism is arranged at the bottom of the vertical displacement mechanism, a shell clamping mechanism is arranged in the middle of the upper end of the base and comprises guide grooves, clamping plates are installed above the guide grooves correspondingly, and the clamping plates are arranged on the upper portions of the guide grooves correspondingly. And a transmission rod is installed in the guide groove, a threaded transmission pipe is installed outside the transmission rod, a sliding block is installed outside the threaded transmission pipe, and the problems that in a traditional welding mode, the welding speed cannot be increased on the premise that the flatness of the welding position is ensured, and the flexibility of a positioning mechanism is poor are solved.

Description

Technical Field

[0001] The invention relates to the technical field of resistor substrate detection, in particular to a friction welding device for a vehicle charger housing and a welding method thereof. Background Art

[0002] The on-board charger is a device installed in electric vehicles and plug-in hybrid electric vehicles. It can convert AC power into DC power to charge the power battery of the electric vehicle. OBC has the ability to adjust voltage and current to meet the needs of different electric vehicles, while the on-board charger shell welding device is a device specifically used to weld the on-board charger shell. It usually adopts ultrasonic welding process, which uses high-frequency vibration to generate friction on the joint surface of the shell and heat it to the welding temperature to melt, thereby achieving a firm connection of the shell. The ultrasonic welding device has the characteristics of high welding efficiency, appearance and strength that meet customer requirements, etc., and is an indispensable equipment in the production process of on-board chargers.

[0003] For example, the Chinese authorized patent "An Ultrasonic Welding Device for Battery Shell" with announcement number CN215846293U includes a workbench, an ultrasonic welding device is provided above the workbench, and a positioning mechanism is provided on the workbench. The positioning mechanism includes a baffle extending left and right, and a lateral block is provided on the front side of the baffle. The baffle and the lateral block form a right angle to abut against a corner of the battery shell, so that the top of the battery shell is just below the ultrasonic welding device, thereby achieving the positioning of the battery shell; two mounting ears are provided on the rear side of the baffle, and the two mounting ears are provided with strip holes extending front and back. A number of threaded mounting holes are provided on the workbench, and the two mounting ears of the baffle are threadedly connected to the threaded mounting holes and locked on the workbench with locking bolts.

[0004] Although the above-mentioned prior art can be applied to the welding and fixation of the on-board charger housing and its matching waterway cover plate, with the continuous expansion of the production scale of on-board chargers, the requirements for welding speed are also increasing. At the same time, it is necessary to ensure the flatness of the welding position. The traditional welding method cannot increase the welding speed while ensuring the flatness of the welding position. In addition, the positioning mechanism of the welding device has poor flexibility, and it is not convenient to adjust the on-board charger housings of different specifications. It is also easy to loosen during the welding process. Therefore, it does not meet the existing needs. In this regard, we propose a friction welding device for the on-board charger housing and a welding method thereof. Summary of the invention

[0005] The purpose of the present invention is to provide a friction welding device and a welding method for a vehicle charger housing, so as to solve the problem that the traditional welding method proposed in the above background technology cannot increase the welding speed while ensuring the flatness of the welding position and the positioning mechanism has poor flexibility.

[0006] To achieve the above-mentioned objectives, the present invention provides the following technical solutions: a friction welding device for a vehicle-mounted charger shell, comprising a base, Y-axis displacement mechanisms are fixedly installed on both sides of the upper end surface of the base, an X-axis displacement mechanism is installed between the two Y-axis displacement mechanisms, a vertical displacement mechanism is installed below the X-axis displacement mechanism, a friction welding mechanism is arranged at the bottom of the vertical displacement mechanism, a shell clamping mechanism is arranged at the middle position of the upper end of the base, the shell clamping mechanism comprises a guide groove, and the guide groove is arranged on the base, a clamping plate is installed above the guide groove, and the lower end of the clamping plate is slidably limited with the guide groove, a transmission rod is installed inside the guide groove, a threaded transmission tube is installed outside the transmission rod, a sliding block is installed outside the threaded transmission tube, the inner screw hole of the sliding block is threadedly connected to the threaded transmission tube, and the upper end of the sliding block is fixed to the bottom of the clamping plate.

