Welding method

Abstract

The invention relates to the technical field of welding, in particular to a welding method. According to the method provided by the invention, when the length of the wire harness is less than or equal to 500mm and the second end and the second terminal of the wire harness are welded, the first end of the wire harness is slightly influenced by vibration, and the tension value of the first terminal at the first end and the wire harness is reduced, so that after the welding parameters are adjusted, on one hand, the welding tension effect of the second end is reduced; on the other hand, vibration generated during welding is reduced, so that damage to the welding position of the first end is reduced, and tension values of the front end and the rear end can be balanced. In addition, the first end of the wire harness welded with the first terminal is clamped in the welding process, so that vibration generated when the second end of the wire harness is welded is counteracted by the clamping mechanism, propagation of the vibration to the first end is greatly reduced, and the influence on the first end is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of welding, and in particular to a welding method. Background Art

[0002] In ultrasonic welding, terminals need to be welded on both ends of the wire harness in sequence; first weld one end of the wire harness to the terminal, then rotate the wire harness 180 degrees and weld the other end of the wire harness to the new terminal.

[0003] In the same wire harness, because the vibration is transferred to the other end through the wire harness, the different lengths of the wire harness will cause the vibration to have different degrees of damage to the solder joint at the first end when the second end is welded, which is manifested as a decrease in the tensile force value at the first end of the weld. When the connection strength between the wire harness and the two terminals is very different, the failure rate of the first end is too high during the tensile test, that is, the first end is often more likely to break before the second end. When the failure rate of the same end reaches 70% or more, the test fails.

[0004] Therefore, a welding method is urgently needed to solve the above-mentioned technical problems. Summary of the invention

[0005] The purpose of the present invention is to propose a welding method, which welds the wire harness and the terminal according to the wire harness of different lengths, ensures that the difference in the tensile force value between the wire harness and the terminals welded at both ends of the wire harness is small, and the failure ratio of each end is close to equal when performing an overall tensile test, and the test passes.

[0006] To achieve this object, the present invention adopts the following technical solutions:

[0007] A welding method is provided for welding terminals to two ends of a wiring harness, comprising the following steps:

[0008] Get the harness length;

[0009] If the length of the wire harness is less than or equal to 500 mm, fix the wire harness and the terminal, weld the first end of the wire harness and the first terminal, flip the wire harness with the first terminal welded on the first end, fix the wire harness and the second terminal, adjust the welding parameters of the welding machine to weld the second end of the wire harness and the second terminal, and the welding parameters at least include the energy and power of the welding machine.

[0010] As a preferred technical solution of the above welding method, the power is set to PA and the energy is set to EA when the welding length of the wire harness is greater than or equal to 500 mm;

[0011] When the welding length of the wire harness is less than 500mm, the welding power for the first terminal is PA, and the energy is EA. The welding power for the second terminal is PB=Y*PA, and the energy is EB=k*EA=EA*(X%+(1-X%)*L / 500), where X=75-90% and Y=1.05-1.2.

[0012] As a preferred technical solution of the above welding method, the length of the wire harness is measured by an ultrasonic detection sensor.

[0013] As a preferred technical solution of the above welding method, during welding, the vibration direction of the welding head of the welding machine is set at an angle to the axial direction of the wire harness.

[0014] As a preferred technical solution of the above welding method, during welding, the angle α between the vibration direction of the welding head of the welding machine and the axial direction of the wire harness is ≤90°.

[0015] As a preferred technical solution for the above welding method, the welding machine is provided with an industrial camera. During welding, the industrial camera is used to obtain terminal information, and welding parameters are switched based on the obtained terminal information. The welding parameters include welding power and welding energy.

[0016] As a preferred technical solution of the above welding method, the wiring harness and the terminal to be welded are fixed by a welding fixture, and the welding fixture includes:

[0017] A positioning and fixing mechanism, used for positioning and fixing the terminal;

[0018] The wire harness fixing mechanism is at least used for fixing the wire harness, and the wire harness fixing mechanism is arranged on one side of the positioning and fixing mechanism.

