Modular booster and welding gun thereof

Abstract

According to the modular booster and the welding gun thereof, the booster is installed at the tail of a welding gun handle or connected between welding cables in series, the limitation of the national standard on the length of a wire pushing welding gun is broken through, and the traditional wire feeding distance of 3 meters is expanded to 30 meters or above. The booster breaks through the limitation of the movement range of manual welding, so that an operator is not limited by a limited space any more during large-scale engineering or complex station operation, and the difficulties and pain points of frequent equipment moving, posture adjustment and the like caused by insufficient wire feeding distance on site are solved. Meanwhile, due to an accurate wire feeding control structure and a stable power transmission system, the wire feeding stability can be remarkably improved, welding wire jamming and speed fluctuation are reduced, the welding seam quality is improved, the welding production efficiency is improved, and the automatic wire feeding device is an important innovation in the field of manual welding in equipment performance and operation mode.

Description

Technical Field

[0001] The invention belongs to the technical field of welding gun auxiliary equipment, and particularly relates to a modular booster and a welding gun thereof. Background Art

[0002] In modern welding and manufacturing, push-wire welding guns are widely used due to their high efficiency and flexibility. Traditional push-wire welding guns utilize an external wire feeder to deliver the welding wire. Due to the dual constraints of the welding cable transmission performance and the mechanical drive system, the wire feeding distance is typically limited to less than 3 meters. In large-scale engineering operations, due to the wide range of welding operations and dispersed workstations, operators must frequently move the wire feeder or adjust the welding gun's posture, significantly reducing welding efficiency. Furthermore, long-distance wire feeding is prone to problems such as wire jamming and wire feed speed fluctuations, which seriously affect the quality of the weld.

[0003] In addition, new welding technologies such as cold metal transfer welding (ASMT) have become the mainstream of high-end manufacturing. They rely on the complex and precise structure of the robot welding gun to achieve pulse retraction wire feeding. The robot welding gun has a complex structure and high cost, and its application scenarios are limited, especially in scenarios such as large structural parts and small welding space. Robot welding guns are useless. Summary of the Invention

[0004] In response to the problems and shortcomings of the above-mentioned existing technologies, the present invention provides a modular booster and its welding gun, which can break through the wire feeding distance limitation, adapt to complex welding space layout, and be compatible with advanced welding processes. The modular wire-pushing welding gun booster is of great significance to promoting the innovation and development of modern welding manufacturing technology.

[0005] The present invention is achieved through the following technical solutions:

[0006] A modular booster comprises a driving wheel, a driven wheel and a driver protruding from the housing, the driving wheel being linked to an output shaft of the driver, and the driving wheel and the driven wheel forming a welding wire clamping pair perpendicular to the axis of the wire feeding channel;

[0007] The wire feeding channel of the same welding equipment can be connected in series with one or more boosters to assist in wire advancement according to the actual wire feeding distance requirements;

[0008] The booster can be mounted to the wire feeding channel at a preset angle via a connecting mechanism, wherein the connecting mechanism comprises a fixed connecting portion and / or a rotating connecting portion.

[0009] Auxiliary wire feeding breaks through distance limit: The wire clamping pair formed by the driving wheel and the driven wheel can generate a continuous and stable pushing force on the welding wire under the power drive of the driver. This structure directly makes up for the power shortage problem of traditional push wire welding guns which only rely on the power of external wire feeder, so that the wire feeding distance is no longer limited to 3 meters, and can be flexibly extended according to actual operation needs, completely solving the problem of frequent equipment movement caused by short wire feeding distance in large-scale engineering.

[0010] Modular expansion improves adaptability: The design allows multiple boosters to be connected in series, achieving segmented supplement of wire feeding power. For example, in an 18-meter wire feeding distance, connecting two boosters can distribute the wire feeding resistance, avoiding excessive load on a single booster, so that the equipment can adapt to various scenes from short-distance precision welding to long-distance large-structure welding, significantly improving the environmental adaptability of the equipment.

[0011] Angle-adjustable to enhance operational flexibility: The preset angle installation function of the connecting mechanism can adjust the position of the booster according to the welding gun operation posture (such as different holding angles when overhead welding or vertical welding). When the welding space is narrow, the angle can be adjusted to avoid interference between the booster and the workpiece, so that the operator does not need to change the welding posture due to equipment structure limitations, reducing the operation difficulty and improving the operation safety.

[0012] Further, the booster is fixedly arranged on the welding gun handle through a fixed connecting part, and the fixed connecting part comprises:

[0013] A first connecting piece fixedly arranged on the shell, having an angle positioning feature;

[0014] A second connecting piece fixedly arranged on the welding gun handle, having a matching structure adapted to the angle positioning feature.

[0015] Stable installation ensures operation stability: The fixed connecting part rigidly connects the booster and the welding gun handle, avoiding displacement of the booster caused by equipment vibration during welding. In high-frequency welding operation, this stability can reduce the wire feeding precision fluctuation caused by position deviation, ensuring the consistency of wire feeding for each weld.

[0016] Angle positioning ensures power transmission efficiency: The angle positioning feature of the first connecting piece and the second connecting piece can ensure that the booster is installed at multiple angles to the welding gun handle. Specifically, for the booster installed to the welding gun handle, the angle between the axis of the driver (servo motor) and the horizontal plane has multiple choices. To adapt to complex welding space.

[0017] Standardized interface simplifies assembly process: The standardized design of the angle positioning feature and the matching structure allows the booster to be assembled with different models of welding gun handles without the need for customized adapters. The operator can complete the installation by simply aligning, shortening the equipment debugging time and improving the assembly efficiency in mass production.

[0018] Further, the fixed connection part further comprises:

[0019] a locking member configured to lock the first connection member and the second connection member at a preset angle position;

[0020] The angle positioning feature and the matching structure are configured to provide at least one preset angle position, so that the first connection member can be installed at a selected preset angle to the second connection member and fixed by the locking member.

[0021] The locking function prevents angle drift: the locking member can keep the preset angle unchanged under working conditions such as welding vibration and impact. For example, in high-intensity operations such as ship deck welding, even if the welding gun is impacted by external force, the angle of the power booster will not change, avoiding the jamming of welding wire or sudden changes in wire feed speed caused by angle drift.

[0022] Multi-angle selection adapts to complex scenarios: the design of at least one preset angle position enables the device to adapt to different operating environments. For example, when welding a pipe, a 30° installation angle can be selected to allow the power booster to avoid the outer wall of the pipe; when welding a flat plate, a 0° installation angle can be selected to reduce the space occupied by the device, achieving flexible application of "one device for multiple scenarios".

[0023] Quick switching improves operating efficiency: when the welding scene needs to be changed, the locking member can be loosened to adjust the angle and relock without disassembling the entire connection structure. Compared with traditional fixed design, more than 50% of the angle adjustment time can be saved, especially suitable for multi-station rotation in batch production.

[0024] Further, the power booster is an independent modular component, which can be selectively arranged between the welding gun handle and the welding cable, between two sections of the welding cable, or both, and the wire feed passage axis of the power booster is coaxially connected with the wire feed passage axis of the adjacent component to form a continuous wire transmission path.

[0025] Independent module simplifies maintenance process: as an independent component, the power booster can be replaced individually. When a power booster fails, the entire welding gun system does not need to be disabled, and only the faulty module needs to be replaced to resume operation, reducing the downtime of the device to 1 / 3 of the traditional structure.