[0007] Preferably, a second servo motor is arranged at the middle position inside the base, and a driving bevel gear is installed on the output shaft of the second servo motor. Driven bevel gears are installed around the driving bevel gear, and the driven bevel gear is meshed with the driving bevel gear. A sleeve is fixedly arranged at one end of the driven bevel gear, and a transmission rod extends to the inside of the sleeve, and the transmission rod and the sleeve are slidably limited. An electric push rod is arranged at the other end of the transmission rod, and the fixed end of the electric push rod is fixed to the base by bolts, and the movable end of the electric push rod is connected to the transmission rod by bearings, and locks are arranged on both sides of the outside of the threaded transmission tube.

[0008] Preferably, a pressure sensor is installed on the inner wall of the clamping plate, a signal output end of the pressure sensor is connected to a single-chip microcomputer, and the output end of the single-chip microcomputer is electrically connected to the input end of the electric push rod.

[0009] Preferably, the inner walls of the sleeve and the threaded transmission tube are both provided with annular tooth grooves, the outer wall of the transmission rod is provided with annular teeth, and the annular teeth are slidably limited with the annular tooth grooves of the sleeve and the threaded transmission tube.

[0010] Preferably, a first displacement drive device is arranged outside the Y-axis displacement mechanism, and a second displacement drive device is arranged outside the X-axis displacement mechanism. A rack is arranged on one side of the Y-axis displacement mechanism and the X-axis displacement mechanism, and a limiting slide groove is arranged on the other side of the Y-axis displacement mechanism and the X-axis displacement mechanism. The first displacement drive device and the second displacement drive device are both composed of a sliding seat, a first servo motor and a transmission gear. The sliding seats are respectively installed on the outside of the Y-axis displacement mechanism and the X-axis displacement mechanism, and the limiting slider on the inner side of the sliding seat is slidably connected to the limiting slide groove. The first servo motor is fixedly installed on one side of the sliding seat, and the transmission gear is installed on the output shaft of the first servo motor, and the transmission gear is meshed with the rack. The other side of the sliding seat in the first displacement drive device is fixed to the X-axis displacement mechanism, and the other side of the sliding seat in the second displacement drive device is fixed to the vertical displacement mechanism.

[0011] Preferably, the friction welding mechanism comprises a driving motor, a housing of which is fixed to the movable end of the vertical displacement mechanism, and a stirring head is installed at the output end of the driving motor.

[0012] Preferably, a cooling chamber is provided at the rear end of the base, an evaporator is installed inside the cooling chamber, a cooling pipe is provided at the upper end of the cooling chamber, and the other end of the cooling pipe is fixed to the friction welding mechanism through a connecting piece, a negative pressure fan is installed outside the cooling pipe, and a cold air nozzle is installed at the other end of the cooling pipe.

[0013] Preferably, a heat dissipation cavity is provided below the rear end of the base, a condenser is installed inside the heat dissipation cavity, a compressor is provided on one side of the heat dissipation cavity, and the evaporator, condenser and compressor are connected by a medium delivery pipe.

[0014] Preferably, an air inlet grille is provided at the rear end of the cooling chamber.

[0015] The welding method of the friction welding device for the vehicle charger housing comprises the following steps:

[0016] Step 1: Prepare the on-board charger housing and water channel cover to be welded, ensure that the water channel of the housing is clean and free of oil and impurities, and ensure that the appearance of the water channel cover is clean, free of oil and impurities. Place the housing to be welded into the housing clamping mechanism, press the housing, and then place the water channel cover on the housing water channel according to the outer contour to ensure that the contact surface is flat and tightly fitted;

[0017] Step 2: At the beginning of welding, select a suitable stirring head, press the tip of the shaft into the joint of the shell and the cover plate to a depth of 0.5mm to 1.0mm to anchor the points, and make a full circle of anchor points according to the outer contour of the cover plate with a spacing of 25mm to 35mm, so that the cover plate is initially combined with the shell without loosening or displacement;