[0019] As a preferred technical solution of the above welding method, the wire harness fixing mechanism includes a first driving structure and a fixing member, and the first driving structure is connected to the fixing member to drive the fixing member to fix the wire harness.

[0020] As a preferred technical solution of the above welding method, the fixing member includes two clamping jaws arranged opposite to each other, and the first driving structure is fixedly connected to the two clamping jaws respectively to drive the two clamping jaws to open and close.

[0021] As a preferred technical solution of the above welding method, the clamping jaw is provided with a receiving groove.

[0022] As a preferred technical solution for the above welding method, when the clamps clamp the wire harness, the two clamps are staggered; or, the clamps are provided with a plurality of slots at intervals on one side facing the wire harness, the slots separate the clamps to form a plurality of teeth, and the teeth arranged opposite to each other cooperate with the slots to adjust the distance between the two clamps.

[0023] As a preferred technical solution of the above welding method, it also includes a lifting assembly, and the lifting assembly and the wire harness fixing mechanism are arranged opposite to each other along the length direction of the wire harness.

[0024] As a preferred technical solution of the above welding method, the welding fixture further includes a lifting assembly, and the lifting assembly and the wire harness fixing mechanism are arranged opposite to each other along the length direction of the wire harness.

[0025] As a preferred technical solution of the above welding method, the positioning and fixing mechanism includes:

[0026] A push block assembly, comprising a push block, a first adjusting member and a second driving structure, wherein the push block is connected to the second driving structure via the first adjusting member, and the push block is used to press the terminal to be welded;

[0027] The push plate assembly comprises a push plate, a second adjusting member and a third driving structure. The push plate is connected to the third driving structure via the second adjusting member. The push plate is used to clamp the terminal to be welded.

[0028] As a preferred technical solution of the above welding method, the first adjusting member includes a first wedge block and a second wedge block, the first wedge block has a first inclined working surface, the second wedge block is connected to the push block, the second wedge block has a second inclined working surface, the first inclined working surface is in contact with the second inclined working surface, and the second driving structure is fixedly connected to the first wedge block to drive the first wedge block to squeeze or release the second wedge block;

[0029] The second adjusting member includes a third wedge block and a fourth wedge block, the third wedge block has a third inclined working surface, the fourth wedge block is connected to the push plate, the fourth wedge block has a fourth inclined working surface, the third inclined working surface is in contact with the fourth inclined working surface, and the third driving structure is fixedly connected to the third wedge block to drive the third wedge block to squeeze or release the fourth wedge block.

[0030] The present invention has at least the following beneficial effects:

[0031] According to the method provided by the present invention, when the length of the welding wire harness is less than 500 mm, when the second end and the second terminal of the welding wire harness are welded, the first end of the wire harness will be slightly affected by vibration, and the tension value between the first terminal and the wire harness at the first end will be reduced. After adjusting the welding parameters, on the one hand, the tension effect of the welding at the second end is reduced, and on the other hand, the vibration generated during welding is reduced, thereby reducing the destructive effect on the welding point of the first end, so that the tension values ​​at the front and rear ends can be balanced. In addition, during the welding process, the first end of the wire harness welded with the first terminal is clamped, so that the vibration generated during the welding of the second end of the wire harness is reduced by the clamping mechanism, which greatly reduces the propagation of the vibration to the first end, thereby reducing the impact on the first end. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments of the present invention. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the contents of the embodiments of the present invention and these drawings without paying any creative work.

[0033] Figure 1 A flow chart of a welding method provided by an embodiment of the present invention;

[0034] Figure 2 A top view of a welding fixture provided by an embodiment of the present invention;

[0035] Figure 3 A schematic diagram of the positional relationship between the wiring harness fixing mechanism and the ejection assembly provided in an embodiment of the present invention;

[0036] Figure 4 A schematic diagram of the structure of a wiring harness fixing mechanism provided by an embodiment of the present invention;

[0037] Figure 5 A schematic structural diagram of a welding fixture provided by an embodiment of the present invention from a first perspective (without a cover plate);

[0038] Figure 6 A schematic structural diagram of a positioning and fixing mechanism provided in an embodiment of the present invention.