[0026] Flexible layout optimizes space utilization: the versatility of installation positions enables the device to adapt to different space limitations. In compact spaces such as automobile chassis welding, the power booster can be integrated into the middle section of the cable; in large steel structure welding, it can be installed near the handle for easy operation, achieving optimal configuration of space resources.

[0027] Gradual power configuration reduces energy consumption: By arranging boosters in sections according to wire feeding distance (e.g., one booster within 3 meters, two within 8 meters), you can avoid running a single booster at full capacity. This graded power output mode can reduce energy consumption by over 30%, in line with the development trend of green manufacturing.

[0028] Furthermore, the rotating shaft of the driving wheel is coaxially arranged with the output shaft of the driver. The driver can be set to a one-way wire feeding mode or a pulse retraction wire feeding mode. The driver is set to a servo motor to realize the pulse retraction wire feeding mode.

[0029] Coaxial drive improves power efficiency: The drive shaft and driver output shaft are coaxially arranged, eliminating the energy loss of indirect connections such as gear transmission, increasing power transmission efficiency to over 95%. At the same wire feed speed requirement, a smaller driver can be selected, reducing equipment energy consumption.

[0030] Dual-mode adaptability supports diverse welding technologies: unidirectional wire feed mode meets conventional welding requirements, while pulsed retraction wire feed mode is suitable for cold metal transfer (ASMT) welding. Precise servo motor control enables stepless adjustment of wire retraction speed, giving ordinary welding guns the pulse welding capabilities of robotic guns at a fraction of the cost.

[0031] Dynamic response optimizes weld quality: The servo motor's high-speed response (response time < 0.01s) compensates for resistance fluctuations during wire feeding in real time. For example, when the wire passes through a curved cable, the motor instantly increases torque to prevent stalls, keeping wire feed speed fluctuations within ±1% and significantly improving weld uniformity.

[0032] Furthermore, the servo motor of the booster is connected to the controller of the welding machine via a cable.

[0033] Centralized control improves collaborative accuracy: After being linked with the welding machine controller, the booster wire feeding speed can be matched with the welding current and voltage parameters in real time.

[0034] Intelligent Adjustment Adapts to Material Variations: When welding different wire materials (such as carbon steel and aluminum alloy), the controller automatically adjusts the booster's clamping force and wire feed acceleration according to preset parameters. For example, for softer aluminum alloy wire, the clamping force can be reduced to prevent deformation, improving adaptability to different material welding.

[0035] Fault diagnosis simplifies maintenance: The controller monitors the booster's operating parameters (such as motor current and speed) in real time, immediately announcing any anomalies and displaying the fault location. Compared to traditional manual troubleshooting, this shortens fault diagnosis time and reduces equipment maintenance costs.

[0036] Furthermore, the booster further comprises a pressure regulator, which comprises a pressure seat hinged to the housing and an adjustment seat fixed to the housing;

[0037] The driven wheel is mounted on the pressure seat, and the adjustment seat can change the position of the pressure seat to move the driven wheel toward or away from the driving wheel.

[0038] Adjustable pressure accommodates multiple wire sizes: By adjusting the pressure seat position, the clamping force can be adjusted within a range of 5-50N, meeting the transmission requirements of wire diameters from 0.8-5.2mm. Changing wire sizes eliminates the need to replace the booster assembly; parameter adjustments can be completed in just 5 minutes, enhancing the device's versatility.

[0039] Stable clamping reduces wire feeding fluctuations: The clamping force can be precisely adjusted for different wire materials (such as stainless steel wire, which is hard, and brass wire, which is easily deformed). For example, a higher clamping force can be applied to stainless steel wire to prevent slipping, while a lower clamping force can be applied to brass wire to prevent damage, improving wire feeding stability by over 40%.

[0040] Self-compensating structure extends service life: The hinged design of the pressure seat automatically adjusts the angle when the welding wire is slightly bent, preventing wear on the gear train caused by rigid clamping. In long-term operation, this self-compensating function can extend the service life of the driving and driven pulleys to twice that of traditional structures.

[0041] Furthermore, the booster is rotatably connected to the welding cable via a rotatable connection portion, and the rotatable connection portion includes:

[0042] a third connecting member fixed to the housing and having a rotation interface;

[0043] a fourth connector fixed to the welding cable, having a mating interface adapted to the rotational interface;

[0044] an adjustment assembly configured to adjust the degree of coupling between the third connecting member and the fourth connecting member to change the rotational resistance therebetween;

[0045] The rotation interface and the mating interface are configured to allow the booster to rotate in multiple directions relative to the welding cable. The adjustment component achieves coordinated adjustment of the resistance in each rotation direction by changing the normal force or contact characteristics between the rotation interfaces.

[0046] Multi-directional rotation adapts to complex trajectories: The design of the rotation and mating interfaces allows the booster to achieve ±30° pitch and ±60° yaw adjustment, fully covering the robot welding gun's motion range. When welding the interior of large pressure vessels, the robot arm can flexibly avoid obstacles, eliminating the motion interference problem of traditional fixed structures.

[0047] A modular booster welding gun comprises a booster. The welding guns include a wire push welding gun, a robot welding gun and a collaborative robot welding gun.

[0048] Cross-type adaptation reduces equipment cost: The same booster can be adapted to push wire welding guns, robot welding guns and other types, and enterprises do not need to purchase separate booster equipment for different welding guns, which can reduce equipment procurement costs. For example, manual welding stations and robot welding stations in automobile factories can share the same type of booster, simplifying spare parts management.

[0049] Technical sinking expands application scenarios: The precision wire feeding technology of robot welding guns is transplanted to ordinary welding guns through the booster, enabling high-end technologies such as cold metal transfer welding to be applied to large structural components (such as bridge steel structures), narrow spaces (such as the inside of pipelines), and other scenarios that robots cannot reach, promoting the popularization of high-end welding technology.

[0050] Upgrade compatibility protects previous investment: Existing welding guns can be upgraded by adding a booster without discarding the original equipment. For example, a traditional push wire welding gun can have long-distance wire feeding capability after adding a booster, improving the return on investment of previous equipment.

[0051] Further, the angle between the straight line where the welding wire is located in the booster and the straight line where the welding wire is located in the welding gun handle is 0-30 degrees.

[0052] Angle limitation ensures smooth wire feeding: The 0-30° angle range ensures that the transition section between the booster and the welding gun handle is a smooth curve. When the angle exceeds 30°, the welding wire will generate additional resistance due to bending. The limited angle can control the resistance increase within 10%, avoiding wire jamming.

[0053] Stable path improves welding precision: The fixed angle range ensures that the welding wire enters the welding gun nozzle at the same position, avoiding arc deviation caused by angle deviation.

[0054] Advantages of the present application:

[0055] 1. Breakthrough in wire feeding length, meeting long-distance welding needs:

[0056] Traditional push wire welding guns are limited by wire feeding motor power and transmission structure, with a wire feeding distance usually not exceeding 3 meters. In large-scale engineering welding, the equipment needs to be moved frequently, which seriously affects efficiency. The present application, through the modular booster's serial connection design, can connect one or more boosters on the wire feeding channel according to actual needs, forming a segmented power supplement. The driving wheel and driven wheel of each booster cooperate to provide continuous propulsion, effectively offsetting the resistance of long-distance wire feeding, making the wire feeding length easily exceed 10 meters, completely covering the welding operation range of large structural components such as bridges, ships, and large pressure vessels, completely solving the short wire feeding distance of traditional equipment, greatly reducing the number of equipment movements, and improving operation continuity.