[0018] Step 3: During the welding process, select a suitable feed position, use the shaft tip to rotate and insert into the joint of the shell and the cover plate to stir and rub to generate high-temperature molten materials at the joint, so as to weld the two materials together; follow the shape of the cover plate to weld in a full circle, because the stirring friction temperature will continue to rise, in order to avoid continuous temperature rise and attenuation of the welding performance of the stirring head, the stirring head is cooled by the cold air nozzle;

[0019] Step 4: When welding is finished, retract the knife at the designated retracting position. To prevent the tip of the stirring head from sticking to aluminum, which will reduce the friction coefficient and thus affect the welding quality, stop the speed, pause for 3 seconds, and then lift the knife to remove the aluminum sticking to the tip of the shaft.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] 1. The present invention fixes the on-board charger housing and the waterway cover plate by friction welding. The friction stir welding technology achieves deep fusion between materials by melting the materials at the joint at high temperature, forming a high-strength welded joint. At the end of welding, the rotation speed is stopped and the stirring head is lifted after a pause, which effectively removes the sticky aluminum on the tip of the stirring head, avoids affecting the welding quality due to the reduction of the friction coefficient, further enhances the durability and reliability of the welded joint, and does not require the use of additional welding materials, such as welding wire, welding rod, etc., thereby reducing material costs. By optimizing the welding process and parameter settings, the scrap rate and rework rate are reduced, further reducing the production cost and labor costs.

[0022] 2. The present invention is provided with a shell clamping mechanism. Through the design of the shell clamping mechanism, it can realize the precise positioning and clamping of the on-board charger shell. The second servo motor is used to drive the active bevel gear to rotate, thereby driving the transmission rod and the threaded transmission tube to rotate, and the base guide groove cooperates with the guiding effect of the sliding block to realize the precise movement and clamping of the shell by the clamping plate. This mechanism can ensure that the shell remains stable during the welding process and avoid welding quality problems caused by position deviation or movement. The pressure sensor installed on the inner wall of the clamping plate can monitor the clamping force in real time. When the pressure value reaches the set value, it indicates that the clamping force is moderate. This design can ensure that the shell is subjected to sufficient clamping force while avoiding deformation or damage to the shell caused by excessive clamping. The movement of the electric push rod is controlled by a single-chip microcomputer to achieve precise control of the transmission rod, thereby adjusting the clamping force. Since the on-board charger housing is not a cubic structure, the clamping mechanism can adapt to the shape and size changes of the housing. Two symmetrical clamping plates preferentially contact the housing and drive it to the center position in one axial direction, and then continue to move through another axially symmetrical clamping plate to achieve center clamping in another axial direction, so that the welding method can be applied to the welding of on-board charger housings of different shapes and sizes.

[0023] 3. The present invention is provided with a three-axis displacement mechanism, which is composed of a Y-axis displacement mechanism, an X-axis displacement mechanism and a vertical displacement mechanism. The first displacement drive device can drive the X-axis displacement mechanism to move longitudinally, the second displacement drive device can drive the vertical displacement mechanism to move horizontally, and the vertical displacement mechanism can drive the friction welding mechanism to move vertically. The first displacement drive device and the second displacement drive device are both composed of a sliding seat, a first servo motor, and a transmission gear. By turning on the first servo motor on the sliding seat, the transmission gear is driven to rotate. When it is engaged with the rack on the corresponding displacement mechanism, the rotational motion is converted into linear motion, driving the corresponding displacement mechanism to adjust. The design of the three-axis displacement mechanism and the servo motor drive is adopted to realize the automatic control of the welding process. By programming the welding path and parameters, the precise control and automatic operation of the welding process can be realized, which reduces manual intervention and improves production efficiency.