[0039] In the figure:

[0040] 1. Wire harness fixing mechanism; 11. First driving structure; 12. Clamping claw; 121. Accommodating groove; 122. Slot; 123. Inserting teeth; 2. Push block assembly; 21. Push plate; 22. First adjusting member; 221. First wedge block; 222. Second wedge block; 223. First elastic member; 23. Second driving structure; 3. Push plate assembly; 31. Push block; 32. Second adjusting member; 321. Third wedge block; 322. Fourth wedge block; 323. Second elastic member; 33. Third driving structure; 4. Limiting frame; 5. Cover plate; 6. Ejecting assembly; 7. Terminal positioning block; 8. Frame;

[0041] 100. Wiring harness; 200. First terminal. DETAILED DESCRIPTION

[0042] The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for ease of description, only parts related to the present invention, rather than all structures, are shown in the accompanying drawings.

[0043] In the description of the present invention, unless otherwise clearly specified and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0044] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0045] In the description of this embodiment, the terms "upper", "lower", "right", etc., directions or positional relationships are based on the directions or positional relationships shown in the drawings, and are only for the convenience of description and simplification of operation, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used to distinguish in the description and have no special meaning.

[0046] The present invention provides a welding method, which welds a wire harness and a terminal according to wire harnesses of different lengths, thereby ensuring that the difference in tension between the wire harness and the terminals welded at both ends of the wire harness is small, and when an overall tension test is performed, the failure ratio of each end is nearly equal, and the test passes.

[0047] The welding method is used to weld the terminals to the two ends of the wiring harness, and the terminal located at the first end of the wiring harness is set as the first terminal 2, and the terminal located at the second end of the wiring harness is set as the second terminal.

[0048] like Figure 1 and Figure 2 As shown, the method comprises the following steps:

[0049] S101, obtaining the length of the wiring harness 100;

[0050] S102. If the length of the wire harness 100 is less than 500 mm, fix the first end of the wire harness 100 to the first terminal 200, weld the first end of the wire harness 100 to the first terminal 200, flip the wire harness 100 with the first terminal 200 welded on the first end, fix the wire harness 100 to the second terminal, adjust the welding parameters of the welding machine to weld the second end of the wire harness 100 to the second terminal, and the welding parameters at least include the energy and power of the welding machine.

[0051] According to the method provided by the present invention, when the length of the welding harness 100 is less than 500 mm, when the second end and the second terminal of the welding harness 100 are welded, the first end of the harness 100 will be slightly affected by vibration, and the tension value between the first terminal 200 at the first end and the harness 100 will be reduced. After adjusting the welding parameters, on the one hand, the tension effect of the welding at the second end is reduced, and on the other hand, the vibration generated during welding is reduced, thereby reducing the destructive effect on the welding point of the first end, so that the tension values ​​at the front and rear ends can be balanced. In addition, during the welding process, the first end of the harness 100 with the first terminal 200 is clamped and welded, so that the vibration generated during the welding of the second end of the harness 100 is reduced by the clamping mechanism, which greatly reduces the propagation of the vibration to the first end, thereby reducing the impact on the first end.

[0052] In short-distance welding, two weldings with the same parameters will result in the second tension being significantly higher than the first end. USCAR38 requires that the failure rate of the same end of the short sample is 70% or more, indicating that the welding sample is "process sensitive" and is considered to have failed the test. By adjusting the welding parameters at the second end, the tension values ​​at both ends tend to be balanced, greatly reducing the failure rate on the same side.

[0053] When the harness welding length is greater than or equal to 500mm, the power is set to PA and the energy is set to EA; when the harness welding length is less than 500mm, the welding power for the first terminal 200 is PA and the energy is set to EA, and the welding power for the second terminal is PB=Y*PA and the energy is EB=k*EA=EA*(X%+(1-X%)*L / 500), where X=75-90% and Y=1.05-1.2. This setting reduces the tension at the second end to 75-85% of the strength of the optimal parameter weld. At the same time, the tension at the first end is affected by the vibration during welding at the second end, and the strength of the weld is reduced. By adjusting the value of X, the tension values ​​at both ends are close. The second end slightly increases the power of the equipment. First, the energy can be transferred to the welded object in a shorter time after being reduced, thereby improving the welding strength. Second, the welding time is reduced, thereby reducing the impact of vibration transmission.