[0057] 2. Flexible switching of wire feeding mode, adapting to multiple welding technologies:

[0058] The driver of the power booster can be flexibly switched to a unidirectional wire feeding mode or a pulse wire feeding and withdrawing mode by replacing a unidirectional motor or a servo motor. The unidirectional wire feeding mode can meet the stable wire feeding requirement of conventional welding and ensure uniform wire feeding. The pulse wire feeding and withdrawing mode can realize precise wire feeding and withdrawing and perfectly adapt to advanced technologies such as cold metal transfer welding (ASMT). This function enables ordinary wire feeding welding guns to complete precise welding without relying on complex and expensive robot structures, breaking the dependence of advanced welding technologies on special equipment and enabling the application of ASMT technology in large structural parts, narrow spaces and other scenarios.

[0059] 3. Multi-angle installation design to adapt to complex operation space

[0060] The power booster can be installed at multiple angles through a connecting mechanism (including a fixed connecting part and a rotating connecting part). The power booster can be fixedly installed on the welding gun handle at a preset angle, and the rotating connecting part allows the power booster to rotate in multiple directions relative to the welding cable. In complex scenarios such as pipe girth welding and welding in narrow spaces inside equipment, the operator can flexibly adjust the angle of the power booster according to the operation environment to avoid interference with the workpiece or surrounding equipment, ensuring smooth welding and significantly improving the adaptability of the equipment in complex spaces.

[0061] 4. Other significant advantages

[0062] Reduced equipment cost and upgrade threshold: Compared with special robot welding guns, the modular design of the present application greatly reduces manufacturing costs. Existing wire feeding welding guns only need to be upgraded by adding a power booster, without the need to replace the entire equipment, significantly reducing enterprise investment.

[0063] Improved welding quality and efficiency: The segmented power booster wire feeding controls the wire feeding speed fluctuation within ±1%, reducing wire jamming and wire breakage, and improving welding quality.

[0064] Enhanced equipment compatibility and maintenance convenience: The power booster, as an independent modular component, can adapt to various equipment such as wire feeding welding guns, robot welding guns, collaborative robot welding guns, etc., with strong versatility. The structure is simple and can be individually disassembled and replaced during later maintenance, reducing downtime and maintenance costs.

[0065] In summary, the present application solves the core problems of wire feeding length, mode switching, space adaptation, etc. by targeted solutions, and provides an efficient, flexible and economical solution for the welding industry in terms of cost, efficiency, compatibility, etc., promoting the development of welding equipment towards multi-function and wide adaptation. BRIEF DESCRIPTION OF DRAWINGS

[0066] Figure 1 A connection diagram illustrating a schematic embodiment of a welding gun with a horizontally installed power booster.

[0067] Figure 2 A schematic structural diagram for illustrating an exemplary embodiment of a horizontal booster in the present invention;

[0068] Figure 3 A schematic structural diagram for illustrating a schematic embodiment of a horizontal booster in a cutaway state according to the present invention;

[0069] Figure 4 A schematic structural diagram for illustrating an exemplary embodiment of a vertical booster in the present invention;

[0070] Figure 5 A schematic structural diagram for illustrating a schematic embodiment of a vertical booster in a cutaway state according to the present invention;

[0071] Figure 6 A schematic structural diagram for illustrating another exemplary embodiment of a vertical booster in a cutaway state according to the present invention;

[0072] Figure 7 A schematic diagram illustrating a connection of a collaborative robot welding gun equipped with a horizontal booster according to an exemplary embodiment of the present invention;

[0073] Figure 8 A schematic diagram illustrating a connection of a robot welding gun equipped with a horizontal booster according to an exemplary embodiment of the present invention;

[0074] Figure 9 A connection diagram for illustrating an exemplary embodiment of a conventional welding gun equipped with a vertical booster according to the present invention.

[0075] List of parts and reference numerals:

[0076] 1. Shell; 11. First half shell; 12. Second half shell; 13. Transparent cover; 2. Driving wheel; 3. Driven wheel; 4. Driver; 5. Connecting mechanism; 51. Fixed connecting part; 511. First connecting member; 512. Second connecting member; 513. Locking member; 52. Rotating connecting part; 521. Third connecting member; 522. Fourth connecting member; 523. Adjusting assembly; 6. Wire feeding channel; 61. Welding gun handle; 62. Welding cable; 7. Operation panel; 71. Voltage adjustment control; 72. Current adjustment control; 8. Welding wire; 9. Pressure regulator; 91. Pressure seat; 911. Support shaft; 912. Pressure shaft; 913. Pin shaft; 92. Adjusting seat; 921. Adjusting slide bar; 922. Slide bar limiter; 923. Pressure bar; 924. Tension spring. DETAILED DESCRIPTION

[0077] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0078] It should be noted that the directional terms such as left, right, up, down, front and back in the embodiments of the present invention are merely relative concepts or are based on the normal use state of the product, that is, the direction of movement of the product, and should not be considered as limiting.

[0079] In addition, it should be noted that the dynamic terms such as "relative motion" mentioned in the embodiments of the present invention not only refer to changes in position, but also include movements such as rotation and rolling in which there is no relative change in position but the state changes.

[0080] Finally, it should be noted that when a component is referred to as being "located on" or "disposed on" another component, it can be on the other component or there may be an intervening component. When a component is referred to as being "connected to" another component, it can be directly connected to the other component or there may be an intervening component.

[0081] In existing technology, push-wire welding guns generally use an external wire feeder. Limited by the transmission performance of the welding cable, the wire feeding distance is difficult to exceed 3 meters. Although some push-wire welding guns have an auxiliary wire feeder installed inside the welding gun handle to assist in wire feeding, they have obvious limitations. First, due to the limited size of the welding gun handle, the motor model of the auxiliary wire feeder is strictly limited, and it cannot provide strong wire feeding propulsion force. Second, existing auxiliary wire feeders are often integrated with the welding gun handle and cannot be disassembled. This makes them extremely inflexible and cannot be used between two sections of welding cable.

[0082] In contrast, this application utilizes a modular design, with the driver's power far exceeding the output power of the motor built into the welding gun handle. Furthermore, the auxiliary wire feeder in a conventional welding gun handle is driven only in one direction by the motor, supporting only one-way wire feeding. This makes it unsuitable for new processes such as cold metal transfer welding that require pulsed wire retraction. This application effectively solves this problem.

[0083] The present invention discloses a modular booster and its welding gun. The booster is an independent modular component, and the installation position can be flexibly selected: it can be set between the welding gun handle 61 and the welding cable 62, or it can be connected in series between two sections of welding cable 62, and it can also be installed in the above two places at the same time; the axis of its wire feeding channel 6 is coaxially connected with the axis of the wire feeding channel 6 of the adjacent component to form a continuous welding wire 8 transmission path to meet the needs of long-distance welding. The wire feeding channel 6 of the same welding equipment is connected in series with one or more boosters according to the actual wire feeding distance requirements. Its core function is to effectively break through the wire feeding distance limit of the traditional wire pushing welding gun through multi-stage auxiliary propulsion. A single booster can enhance the local wire feeding power, and when multiple boosters are connected in series, a relay wire feeding drive can be formed, which greatly extends the wire feeding range, breaks through the national standard limit on the length of the wire pushing welding gun, and can expand and extend the traditional 3-meter wire feeding distance. The booster breaks the limitations of manual welding range, allowing operators to no longer be constrained by limited space when working in large projects or complex workstations. It solves the difficulties and pain points of frequent equipment movement and posture adjustment caused by insufficient wire feeding distance on site, and improves the continuity and efficiency of welding operations.