[0024] 4. The present invention is provided with a cooling device. During the friction welding process, due to the rotation and friction of the stirring head, a large amount of heat will be generated at the welding position, causing the temperature to rise rapidly. By turning on the compressor, the refrigerant circulates in the cooling chamber, absorbs and takes away the heat from the welding position, so that the welding area is kept within a relatively low and stable temperature range. This helps to reduce defects such as thermal deformation and thermal cracks during welding, and significantly improves the welding quality. In a high temperature environment, the stirring head is easily damaged by overheating. By using a cooling device to air-cool the stirring head, its operating temperature can be effectively reduced, thermal damage can be reduced, and the service life of the stirring head can be extended. Compared with traditional water cooling or air cooling methods, it has higher energy efficiency and is more environmentally friendly. This not only reduces energy consumption during welding, but also reduces the impact on the environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a front oblique perspective stereogram of the present invention;

[0026] Figure 2 It is a rear oblique perspective view of the present invention;

[0027] Figure 3 It is a three-dimensional diagram of the transmission structure of the housing clamping mechanism of the present invention;

[0028] Figure 4 It is a schematic diagram of the transmission structure of the housing clamping mechanism of the present invention;

[0029] Figure 5 It is a schematic diagram of the structure of the cooling device of the present invention;

[0030] Figure 6 It is a top view of the present invention.

[0031] In the figure: 1. base; 2. shell clamping mechanism; 3. guide groove; 4. clamping plate; 5. Y-axis displacement mechanism; 6. X-axis displacement mechanism; 7. first displacement drive device; 8. second displacement drive device; 9. sliding seat; 10. first servo motor; 11. transmission gear; 12. rack; 13. limit slide groove; 14. vertical displacement mechanism; 15. drive motor; 16. stirring head; 17. cooling pipe; 18. cold air nozzle; 19. active bevel gear; 20. driven bevel gear; 21. sleeve; 22. threaded transmission pipe; 23. sliding block; 24. electric push rod; 25. transmission rod; 26. second servo motor; 27. cooling chamber; 28. heat dissipation chamber; 29. ​​evaporator; 30. negative pressure fan; 31. condenser; 32. compressor; 33. lock. DETAILED DESCRIPTION

[0032] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0033] See also Figure 1-6 , an embodiment of the present invention: a friction welding device for a vehicle charger housing, comprising a base 1, a housing clamping mechanism 2 is arranged at the middle position of the upper end of the base 1, the housing clamping mechanism 2 comprises a guide groove 3, and the guide groove 3 is arranged on the base 1, a clamping plate 4 is installed above the guide groove 3, and the lower end of the clamping plate 4 is slidably limited with the guide groove 3, a transmission rod 25 is installed inside the guide groove 3, a threaded transmission tube 22 is installed outside the transmission rod 25, a sliding block 23 is installed outside the threaded transmission tube 22, an inner screw hole of the sliding block 23 is threadedly connected with the threaded transmission tube 22, and the upper end of the sliding block 23 is fixed to the bottom of the clamping plate 4, a second servo motor 26 is arranged at the middle position inside the base 1, an active bevel gear 19 is installed on the output shaft of the second servo motor 26, and a driven bevel gear 20 is installed around the active bevel gear 19, The driven bevel gear 20 is meshed and connected with the active bevel gear 19, a sleeve 21 is fixedly provided at one end of the driven bevel gear 20, a transmission rod 25 extends into the interior of the sleeve 21, and the transmission rod 25 and the sleeve 21 are slidably limited, an electric push rod 24 is provided at the other end of the transmission rod 25, the fixed end of the electric push rod 24 is fixed to the base 1 by bolts, and the movable end of the electric push rod 24 is connected to the transmission rod 25 by a bearing, lockers 33 are provided on both sides of the outside of the threaded transmission tube 22, a pressure sensor is installed on the inner wall of the clamping plate 4, a signal output end of the pressure sensor is connected to a single-chip microcomputer, and the output end of the single-chip microcomputer is electrically connected to the input end of the electric push rod 24, annular tooth grooves are provided on the inner walls of the sleeve 21 and the threaded transmission tube 22, annular teeth are provided on the outer wall of the transmission rod 25, and the annular teeth are slidably limited with the annular tooth grooves of the sleeve 21 and the threaded transmission tube 22;