[0054] For example, a 300mm 70 square copper wire is welded with a 3mm T2 copper terminal at both ends, and the first end is welded with a power of 4500W and an energy of 14000J. The second end is welded with a power of 5000W and an energy of 13000J. The tension of the first end of the wire harness 100 and the second end of the wire harness 100 are both close to 7000N.

[0055] In some embodiments, the length of the wire harness 100 is measured by an ultrasonic detection sensor. Before welding, the length of the wire harness 100 is detected by an ultrasonic detection sensor. If the measured length of the wire harness 100 is ≥ 500 mm, it is normal long-distance welding. When welding terminals at both ends of the normal long-distance wire harness, the parameters remain unchanged and welding is carried out according to the normal process.

[0056] In some embodiments, during welding, the vibration direction of the welding head of the welding machine is set at an angle to the axial direction of the wire harness 100. Without changing the placement direction and position of the material, the device can be compatible with different vibration directions. By adjusting the position of the device, if the vibration direction of the welding head is set at an angle α to the axial direction of the wire harness 100, the vibration transmission along the axial direction of the wire harness 100 can be reduced, and the two can even be made perpendicular. At this time, the vibration will not be transmitted along the axial direction of the wire harness 100, and will not affect the welding strength of the second end of the wire harness 100.

[0057] Specifically, the direction of the transducer is adjusted so that an angle is formed between the vibration direction of the welding head and the axial direction of the wire harness 100 so as to reduce the vibration transmission.

[0058] For example, the angle α between the vibration direction of the welding head of the welding machine and the axial direction of the wire harness is ≤90°.

[0059] In some embodiments, the welding machine is provided with an industrial camera, which is used in conjunction with an ultrasonic detection sensor. During welding, the industrial camera is used to obtain terminal information of the end of the wire harness 100 away from the welding position, and the welding parameters are switched based on the obtained terminal information. The welding parameters include welding power and welding energy. Exemplarily, the industrial camera (CCD) detects the end of the wire harness 100 away from the welding position. If there is a terminal at this end and when the length of the wire harness is detected to be less than 500 mm, the welding parameters are adjusted. For example, the adjusted welding parameters include power PB and energy EB. If there is no terminal at this end, the welding parameters are set parameters, and the set parameters include power PA and energy EA, where PB>PA, EA>EB.

[0060] The present invention fixes the wire harness 100 and the terminal to be welded by welding with a welding fixture, and the welding fixture includes a positioning and fixing mechanism and a wire harness fixing mechanism 1, the positioning and fixing mechanism is used to position and fix the terminal to be welded, wherein the terminal to be welded can be a first terminal 200 or a second terminal, and the wire harness fixing mechanism 1 is at least used to fix the wire harness 100, and the wire harness fixing mechanism 1 is set on one side of the positioning and fixing mechanism. The positioning and fixing mechanism can fix the position of the terminal to be welded when the wire harness 100 is welded, and reduce the vibration effect transmitted to the welded first end during welding.

[0061] The influence of the second end welding on the first end in short-distance welding causes the first end tension value to be insufficient. When the wire harness 100 is shorter, the damage effect on the first end is more obvious. Through the wire harness and terminal clamping device, the influence of the second end welding on the first end welding is significantly reduced, so as to achieve the effect of nearly equal tension at both ends of the wire harness.

[0062] like Figure 3 As shown, the welding fixture further includes a frame 8 , and the positioning and fixing mechanism and the wire harness fixing mechanism 1 are both fixedly disposed on the frame 8 to be supported by the frame 8 .

[0063] In some embodiments, continue to refer to Figure 3 The wire harness fixing mechanism 1 includes a first driving structure 11 and a fixing member, wherein the first driving structure 11 is connected to the fixing member to drive the fixing member to fix the wire harness 100. The fixing member can fix the wire harness 100 and reduce the vibration effect transmitted to the welded first end.