[0084] In addition, the booster can be used alone and installed on a common welding gun (such as Figure 1 ), robot welding gun (such as Figure 8 ) or collaborative robot welding gun (such as Figure 7 ) can effectively improve the wire feeding stability, thereby stabilizing arc burning, reducing spatter, and significantly expanding the range of activities of the collaborative robot.

[0085] This application proposes Figures 1 to 9 A modular booster and its welding gun are shown. The booster is a miniaturized compression wire feeding device, in which the driving wheel 2 and the driven wheel 33 in the housing 1 form a clamping pair for the welding wire 8. The rims of the wire feeding wheels (driving wheel 2 and driven wheel 3) are processed to form V-shaped grooves or U-shaped grooves, which are respectively suitable for the feeding of steel wire and aluminum wire. This not only increases the friction between the wire feeding wheel and the welding wire 8, but also guides the welding wire 8. The booster device drives the wire feeding wheel through a driver 44 (usually a conventional motor) to feed the welding wire 8 to the welding gun. The conventional motor is replaced by a servo motor, and the wire feeding mode is changed from one-way wire feeding to pulsed retraction wire feeding ("more in, less out" wire feeding mode), thereby adapting to the ASMT welding process and greatly broadening the scope of application. The precise wire feeding control structure and stable power transmission system in the booster can significantly improve wire feeding stability, reduce wire jamming and speed fluctuations, improve weld formation accuracy and product quality, and enhance welding production efficiency. It is an important innovation in equipment performance and operating mode in the field of manual welding.

[0086] The booster is mounted at a preset angle to the wire feed channel 6 via a connection mechanism 5 comprising a fixed connection portion 51 and / or a rotating connection portion 52. The fixed connection portion 51 provides a rigid connection between the booster and the wire feed channel 6. This stable structural fit ensures the consistency of the wire feed axis, fundamentally preventing wire feed deviations caused by loose connections and ensuring a precise delivery path for the welding wire 8. For example, in space-constrained welding scenarios, the booster can be pre-fixed to the welding gun handle 61 based on the actual working space. This rigid connection prevents collision and interference between the protruding driver 4 on the booster and the workpiece, ensuring safe and stable operation.

[0087] The rotating connection 52 provides the booster with flexible angle adjustment capabilities, enabling it to adapt to the different orientations of the wire feed channel 6 or complex welding environments. By dynamically adjusting the angle to match the welding gun posture and changes in the working space, it ensures that the welding wire 8 can continue to advance smoothly even in complex conveying paths such as bends and turns, significantly improving the device's adaptability to diverse welding scenarios. For example, when the booster and welding cable 62 are connected using a ball joint, a certain bending allowance can be formed between the welding gun handle 61 and the welding cable 62, allowing the operator to more naturally adjust the welding gun angle during operation, effectively improving the comfort of the welding operation.

[0088] A modular booster, whose technical solution consists of four parts: structural design, installation system, drive control and function expansion.

[0089] The structural design utilizes a split housing 1, combining a vertical wire clamping pair (8). The driving and driven pulleys (2, 3) are arranged perpendicular to the axis of the wire feed channel (6), enhancing the restraint of the wire (8) through orthogonal clamping. V- or U-shaped grooves are machined into the rims of the wire feed rollers to prevent deflection and shaking during wire feeding. The first and second housing halves (11, 12), separated along the axis of the wire feed channel (6), are connected by a removable seal, facilitating rapid inspection and replacement of internal components while ensuring the equipment's protective performance.

[0090] The mounting system integrates both fixed and rotating connection mechanisms. The fixed connection 51, through angular positioning features, a mating structure, and a locking member 513, enables precise, multi-level angle adjustment of the booster on the welding gun handle 61, ensuring posture adaptation for working in confined spaces. The rotating connection 52, through a rotating interface, a mating interface, and an adjustment assembly 523, grants the booster multi-directional rotational freedom at the connection to the welding cable 62, and allows for adjustable rotational resistance as needed to meet posture adjustments during dynamic welding.

[0091] The drive control system features bidirectional wire feeding and modular expansion. The driver's output shaft (4) is directly connected to the driving wheel (2) coaxially, supporting dual-mode switching between unidirectional wire feeding and pulsed retraction. The pulsed retraction mode precisely matches the requirements of new welding processes such as cold metal transfer through periodic wire feeding and retraction. The booster, an independent modular component, can be flexibly deployed between the welding gun handle (61) and the cable, at cable sections, and other locations. Standardized connectors enable cascading of multiple boosters, effectively extending wire feeding distances and establishing a continuous and stable wire transmission path (8).

[0092] Functional expansion modules further enhance the device's applicability and ease of use. An integrated control panel 7, featuring voltage, current, wire feed speed adjustment, and mode switching, enables precise, one-stop control of welding parameters. A hinged, transparent cover 13 allows for both real-time monitoring of the welding status and convenient equipment maintenance. A pressure regulator 9 dynamically adjusts the clamping pressure of the driven wheel 3 based on the diameter and material of the welding wire 8, broadening the device's applicability. Standardized connectors allow for quick adaptation of boosters with various power specifications, reducing equipment selection and maintenance costs.

[0093] Among them, the driving wheel 2 refers to the roller that provides rotational power through the driver 4. The surface of the driving wheel 2 is provided with anti-slip grooves to increase the friction with the welding wire 8. The driven wheel 3 refers to the passive roller that cooperates with the driving wheel 2 to clamp the welding wire 8, and maintains the clamping force with the driving wheel 2 through elastic pressure. The driver 4 refers to the driving device that provides wire feeding power, which can be specifically implemented by a servo motor. Its output shaft is coaxially connected to the driving wheel 2 to reduce transmission loss. The booster can be installed 360° circumferentially in the wire feeding channel 6. The booster can be rotated to any angle relative to the axis of the wire feeding channel 6 and installed and fixed to the wire feeding channel 6.

[0094] Specifically, the wire feed roller group formed by the driving wheel 2 and the driven wheel 3 is arranged perpendicular to the axis of the welding wire 8, so that the welding wire 8 can be stably transported during the clamping and conveying process. The driver 4 is mounted to the housing 1 and biased to one side to form a local protruding structure. When the booster is installed in the wire feeding channel 6, the operator can rotate the booster so that the protrusion (driver 4) faces the direction of the unobstructed space. For example, in pipeline welding, the protrusion (driver 4) can be adjusted to the recessed area of ​​the inner wall of the pipeline to avoid collision, and then the housing 1 and the wire feeding channel 6 are fixed. The two ends of the housing 1 can be connected to the wire feeding channel 6 by hinges or ball head connectors, allowing the booster to swing or rotate freely in a specific direction. It can also be installed to the welding gun handle 61 of the wire feeding channel 6 by fixing the clip.

[0095] Through the above-mentioned technical solution, this application solves the problem of wire jamming during long-distance wire feeding, extending the wire feeding distance to 30 meters. The circumferentially adjustable mounting prevents interference between the booster and surrounding structures, making it suitable for welding in confined spaces such as pipeline interiors. Driver 4 supports switching between unidirectional wire feeding and pulse retraction modes, adapting to the wire feeding accuracy requirements of cold metal transfer welding processes.