[0034] By placing the housing in the positioning area of ​​the base 1, turning on the second servo motor 26, its output shaft drives the active bevel gear 19 to rotate, and drives the transmission rod 25 to rotate under the meshing with the driven bevel gear 20, and drives the threaded transmission tube 22 to rotate through the protrusion on the surface of the transmission rod 25, so that its external thread and the internal screw hole of the sliding block 23 rub against each other, and cooperate with the guiding effect of the guide groove 3 of the base 1 on the sliding block 23, and drive the clamping plate 4 to move toward the charger housing through the sliding block 23. Since the vehicle-mounted charger housing is not a cubic structure, the two symmetrical clamping plates 4 will preferentially contact the charger housing and drive it to be centrally positioned in one axial direction. A pressure sensor is installed on the inner wall of the clamping plate 4. When the pressure value reaches the set value, it means that the clamping force is moderate. At this time, the electric push rod 24 is turned on by the single-chip microcomputer, driving the corresponding transmission rod 25 to shrink, so that one end of it is moved out of the sleeve 21 of the corresponding driven bevel gear 20, so that the corresponding threaded transmission tube 22 loses the transmission force, and cooperates with the locker 33 to prevent the threaded transmission tube 22 from rotating, thereby ensuring the stability of the clamping plate 4 in the corresponding position. In the process again, the other axially symmetrical clamping plate 4 continues to move toward the charger housing until it contacts the outer wall to apply pressure to achieve center clamping of the charger housing in another axial direction.

[0035] See also Figure 1 and Figure 2 , Y-axis displacement mechanisms 5 are fixedly installed on both sides of the upper end surface of the base 1, an X-axis displacement mechanism 6 is installed between the two Y-axis displacement mechanisms 5, a vertical displacement mechanism 14 is installed below the X-axis displacement mechanism 6, a first displacement drive device 7 is arranged outside the Y-axis displacement mechanism 5, and a second displacement drive device 8 is arranged outside the X-axis displacement mechanism 6, a rack 12 is arranged on one side of the Y-axis displacement mechanism 5 and the X-axis displacement mechanism 6, and a limiting slide groove 13 is arranged on the other side of the Y-axis displacement mechanism 5 and the X-axis displacement mechanism 6, and the first displacement drive device 7 and the second displacement drive device 8 are both provided by a sliding seat 9, a first servo motor 10 and a transmission gear 11, the sliding seat 9 is respectively installed on the outside of the Y-axis displacement mechanism 5 and the X-axis displacement mechanism 6, and the limit slider inside the sliding seat 9 is slidably connected with the limit slide groove 13, the first servo motor 10 is fixedly installed on one side of the sliding seat 9, the transmission gear 11 is installed on the output shaft of the first servo motor 10, and the transmission gear 11 is meshed with the rack 12, the other side of the sliding seat 9 in the first displacement driving device 7 is fixed to the X-axis displacement mechanism 6, and the other side of the sliding seat 9 in the second displacement driving device 8 is fixed to the vertical displacement mechanism 14;

[0036] The three-axis displacement mechanism is composed of a Y-axis displacement mechanism 5, an X-axis displacement mechanism 6, and a vertical displacement mechanism 14. This multi-dimensional displacement design enables the welding process to achieve precise positioning of the on-board charger housing. The first displacement drive device 7 and the second displacement drive device 8 drive the X-axis displacement mechanism 5 and the vertical displacement mechanism 6 to move longitudinally and horizontally respectively, and then cooperate with the vertical displacement mechanism 14 to drive the friction welding mechanism to move vertically, thereby achieving precise control of the welding position and improving the accuracy and flexibility of welding. The first displacement drive device 7 and the second displacement drive device 8 are both composed of a sliding seat 9, a first servo motor 10, and a transmission gear 11. By turning on the first servo motor 10 on the sliding seat 9, the transmission gear 11 is driven to rotate and mesh with the rack 12 on the corresponding displacement mechanism to convert the rotational motion into linear motion. This transmission method is stable and reliable, and can ensure the smooth operation of each displacement mechanism during the welding process, thereby improving the stability and efficiency of welding, and enabling the welding equipment to adapt to the welding requirements of on-board charger housings of different shapes and sizes. By adjusting the displacement of each displacement mechanism, welding operations at different positions and angles can be achieved, which enhances the adaptability and flexibility of the equipment.