[0064] The first drive structure 11 is determined according to the selection of the fixing member, and the first drive structure 11 can be a rod cylinder, a rodless cylinder or a motor. For example, when the first drive structure 11 is a motor, the wiring harness fixing mechanism 1 also includes a transmission structure, and the transmission structure can be a lead screw nut, and the fixing member is connected to the second drive structure 23 through the lead screw nut to achieve linear movement. When the first drive structure 11 is a rod cylinder, the number of the first drive structures 11 is two, and the two first drive structures 11 are relatively arranged on both sides of the wiring harness 100. The first drive structure 11 and the fixing member are arranged one by one, and then the first drive structure 11 is connected to the fixing member to achieve the clamping of the wiring harness 100 by the two fixing members. When the first drive structure 11 is a rodless cylinder, two fixing members are connected to the first drive structure 11, and the first drive structure 11 drives the two fixing members to move toward each other, thereby clamping the wiring harness 100, and the first drive structure 11 drives the two fixing members to move away from each other, thereby releasing the wiring harness 100.

[0065] In some embodiments, Figure 4As shown, the fixing member includes two oppositely arranged jaws 12, and the first driving structure 11 is fixedly connected to the two jaws 12 to drive the two jaws 12 to open and close. The jaws 12 can clamp the wire harness 100 from both sides of the wire harness 100 to prevent the wire harness 100 from swinging randomly during welding.

[0066] In order to prevent the clamping jaws 12 from clamping the wire harness 100, in some embodiments, the clamping jaws 12 are provided with a receiving groove 121. The shape of the receiving groove 121 can be V-shaped, and the two clamping jaws 12 arranged opposite to each other are each provided with a receiving groove 121, and the receiving grooves 121 arranged on different clamping jaws 12 are also arranged opposite to each other, so that it can be ensured that a space for accommodating the wire harness 100 can be formed after the two clamping jaws 12 are closed, and the wire harness 100 can be prevented from being excessively clamped by the clamping jaws 12.

[0067] In some embodiments, a plurality of slots 122 are provided at intervals on one side of the clamping jaw 12 facing the wire harness 100, and the slots 122 separate the clamping jaws 12 to form a plurality of insert teeth 123, and the clamping jaws 12 arranged oppositely are inserted into each other through the slots 122, and the insert teeth 123 arranged oppositely cooperate with the slots 122 to adjust the distance between the two clamping jaws 12. The cooperation between the insert teeth 123 and the slots 122 can prevent the clamping jaws 12 arranged oppositely from moving relative to each other along the axis direction of the wire harness 100, so as to ensure that the wire harness 100 can be firmly fixed.

[0068] In other embodiments, when the clamping jaws 12 clamp the wire harness 100, the two clamping jaws 12 are staggered. The staggered arrangement of the two clamping jaws 12 can increase the moving stroke of the clamping jaws 12, so that the clamping jaws 12 can be applied to wire harnesses 100 with more diameters.

[0069] When the welding machine is welding, the terminal to be welded will vibrate and the position of the wire harness 100 will change, which will affect the welding effect. For this reason, in some embodiments, the clamp further includes a lifting component 6, and the lifting component 6 and the wire harness fixing mechanism 1 are arranged opposite to each other along the length direction of the wire harness 100. The wire harness fixing mechanism 1 clamps the wire harness 100, and the lifting component 6 presses the terminal to be welded tightly, and the positioning and fixing mechanism clamps the terminal to be welded from the side of the terminal.

[0070] like Figure 5 and Figure 6As shown, the positioning and fixing mechanism includes a push block assembly 2 and a push plate assembly 3, wherein the push block assembly 2 includes a push plate 21, a first adjusting member 22 and a second driving structure 23, the push plate 21 and the second driving structure 23 are connected through the first adjusting member 22, the push plate 21 is used to clamp the tail of the terminal to be welded, thereby clamping both sides of the terminal to be welded, and during the welding process, the terminal to be welded changes the vibration frequency of the terminal to be welded due to the clamping of the push plate 21, thereby avoiding the cracking of the terminal to be welded from the welding area to the clamping area; the push plate assembly 3 includes a push block 31, a second adjusting member 32 and a third driving structure 33, the push block 31 and the third driving structure are connected through the second adjusting member 32, and the push block 31 is used to clamp the edge of the to-be-welded portion of the terminal to be welded.