[0096] The present application further proposes that the booster is fixed to the welding gun handle 61 via a fixed connection portion 51, and the fixed connection portion 51 includes:

[0097] A first connecting member 511 fixed to the housing 1 has an angle positioning feature;

[0098] A second connecting member 512 fixed to the welding gun handle 61 has a matching structure adapted to the angle positioning feature;

[0099] The locking member 513 is configured to lock the first connecting member 511 and the second connecting member 512 at a preset angle;

[0100] The angular positioning features and the mating structure are configured to provide at least one preset angular position, so that the first connecting member 511 can be mounted to the second connecting member 512 at a selected preset angle and held in place by the locking member 513 .

[0101] In one embodiment, the modular booster housing 1 is made of high-temperature-resistant engineering plastic and is flat, elongated. A first connector 511 is integrally formed on the outer wall of the housing 1 facing the welding gun handle 61. The first connector 511 is a rectangular plate with an angle positioning feature on the side facing away from the housing 1. Specifically, it is provided with three evenly spaced semicircular grooves corresponding to the three preset angle positions of 0°, 15°, and 30°. The grooves have smooth inner walls and a certain depth to ensure stable angle positioning.

[0102] The welding gun handle 61 is made of a conventional insulating material. A second connector 512 is screwed to the handle near the booster housing 1. The second connector 512 is also a rectangular plate that matches the first connector 511. On the side facing the first connector 511, a mating structure is provided: a resiliently extendable ball. The ball's diameter matches the diameter of the semicircular groove on the first connector 511, allowing it to fit snugly within the groove, achieving angular alignment between the two.

[0103] The locking member 513 is a butterfly bolt, and corresponding bolt holes are provided on the first connecting member 511 and the second connecting member 512. The positions of the bolt holes avoid the angle positioning features and the matching structure to ensure that the angle positioning function is not affected.

[0104] During installation, select an appropriate preset angle based on the actual space requirements and operating habits of the welding operation. If a 15° angle is selected, align the semicircular groove corresponding to 15° on the first connector 511 with the convex ball on the second connector 512 and gently press. The convex ball will embed into the groove under the action of elastic force, achieving preliminary angle positioning. Subsequently, pass the butterfly bolt through the bolt holes on the first connector 511 and the second connector 512 and tighten. The tightening force of the bolt securely locks the first connector 511 and the second connector 512 at the preset 15° angle, preventing the angle from shifting due to factors such as vibration during the welding operation.

[0105] When the angle position needs to be changed, just loosen the butterfly bolt to make the metal convex ball fall out of the current groove, then adjust the first connecting member 511 to the groove position corresponding to the required angle, re-embed the convex ball and tighten the bolt. The operation is convenient and flexible.

[0106] Through such a structural design, the booster can be stably and flexibly installed on the welding gun handle 61 at a preset angle, adapting to different welding operation scenarios, improving the convenience of operation and the stability of welding.

[0107] In one embodiment, the first connecting member 511 can be configured as a first flange plate, the second connecting member 512 can be configured as a second flange plate, and the locking member 513 can be configured as a bolt. Both the first and second flange plates are provided with circumferentially arranged positioning holes. The specific application method is conventional bolt connection and will not be further described.

[0108] In one embodiment, during pressure vessel welding operations, the booster needs to be installed on the welding gun handle 61 at a 90° vertical angle. The first connecting member 511 is an annular gear disc structure, fixed to the end of the booster housing 1, with 36 positioning teeth evenly distributed around the circumference of the gear disc as an angle positioning feature; the second connecting member 512 is a corresponding tooth groove structure, fixed to the mounting end face of the welding gun handle 61, and the shape and size of the positioning teeth of the tooth groove and the gear disc are fully adapted. During installation, the gear disc is embedded in the tooth groove, and different tooth positions can be selected by rotating the gear disc to achieve installation at multiple preset angles such as 0°, 90°, 180°, and 270°. After selecting the 90° angle, use bolts and nuts as locking members 513, tighten them through the corresponding through holes on the gear disc and the tooth groove, so that the gear disc and the tooth groove are tightly engaged, ensuring that the booster maintains a fixed angle under welding vibration conditions, and effectively avoiding the impact of angle offset on welding accuracy.

[0109] The present application further proposes a booster as an independent modular component, which is selectively arranged between the welding gun handle 61 and the welding cable 62, between two sections of welding cable 62, or simultaneously arranged in both, and the axis of the wire feeding channel 6 of the booster is coaxially connected with the axis of the wire feeding channel 6 of the adjacent component to form a continuous welding wire 8 transmission path.

[0110] In one embodiment, the booster is installed only between the welding gun handle 61 and the welding cable 62. The welding gun handle 61 refers to the main body of the welding tool held by the operator, which can be specifically manufactured by injection molding or metal casting, and has a guide channel for the welding wire 8 inside. The welding cable 62 refers to a flexible tubular structure that wraps around the welding wire 8 and transmits electricity, which can be specifically implemented by a composite structure of multiple layers of metal braiding and an insulating sheath, used to protect the welding wire 8 and conduct the welding current. The booster is installed only between the welding gun handle 61 and the welding cable 62, which means that the two ends of the booster housing 1 are connected to the end of the welding gun handle 61 and the outlet end of the welding cable 62, respectively. Specifically, it can be implemented by flange docking or a snap-on quick-release structure. By limiting the installation position of the booster, linear optimization of the wire feeding path is achieved.

[0111] Through the above technical solution, the present application solves the problems of welding wire 8 jamming and unstable wire feeding speed during long-distance wire feeding, while ensuring the compact installation of the booster at the connection between the welding gun handle 61 and the welding cable 62, so that it can adapt to space-constrained working environments such as pipeline welding.

[0112] In one embodiment, the booster is installed only between two sections of welding cable 62. The wire feed channel 6 refers to the path for welding wire 8 to travel from the wire feeder to the end of the welding gun. Specifically, it can be implemented as a continuous structure comprising a welding gun handle 61 and a welding cable 62. The welding gun handle 61 is used for gripping, while the welding cable 62 is used for power transmission and feeding the welding wire 8. The area between the two sections of welding cable 62 is the connecting area formed by the front and rear sections of the welding cable 62. This can be achieved by providing a detachable joint or a segmented sleeve structure in the middle section of the welding cable 62.

[0113] Specifically, by installing the booster between two sections of welding cable 62, the connection area between the welding gun handle 61 and the welding cable 62 remains simple. The booster housing 1 is secured to the outer wall of the welding cable 62 via a flange or snap-fit ​​mechanism. The wire feed roller assembly clamps the welding wire 8 and drives it along the wire feed channel 6. Because the booster is not directly connected to the welding gun handle 61, the rotation angle of the welding gun handle 61 is not limited by the booster's size when the operator is working in a confined space. Furthermore, the segmented structure of the welding cable 62 allows the booster's installation position to be adjusted according to the working conditions.

[0114] Compared to existing technologies, traditional welding gun boosters are typically integrated near the welding gun handle 61, which increases the handle's bulk and easily interferes with surrounding structures. This solution relocates the booster to the middle section of the welding cable 62, maintaining the compactness of the welding gun handle 61 while leveraging the flexibility of the welding cable 62 to adapt to various spatial layouts. For example, when welding inside a pipe, the booster can be installed away from bends to prevent collisions with the pipe wall.

[0115] Through the above technical solution, this application solves the problem of difficulty in installing the booster in a narrow space, reduces the risk of spatial interference when operating the welding gun handle 61, and at the same time realizes flexible adjustment of the booster position through the segmented design of the welding cable 62, meeting the need for free switching of the welding gun posture in long-distance wire feeding scenarios.