[0037] See also Figure 1 and Figure 2 A friction welding mechanism is provided at the bottom of the vertical displacement mechanism 14. The friction welding mechanism includes a driving motor 15, whose housing is fixed to the movable end of the vertical displacement mechanism 14. A stirring head 16 is installed at the output end of the driving motor 15. The on-board charger housing and the waterway cover are fixed by friction welding. The friction stirring welding technology achieves deep fusion between materials by melting the materials at the junction at high temperature, forming a high-strength welded joint.

[0038] See also Figure 2 and Figure 5 A cooling chamber 27 is provided at the rear end of the base 1, an air inlet grille is provided at the rear end of the cooling chamber 27, an evaporator 29 is installed inside the cooling chamber 27, a cooling pipe 17 is provided at the upper end of the cooling chamber 27, and the other end of the cooling pipe 17 is fixed to the friction welding mechanism through a connector, a negative pressure fan 30 is installed outside the cooling pipe 17, and a cold air nozzle 18 is installed at the other end of the cooling pipe 17, a heat dissipation chamber 28 is provided below the rear end of the base 1, a condenser 31 is installed inside the heat dissipation chamber 28, a compressor 32 is provided on one side of the heat dissipation chamber 28, and the evaporator 29, the condenser 31 and the compressor 32 are connected by a medium delivery pipe;

[0039] The compressor 32 is turned on. The compressor 32 compresses the refrigerant into a high-pressure and high-temperature gas, and then sends it to the condenser 31. In the condenser, the refrigerant releases heat and condenses into liquid. The expansion valve controls the flow and pressure of the refrigerant so that it reaches an appropriate state before entering the evaporator 29. When the refrigerant flows through the evaporator 29, it absorbs the surrounding heat, so that the temperature in the cooling chamber 27 is reduced. When the negative pressure fan 30 is started, it generates suction, sucks the cold air in the cooling chamber 27 through the cooling pipe 17, and sprays it onto the welding position through the cold air nozzle 18. The cold air directly acts on the welding position, quickly takes away the heat generated during the welding process, and realizes instant cooling of the welding position.

[0040] The welding method of the friction welding device for the vehicle charger housing comprises the following steps:

[0041] Step 1: Prepare the on-board charger housing and water channel cover to be welded, ensure that the water channel of the housing is clean and free of oil and impurities, and ensure that the appearance of the water channel cover is clean, free of oil and impurities. Place the housing to be welded into the housing clamping mechanism 2, press the housing, and then place the water channel cover on the housing water channel according to the outer contour to ensure that the contact surface is flat and tightly fitted;

[0042] Step 2: At the beginning of welding, select a suitable stirring head 16, press the tip of the shaft into the joint of the shell and the cover plate to a depth of 0.5mm to 1.0mm to anchor the points, and make a full circle of anchor points according to the outer contour of the cover plate with a spacing of 25mm to 35mm, so that the cover plate is initially combined with the shell without loosening or displacement;

[0043] Step 3: During the welding process, select a suitable feed position, use the shaft tip to rotate and insert into the joint of the shell and the cover plate to stir and rub to generate high-temperature molten materials at the joint, so as to weld the two materials together; follow the shape of the cover plate to weld in a full circle, because the stirring friction temperature will continue to rise, in order to avoid continuous temperature rise and attenuation of the welding performance of the stirring head, the stirring head 16 is air-cooled by the cold air nozzle 18;

[0044] Step 4. When welding is finished, retract the knife at the designated retracting position. To prevent the tip of the stirring head 16 from sticking to aluminum, which will reduce the friction coefficient and thus affect the welding quality, stop the speed, pause for 3 seconds, and then lift it up to remove the aluminum sticking to the tip of the shaft.