[0071] The second driving structure 23 and the third driving structure 33 are arranged opposite to each other, which saves space compared to the side-by-side arrangement of the second driving structure 23 and the third driving structure 33 .

[0072] In some embodiments, the first adjusting member 22 includes a first wedge block 221, the first wedge block 221 has a first inclined working surface, the push plate 21 is connected to a second wedge block 222, the second wedge block 222 has a second inclined working surface, the first inclined working surface is in contact with the second inclined working surface, and the second driving structure 23 is fixedly connected to the first wedge block 221 to drive the first wedge block 221 to squeeze or release the push plate 21. When the second driving structure 23 pushes the first wedge block 221 to move forward, since the first wedge block 221 has a first inclined working surface and the second wedge block 222 has a second inclined working surface, the first inclined working surface will be squeezed against the second inclined working surface, and the second wedge block 222 connected to the push plate 21 moves toward the direction of the terminal to be welded under the squeezing of the first wedge block 221, and thus has a tendency to clamp the edge of the terminal to be welded.

[0073] In some embodiments, the second adjusting member 32 includes a third wedge block 321, the third wedge block 321 has a third inclined working surface, the push block 31 is connected to a fourth wedge block 322, the fourth wedge block 322 has a fourth inclined working surface, the third inclined working surface is in contact with the fourth inclined working surface, and the third driving structure 33 is fixedly connected to the third wedge block 321 to drive the third wedge block 321 to squeeze or release the fourth wedge block 322 connected to the push block 31. Driven by the third driving structure 33, the third wedge block 321 moves forward along the axial direction of the third driving structure 33. Since the third inclined working surface and the fourth inclined working surface are in contact with each other, when the third inclined working surface moves relative to the fourth inclined working surface, it will force the fourth wedge block 322 having the fourth inclined working surface to move, and then the fourth wedge block 322 drives the push block 31 to move, so as to clamp the terminal from both sides of the terminal.

[0074] When the first wedge block 221 extends back under the drive of the second driving structure 23, the pushing force on the push plate 21 also disappears accordingly. In order to enable the push plate 21 to always maintain a fit with the first wedge block 221 to facilitate the next squeezing of the terminal, in some embodiments, the positioning and fixing mechanism also includes a limit frame 4, and the first adjustment member 22 also includes a first elastic member 223. One end of the first elastic member 223 extends into the second wedge block 222, and the other end is against the limit frame 4. In this way, when the push plate 21 is squeezed, the first elastic member 223 is compressed. After the pushing force on the push plate 21 disappears, the first elastic member 223 will push the push plate 21 to move in the direction of the first wedge block 221 under the action of its own restoring force, thereby keeping the first wedge block 221 and the push plate 21 in a fit state, so as to facilitate the next clamping of the terminal to be welded.

[0075] The third wedge block 321 extends back under the drive of the third driving structure 33, and the pushing force exerted on the push block 31 will disappear accordingly. In order to enable the push block 31 to maintain a fit with the third wedge block 321, in some embodiments, the second adjusting member 32 also includes a second elastic member 323, one end of the second elastic member 323 extends into the fourth wedge block 322, and the other end is against the limit frame 4, and the push block 31 and the push plate 21 are both arranged in the area surrounded by the limit frame 4. In this way, when the push block 31 is squeezed, the second elastic member 323 is compressed. After the pushing force exerted on the push block 31 disappears, the second elastic member 323 will push the push block 31 to move toward the third wedge block 321 under the action of its own restoring force, thereby maintaining the third wedge block 321 and the push block 31 in a fit state, so as to facilitate the next clamping of the terminal to be welded.