[0116] Installing a booster at the junction of the welding gun handle 61 and the welding cable 62 directly enhances the wire feeding drive force near the welding gun handle 61, reducing speed fluctuations of the welding wire 8 before it enters the welding gun handle 61. Adding a booster between two sections of welding cable 62 can compensate for the attenuation of driving force during long-distance wire feeding in sections. By installing boosters in multiple locations, the welding wire 8 forms a segmented drive mode within the wire feed channel 6, with each booster operating independently and collaboratively maintaining the continuity of the welding wire 8 feed. For example, after passing through the booster between the welding cables 62, the welding wire 8 is relay-driven by the boosters between the two sections of welding cable 62 as it enters the welding gun handle 61, avoiding wire 8 jamming caused by insufficient power from a single drive source.

[0117] Compared to existing technologies, conventional welding gun boosters are installed only between the welding gun handle 61 and the welding cable 62, failing to meet the wire feeding requirements of long welding cable 62 sections. This can lead to insufficient driving force for the welding wire 8 within this section of welding cable 62. This solution, by adding a booster between two sections of welding cable 62, distributes the wire feeding force along the length of the welding cable 62, effectively addressing the issue of long-distance wire feeding stability. Furthermore, conventional boosters, due to their single installation location, are prone to interfering with surrounding structures in confined spaces. This solution allows for dispersed installation of boosters, allowing for flexible layout adjustments based on space constraints.

[0118] Through the above technical solution, the present application can significantly extend the effective working distance of the wire feeding channel 6 and reduce the speed fluctuation of the welding wire 8 during long-distance transportation; at the same time, the segmented installation method of the booster in the welding cable 62 can adapt to the space limitations of different welding scenarios, avoiding installation interference problems caused by the excessive size of a single booster, thereby improving the adaptability of welding equipment in complex working environments.

[0119] The present application further proposes that the rotating shaft of the driving wheel 2 is coaxially arranged with the output shaft of the driver 4, and the driver 4 can be set to a one-way wire feeding mode or a pulse retraction wire feeding mode. The driver 4 is set to a servo motor to realize the pulse retraction wire feeding mode. The pulse retraction wire feeding mode is configured to control the output shaft to perform periodic wire feeding and retraction actions to feed the wire progressively.

[0120] Among them, the coaxial arrangement of the rotating shaft of the driving wheel 2 and the output shaft of the driver 4 means that the rotation axis of the driving wheel 2 coincides with the power output axis of the driver 4. Specifically, this can be achieved by adopting a direct-connected transmission structure or an integrated shaft structure, thereby reducing the length of the transmission chain and reducing power loss. Among them, the one-way wire feeding mode means that the driver 4 only drives the driving wheel 2 to rotate in a single direction to achieve continuous feeding of the welding wire 8. Specifically, this can be achieved by adopting a one-way electromagnetic clutch or a directional control circuit, thereby maintaining the stable wire feeding requirements of the traditional welding process. Among them, the pulse retraction wire feeding mode means that the driver 4 periodically switches the forward and reverse movement of the driving wheel 2 to achieve intermittent advancement and retraction of the welding wire 8. Specifically, this can be achieved by adopting a servo motor in conjunction with a pulse control program, thereby adapting to the requirements of the cold metal transfer welding process for dynamic adjustment of the welding wire 8.

[0121] Specifically, the driver 4 directly drives the active wheel 2 to rotate through a coaxial transmission structure. In the one-way wire feeding mode, the active wheel 2 pushes the welding wire 8 to be continuously fed along the wire feeding channel 6 at a constant speed. In the pulsed retraction wire feeding mode, the driver 4 generates a periodic pulse signal according to the welding parameter requirements, and controls the active wheel 2 to alternately perform forward rotation wire feeding and reverse rotation retraction. As a result, the welding wire 8 forms intermittent advancement and slight retraction in the wire feeding channel 6, thereby accurately controlling the droplet transfer process and avoiding the molten pool disturbance problem caused by traditional one-way wire feeding. It should be noted that the switching between the one-way wire feeding mode and the pulsed retraction wire feeding mode is achieved by replacing the driver.

[0122] This solution simplifies the transmission path through a coaxial direct connection design and integrates a bidirectional control function, allowing the wire feeding mode to be flexibly switched according to the welding process requirements. This application solves the technical problem that traditional boosters cannot adapt to the pulse retraction wire feeding process. Through bidirectional wire feeding control, the movement trajectory of the welding wire 8 can be precisely adjusted to meet the requirements of cold metal transfer welding for dynamic changes in wire feeding speed, thereby improving weld formation quality and process stability.

[0123] The present application further proposes that the servo motor of the booster be connected to the controller of the welding machine via a cable. Specifically, the booster is provided with an operation panel 7 that is communicatively connected to the controller of the welding machine. The operation panel 7 includes a voltage adjustment control 71, a current adjustment control 72, a wire feeding speed adjustment control, and a wire feeding mode switching control. The wire feeding mode switching control is configured to switch between a unidirectional wire feeding mode and a pulsed retraction wire feeding mode, and each control coordinates to adjust the wire feeding parameters.

[0124] In one embodiment, welding thin aluminum alloy sheets for new energy vehicle battery housings (1) requires extremely high control over welding heat input. The operator first uses the wire feed mode switch to adjust the booster to pulsed retraction wire feed mode to reduce heat input during welding and prevent sheet deformation. Subsequently, the voltage adjustment control 71 is used to lower the welding voltage according to the thickness of the aluminum alloy sheet to reduce arc energy. The current adjustment control 72 is then used to fine-tune the welding current to ensure arc stability.

[0125] Regarding wire feed speed adjustment, since the pulsed retraction wire feeding mode requires frequent feeding and retraction of the welding wire 8, the operator sets the wire feed speed control to an appropriate value, taking into account the welding speed, so that the welding wire 8 is accurately fed to the appropriate length within each pulse cycle. Throughout the welding process, the voltage, current, wire feed speed, and wire feed mode interact with each other, and the coordinated adjustment of these controls results in a minimal heat-affected zone (HAZ) of the weld, a beautiful weld, and weld deformation within 1mm, effectively ensuring the welding quality and sealing of the battery casing 1.

[0126] The present application further proposes that the booster also includes a pressure regulator 9, which includes a pressure seat 91 hinged to the housing 1 and an adjustment seat 92 fixed to the housing 1. Specifically, one end of the pressure seat 91 is hinged to the housing 1 through a pin 913, a driven wheel 3 is installed in the middle, and a support shaft 911 and a pressure shaft 912 are respectively provided on both sides; the adjustment seat 92 is provided with a slidable adjustment slide 921, a slide limiter 922 that limits the adjustment slide 921, and a pressure rod 923 hinged to the adjustment slide 921; one end of the pressure rod 923 is sleeved on the support shaft 911, and the side wall abuts the pressure shaft 912. The adjustment slide 921 is sleeved with a connecting tension spring 924, and the tension spring 924 drives the pressure rod 923 to squeeze the pressure shaft 912.

[0127] The pressure regulator 9 refers to a device that dynamically adjusts the pressure applied by the driven wheel 3 to the welding wire 8 through a mechanical structure. Specifically, it can be implemented by a combination of an articulated lever and an elastic element. The pressure seat 91 forms a fulcrum through the hinge point, and the support shaft 911 and the pressure shaft 912 serve as the force receiving point and the force applying point, respectively, to achieve the transmission and adjustment of the pressure of the driven wheel 3. The adjustment slide 921 refers to a guide component that moves linearly along the adjustment seat 92. Specifically, it can be implemented by a metal rod with a limit groove. The slide limiter 922 limits the slide position through a threaded knob or a snap structure, thereby controlling the swing amplitude of the pressure rod 923. The tension spring 924 refers to an element that provides elastic restoring force. Specifically, it can be implemented by a coil spring or a leaf spring. Its two ends are respectively connected to the adjustment slide 921 and the adjustment seat 92. The preload force drives the pressure rod 923 to continuously apply pressure to the pressure shaft 912, ensuring a stable clamping force between the driven wheel 3 and the driving wheel 2.