[0045] Through strict preliminary preparation, including cleaning the shell and waterway cover, precise placement and pressing, the material state before welding is ensured to be optimal, thus greatly improving the quality and reliability of the welded joint. The introduction of the anchor point step enables the waterway cover to be preliminarily and stably combined with the shell before welding, avoiding loosening and displacement during welding, further ensuring the accuracy and overall quality of welding. The friction welding method itself is characterized by high efficiency and speed. Combined with the optimized welding path and parameter settings, it can significantly shorten the welding cycle and improve production efficiency. By precisely controlling the feed position, rotation speed and feed speed of the stirring head, as well as timely air cooling measures, the continuity and stability of the welding process are ensured, and production interruptions caused by equipment failure or operational errors are reduced. Stir friction welding technology achieves deep fusion between materials through high-temperature melting of the materials at the joint, forming a high-strength welded joint. At the end of welding, the aluminum sticking on the tip of the stirring head is effectively removed by stopping the rotation speed and lifting it after a pause, avoiding the impact of the welding quality due to the reduction of the friction coefficient, and further enhancing the durability and reliability of the welded joint.

[0046] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A friction welding device for a vehicle charger housing and a welding method thereof, comprising a base (1), characterized in that: Y-axis displacement mechanisms (5) are fixedly mounted on both sides of the upper end surface of the base (1); an X-axis displacement mechanism (6) is mounted between the two Y-axis displacement mechanisms (5); a vertical displacement mechanism (14) is mounted below the X-axis displacement mechanism (6); a friction welding mechanism is disposed at the bottom of the vertical displacement mechanism (14); a shell clamping mechanism (2) is disposed at the middle position of the upper end of the base (1); the shell clamping mechanism (2) comprises a guide groove (3), and the guide groove (3) is disposed on the base ( 1), a clamping plate (4) is installed above the guide groove (3), and the lower end of the clamping plate (4) is slidably limited with the guide groove (3), a transmission rod (25) is installed inside the guide groove (3), a threaded transmission tube (22) is installed outside the transmission rod (25), a sliding block (23) is installed outside the threaded transmission tube (22), an inner screw hole of the sliding block (23) is threadedly connected with the threaded transmission tube (22), and the upper end of the sliding block (23) is fixed to the bottom of the clamping plate (4).

2. A friction welding device and welding method for a vehicle charger housing according to claim 1, characterized in that: A second servo motor (26) is arranged at a middle position inside the base (1), an output shaft of the second servo motor (26) is installed with a driving bevel gear (19), a driven bevel gear (20) is installed around the driving bevel gear (19), and the driven bevel gear (20) is meshedly connected with the driving bevel gear (19), a sleeve (21) is fixedly arranged at one end of the driven bevel gear (20), a transmission rod (25) extends into the inside of the sleeve (21), and the transmission rod (25) and the sleeve (21) are slidably limited, an electric push rod (24) is arranged at the other end of the transmission rod (25), a fixed end of the electric push rod (24) is fixed to the base (1) by bolts, and a movable end of the electric push rod (24) is connected to the transmission rod (25) by bearings, and lockers (33) are arranged on both sides of the outside of the threaded transmission tube (22).

3. A friction welding device and welding method for a vehicle charger housing according to claim 2, characterized in that: A pressure sensor is installed on the inner wall of the clamping plate (4), the signal output end of the pressure sensor is connected to a single chip microcomputer, and the output end of the single chip microcomputer is electrically connected to the input end of the electric push rod (24).

4. A friction welding device and welding method for a vehicle charger housing according to claim 3, characterized in that: The inner walls of the sleeve (21) and the threaded transmission tube (22) are both provided with annular tooth grooves, and the outer wall of the transmission rod (25) is provided with annular teeth, and the annular teeth are slidably limited with the annular tooth grooves of the sleeve (21) and the threaded transmission tube (22).