[0076] The welding fixture also includes a terminal positioning block 7, which is fixed on the frame 8 and located between two positioning and fixing mechanisms. The terminal positioning block 7 is used to carry and position the terminal to be welded. The ejector assembly 6 is located on one side of the terminal positioning block 7 to limit the position of the terminal to prevent the terminal from vibrating and causing a large position offset. The terminal positioning block 7 is installed on the frame 8 and can move relative to the frame 8 along the axial direction of the wire harness 100. The movement of the terminal positioning block 7 relative to the frame 8 can be achieved by a slide rail slider.

[0077] The present embodiment also includes a controller, which is respectively connected to the first drive structure 11, the second drive structure 23 and the third drive structure 33 for communication, so as to send instructions to the first drive structure 11, the second drive structure 23 and the third drive structure 33, so as to coordinate the work of the first drive structure 11, the second drive structure 23 and the third drive structure 33. For example, the second drive structure 23 and the third drive structure 33 are both rod cylinders.

[0078] In addition, the above are only preferred embodiments of the present invention and the technical principles used. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and that various obvious changes, readjustments and substitutions can be made by those skilled in the art without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in more detail through the above embodiments, the present invention is not limited to the above embodiments, and may include more other equivalent embodiments without departing from the concept of the present invention, and the scope of the present invention is determined by the scope of the appended claims.

Claims

1. A welding method for welding terminals to two ends of a wiring harness (100), characterized in that: The steps include: Get the length of the harness (100); If the length of the wire harness (100) is less than 500 mm, the first end of the wire harness (100) is fixed to the first terminal (200), the first end of the wire harness (100) and the first terminal (200) are welded, the wire harness (100) with the first terminal (200) welded at the first end is turned over, the wire harness (100) is fixed to the second terminal, and the welding parameters of the welding machine are adjusted to weld the second end of the wire harness (100) to the second terminal, wherein the welding parameters at least include energy and power of the welding machine.

2. The welding method according to claim 1, characterized in that: When the harness welding length is greater than or equal to 500 mm, the power is set to PA and the energy is set to EA; When the welding length of the wire harness is less than 500 mm, the welding power for the first terminal (200) is PA, and the energy is EA; the welding power for the second terminal is PB=Y*PA, and the energy is EB=k*EA=EA*(X%+(1-X%)*L / 500), where X=75-90% and Y=1.05-1.

2.

3. The welding method according to claim 1, characterized in that: The length of the wire harness (100) is measured by an ultrasonic detection sensor.

4. The welding method according to claim 1, characterized in that: During welding, the vibration direction of the welding head of the welding machine is arranged at an angle to the axial direction of the wire harness (100).

5. The welding method according to claim 4, characterized in that: During welding, the angle α between the vibration direction of the welding head of the welding machine and the axial direction of the wire bundle (100) is ≤90°.

6. The welding method according to claim 1, characterized in that: The welding machine is provided with an industrial camera, which is used to obtain terminal information of a wire harness (100) at one end away from a welding position during welding, and switches welding parameters based on the obtained terminal information, wherein the welding parameters include welding power and welding energy.

7. The welding method according to any one of claims 1 to 6, characterized in that: The wire harness (100) and the terminal to be welded are fixed by a welding fixture, and the welding fixture comprises: A positioning and fixing mechanism, used for positioning and fixing the terminal; A wire harness fixing mechanism (1) is used at least to fix a wire harness (100), and the wire harness fixing mechanism (1) is arranged on one side of the positioning and fixing mechanism.

8. The welding method according to claim 7, characterized in that: The wire harness fixing mechanism (1) comprises a first driving structure (11) and a fixing member, wherein the first driving structure (11) is connected to the fixing member to drive the fixing member to fix the wire harness (100).

9. The welding method according to claim 8, characterized in that: The fixing member comprises two clamping jaws (12) arranged opposite to each other, and the first driving structure (11) is respectively fixedly connected to the two clamping jaws (12) to drive the two clamping jaws (12) to open and close.

10. The welding method according to claim 9, characterized in that: The clamping jaw (12) is provided with a receiving groove (121).

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