[0128] Specifically, the pressure seat 91 forms a rotatable connection with the housing 1 via a hinge. As the adjustment slide 921 slides along the adjustment seat 92, the angle of the pressure rod 923 changes around the support shaft 911, thereby altering the thrust of the pressure shaft 912 on the pressure seat 91. The slide limiter 922 secures the position of the adjustment slide 921, locking and limiting the swing angle of the pressure rod 923, thereby controlling the clamping pressure between the driven wheel 3 and the driving wheel 2. The preload of the tension spring 924 ensures that the pressure rod 923 remains in close contact with the pressure shaft 912. As the diameter of the welding wire 8 changes or the wire feeding resistance fluctuates, the pressure seat 91 can adaptively adjust its angle to maintain a dynamic balance in the clamping force.

[0129] This solution uses a linkage mechanism between the slide rod and the pressure rod 923, combined with the elastic buffer of the tension spring 924, to make the pressure adjustment process adaptive. When the diameter of the welding wire 8 changes or the wire feeding resistance suddenly changes, it can automatically balance the clamping force to avoid the protrusion of the welding wire 8 being stuck between the driving wheel 2 and the driven wheel 3 due to pressure fixation.

[0130] Through the above technical solution, the present application solves the problem of wire 8 jamming caused by unstable clamping force during long-distance wire feeding. It also adapts to the feeding requirements of wires 8 of different diameters, reduces the frequency of manual adjustments, and improves the continuity of welding operations. In complex space operations, the slide bar limiter 922 quickly locks the pressure parameters, preventing clamping force failure due to external interference and ensuring consistent welding quality.

[0131] The present application further proposes that the booster is rotatably connected to the welding cable 62 via a rotatable connection portion 52, and the rotatable connection portion 52 includes:

[0132] A third connecting member 521 fixed to the housing 1 and having a rotation interface;

[0133] A fourth connector 522 fixed to the welding cable 62 has a mating interface adapted to the rotational interface;

[0134] an adjusting component 523 configured to adjust the degree of coupling between the third connecting member 521 and the fourth connecting member 522 to change the rotational resistance therebetween;

[0135] The rotation interface and the mating interface are configured to allow the booster to rotate in multiple directions relative to the welding cable 62. The adjustment component 523 achieves coordinated adjustment of the resistance in each rotation direction by changing the normal force or contact characteristics between the rotation interfaces.

[0136] In one embodiment, during curved hull welding operations, the booster needs to flexibly adjust its position to conform to complex welds. The third connector 521 is a hemispherical boss structure, fixedly mounted on the bottom of the booster housing 1. The hemispherical surface serves as the rotational interface and is precision-polished. The fourth connector 522 is a corresponding hemispherical groove structure, fixed to the end of the welding cable 62. The inner wall of the groove is inlaid with a wear-resistant polytetrafluoroethylene gasket, forming a mating interface that adapts to the rotational interface.

[0137] Adjustment assembly 523 uses a disc spring assembly and a screw mechanism. A blind hole is provided inside the hemispherical boss, through which the screw passes and engages with the threaded hole at the bottom of the hemispherical groove. Multiple disc springs are sleeved on the screw and located between the bottom of the blind hole on the boss and the bottom surface of the groove. When the screw is turned, the disc spring is compressed or relaxed, changing the normal force between the boss and the groove, thereby adjusting the rotational resistance. During welding, the booster can rotate freely in pitch, yaw, and roll, allowing the welder to easily adjust their posture according to the direction of the weld. By tightening or loosening the screw, the rotational resistance can be increased or decreased as needed, ensuring that the booster can be flexibly adjusted and remains stable during complex curved surface welding, significantly improving welding efficiency and accuracy.

[0138] In one embodiment, a compact and efficient rotating connection 52 is designed for the confined spaces of automotive component welding. The third connector 521 is a small cross-shaft universal joint, rigidly connected to the booster housing 1 at one end, with the four journals of the cross-shaft serving as the rotational interface. The fourth connector 522 is a matching fork joint secured to the welding cable 62, with the fork joint's fork fitting over the cross-shaft journals to form a mating interface.

[0139] Adjustment component 523 utilizes a magnetorheological fluid damper. A sealed chamber is located at the center of the universal joint's cross shaft, filled with magnetorheological fluid. An electromagnetic coil is wound around the periphery of the sealed chamber. By adjusting the current flowing through the electromagnetic coil, the viscosity of the magnetorheological fluid is altered, thereby adjusting the contact characteristics between the rotating interfaces and enabling rapid adjustment of the rotational resistance. During welding of automobile chassis, the booster can achieve flexible, multi-directional rotation through the universal joint, adapting to different welding angles within confined spaces. When precise welding requires a fixed posture, the current flowing through the electromagnetic coil is increased, increasing the viscosity of the magnetorheological fluid and the rotational resistance. The booster instantly stabilizes in the desired position, effectively resolving the inconvenience of welding operations in confined spaces.

[0140] In one embodiment, a durable rotating connection 52 is designed to withstand long-term, high-intensity welding operations during the welding of large-scale engineering machinery structures. The third connecting member 521 is a ball-joint structure, with the spherical portion fixed to the side of the booster housing 1, and the spherical surface serving as the rotating interface. The fourth connecting member 522 is a connector with a ball socket, which is mounted on the welding cable 62. The inner wall of the ball socket is covered with a copper-based powder metallurgy friction plate, forming a mating interface.

[0141] The adjustment assembly 523 consists of an annular pressure cover, an adjusting bolt and a spring. After the ball of the ball joint passes through the ball socket, it is limited by the annular pressure cover. The adjusting bolt passes through the annular pressure cover and is threadedly connected to the connecting seat. The spring is sleeved on the adjusting bolt and is located between the annular pressure cover and the connecting seat. By turning the adjusting bolt, the spring can be compressed or relaxed, changing the pressure of the annular pressure cover on the ball, thereby adjusting the friction between the ball and the friction plate and realizing the adjustment of the rotational resistance. During the welding process of engineering machinery, the booster relies on the ball joint to achieve multi-directional rotation to meet the welding requirements of different parts; by adjusting the adjusting bolt, the rotational resistance can be accurately set according to the welder's operating habits and welding conditions. Even in a long-term vibration environment, the booster can maintain a stable posture to ensure welding quality.

[0142] The present application also proposes that the housing 1 adopts a split structure extending along the axial direction of the wire feeding channel 6, including a first half shell 11 and a second half shell 12 connected to each other along a dividing surface, and the first half shell 11 and the second half shell 12 are detachably sealed.

[0143] In one embodiment, in the context of welding automotive parts on an assembly line, where equipment requires frequent maintenance to ensure production efficiency, a convenient split housing 1 structure is employed. The first half-shell 11 and the second half-shell 12 are horizontally divided along the axis of the wire feed channel 6. The dividing surface is designed to be stepped, and two annular grooves are provided at the joint. A high-temperature resistant nitrile rubber O-ring is embedded in the groove of the first half-shell 11, and a raised sealing lip is provided in the corresponding position of the second half-shell 12 to ensure a good seal. After the two are docked, they are secured using four sets of press-on clips distributed around the periphery of the housing 1. One end of the clip is hinged to the first half-shell 11, and the other end is provided with a barbed structure that quickly engages with the slot of the second half-shell 12. When the driving wheel 2 wears and needs to be replaced, the operator simply presses the clip to unlock it, and the two halves of the housing 1 can be separated in 10 seconds. After the parts are replaced, they can be re-fastened, greatly reducing downtime for maintenance and meeting the requirements of efficient assembly line production.