5. A friction welding device and welding method for a vehicle charger housing according to claim 4, characterized in that: A first displacement drive device (7) is arranged outside the Y-axis displacement mechanism (5), and a second displacement drive device (8) is arranged outside the X-axis displacement mechanism (6). A rack (12) is arranged on one side of the Y-axis displacement mechanism (5) and the X-axis displacement mechanism (6), and a limiting slide groove (13) is arranged on the other side of the Y-axis displacement mechanism (5) and the X-axis displacement mechanism (6). The first displacement drive device (7) and the second displacement drive device (8) are both composed of a sliding seat (9), a first servo motor (10) and a transmission gear (11). The sliding seat (9) is respectively mounted on the Y-axis position The first servo motor (10) is fixedly mounted on one side of the sliding seat (9), the transmission gear (11) is mounted on the output shaft of the first servo motor (10), and the transmission gear (11) is meshed with the rack (12); the other side of the sliding seat (9) in the first displacement driving device (7) is fixed to the X-axis displacement mechanism (6); and the other side of the sliding seat (9) in the second displacement driving device (8) is fixed to the vertical displacement mechanism (14).

6. A friction welding device and welding method for a vehicle charger housing according to claim 5, characterized in that: The friction welding mechanism comprises a driving motor (15), the housing of which is fixed to the movable end of the vertical displacement mechanism (14), and a stirring head (16) is installed at the output end of the driving motor (15).

7. A friction welding device and welding method for a vehicle charger housing according to claim 6, characterized in that: A cooling chamber (27) is provided at the rear end of the base (1), an evaporator (29) is installed inside the cooling chamber (27), a cooling pipe (17) is provided at the upper end of the cooling chamber (27), and the other end of the cooling pipe (17) is fixed to a friction welding mechanism via a connecting piece, a negative pressure fan (30) is installed outside the cooling pipe (17), and a cold air nozzle (18) is installed at the other end of the cooling pipe (17).

8. The friction welding device and welding method for a vehicle charger housing according to claim 7, characterized in that: A heat dissipation cavity (28) is provided below the rear end of the base (1), a condenser (31) is installed inside the heat dissipation cavity (28), a compressor (32) is provided on one side of the heat dissipation cavity (28), and the evaporator (29), the condenser (31) and the compressor (32) are connected via a medium delivery pipe.

9. A friction welding device and welding method for a vehicle charger housing according to claim 8, characterized in that: The rear end of the cooling chamber (27) is provided with an air inlet grille.

10. The welding method of the friction welding device for the vehicle charger housing according to claim 9 is characterized in that: The steps include: Step 1: Prepare the on-board charger housing and water channel cover to be welded, ensure that the water channel of the housing is clean and free of oil and impurities, and ensure that the appearance of the water channel cover is clean and free of oil and impurities. Place the housing to be welded into the housing clamping mechanism (2), press the housing, and then place the water channel cover onto the housing water channel according to the outer contour to ensure that the contact surface is flat and tightly fitted; Step 2: When welding begins, use a suitable stirring head (16) to press the tip of the shaft into the joint of the shell and the cover plate to a depth of 0.5 mm to 1.0 mm to form an anchor point. The anchor points are formed in a circle with a spacing of 25 mm to 35 mm according to the outer contour of the cover plate, so that the cover plate is initially combined with the shell without loosening or displacement. Step 3: During the welding process, a suitable cutting position is selected, and the tip of the shaft is rotated to insert into the joint of the shell and the cover plate to stir and rub to generate high-temperature molten materials at the joint, thereby welding the two materials together; the cutting is performed in a full circle according to the shape of the cover plate. Since the stirring friction temperature will continue to rise, in order to avoid the continuous temperature rise and attenuation of the welding performance of the stirring head, the stirring head (16) is air-cooled by a cold air nozzle (18); Step 4: When welding is finished, the knife is retracted at the designated knife retraction position. To prevent the tip of the stirring head (16) from sticking to aluminum, which may reduce the friction coefficient and thus affect the welding quality, the tip of the stirring head (16) is removed by stopping the speed, pausing for 3 seconds, and then lifting the knife to remove the aluminum.

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