[0144] The present application also proposes that the housing 1 of the booster is hingedly mounted with a transparent cover 13, and the booster is provided with a display device and an operation panel 7 located on the inside of the cover. The cover is configured to allow visual reading of the contents of the display device in a closed state, and to adjust the operation panel 7 and enable inspection of internal components in an open state.

[0145] In one embodiment, welding conditions frequently change in an automated automotive body-in-white welding production line. The booster housing 1 is constructed of high-strength engineering plastic, and the hinged, transparent cover 13 is constructed of polycarbonate (PC), which offers high light transmittance and impact resistance. Inside the cover, a color LCD touchscreen displays parameters such as welding voltage, current, and wire feed speed in real time. The voltage and current adjustment knobs and wire feed mode selector on the operating panel 7 are compactly positioned around the display.

[0146] When the production line switches the welding vehicle model and the parameters need to be adjusted, the operator does not need to open the cover plate, but can clearly view the data of the display device through the closed transparent cover plate 13 and quickly modify the parameters through the touch screen. If the device abnormally alarms the wire feeding, the operator opens the cover plate to directly operate the adjustment knob for fine tuning, and at the same time can check whether there is blockage in the channel between the internal driving wheel 2 and the welding wire 8. After completing the maintenance, the cover plate is quickly closed to restore production. The whole process is efficient and convenient, and effectively reduces the downtime of the production line.

[0147] The application also proposes a type of booster with multiple power specifications. The input end and the output end of each booster are respectively provided with a standardized connector, which includes a coaxially arranged welding wire 8 channel interface, a protective gas channel interface, and an electrical signal transmission interface.

[0148] In an embodiment, the new energy vehicle battery box production line needs to consider both aluminum alloy sheet and stainless steel frame welding. The low-power booster is used for sheet welding, and its standardized connector is adapted to 0.8mm welding wire 8, quick plug-in gas circuit, and high-speed data transmission protocol. When switching to stainless steel frame welding, the high-power booster is directly replaced, and because the interface specifications are unified, there is no need to rewire and pipe, realizing rapid switching of the device.

[0149] In an embodiment, the modular booster welding gun is a push wire welding gun, and the booster is installed on the welding gun handle near the gun barrel through a fixed connection part. The included angle between the straight line where the welding wire in the booster is located and the straight line where the welding wire in the welding gun handle is located is 15 degrees, which is within the range of 0-30 degrees. From the design direction of the motor, the output shaft direction of the motor forms an adaptive angle with the extension direction of the welding gun handle, so that the center of gravity of the motor falls near the holding area of the welding gun handle, and the operator can maintain good balance when holding, without increasing the operation burden due to the offset of the center of gravity.

[0150] In actual welding operation, this angle setting makes the transition of the welding wire between the booster and the handle smooth, reduces the resistance in the welding wire transmission process, and ensures the stability of the wire feeding. It improves the comfort of operation and improves the welding efficiency.

[0151] In an embodiment, the modular booster welding gun is a robot welding gun. The handle of the robot welding gun does not need to be manually held, but in order to adapt to the mounting structure of the robot arm, the handle is designed with a specific connection interface, and the whole handle is in a shape similar to a straight handle, but there is a slight bending at the part connected with the booster, and the bending angle is 0 degrees to meet the posture requirements in robot operation.

[0152] The booster is mounted on the handle, with the angle between the welding wire in the booster and the welding wire in the handle at 0 degrees, minimizing resistance to wire movement. The motor's design orientation is optimized based on the robot arm's motion trajectory, aligning the motor's center of gravity with the robot's welding gun's overall center of gravity. This ensures that even during high-speed movement and precise positioning, the welding gun's center of gravity remains unbalanced, preventing welding accuracy from being compromised.

[0153] This angle setting ensures that the welding wire can be transmitted stably during the high-speed movement of the robot welding gun, avoiding the welding wire jitter or jamming caused by excessively large angles, and meeting the requirements of robot welding for high precision and high stability.

[0154] In one embodiment, the modular booster welding gun is a collaborative robot welding gun. Collaborative robot welding guns sometimes require manual assistance to adjust their posture. Therefore, the handle design takes into account the needs of robot installation and manual gripping. The booster is installed on the handle, and the angle between the welding wire in the booster and the welding wire in the handle is 5 degrees. The design direction of the motor comprehensively considers the characteristics of collaborative work. The position of its center of gravity ensures that there will not be an obvious sense of weight imbalance during manual assistance adjustment, and the robot can also maintain balance when driving the welding gun to move. The 5-degree welding wire angle can adapt to a larger range of robot movements in collaborative work, and can also allow the operator to clearly observe the transmission of the welding wire during manual assistance adjustment. It fully demonstrates the adaptability and practicality of the modular booster on different types of welding guns.

[0155] The foregoing is merely an embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various changes and variations. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present application should all be included within the scope of the claims of the present application.

Claims

1. A modular booster, characterized in that: It includes a driving wheel, a driven wheel and a driver protruding from the housing, wherein the driving wheel is linked with the output shaft of the driver, and the driving wheel and the driven wheel form a welding wire clamping pair perpendicular to the axis of the wire feeding channel; The wire feeding channel of the same welding equipment can be connected in series with one or more of the boosters to assist in advancing the welding wire according to the actual wire feeding distance requirements; The booster can be mounted to the wire feeding channel at a preset angle via a connecting mechanism, wherein the connecting mechanism includes a fixed connecting portion and / or a rotating connecting portion.

2. A modular booster according to claim 1, characterized in that: The booster is fixed to the welding gun handle through the fixed connection part, and the fixed connection part includes: A first connecting member fixed to the housing, having an angle positioning feature; The second connecting piece fixedly arranged on the welding gun handle has a matching structure adapted to the angle positioning feature.

3. A modular booster according to claim 2, characterized in that: The fixed connection portion further includes: a locking member configured to lock the first connecting member and the second connecting member at a preset angular position; The angular positioning feature and the mating structure are configured to provide at least one preset angular position, so that the first connector can be mounted to the second connector at a selected preset angle and held in place by the locking member.

4. A modular booster according to claim 1, characterized in that: The booster is an independent modular component, which is selectively arranged between the welding gun handle and the welding cable, between two sections of welding cable, or simultaneously arranged in both, and the wire feeding channel axis of the booster is coaxially connected with the wire feeding channel axis of the adjacent component to form a continuous welding wire transmission path.

5. The modular booster according to claim 1, characterized in that: The rotating shaft of the driving wheel is coaxially arranged with the output shaft of the driver. The driver can be set to a one-way wire feeding mode or a pulsed retraction wire feeding mode. The driver is set to a servo motor to realize the pulsed retraction wire feeding mode.

6. A modular booster according to claim 5, characterized in that: The servo motor of the booster is connected to the controller of the welding machine through a cable.

7. The modular booster according to claim 1, further comprising a pressure regulator, wherein the pressure regulator comprises a pressure seat hinged to the housing and an adjustment seat fixed to the housing; The driven wheel is mounted on the pressure seat, and the adjustment seat can change the position of the pressure seat so that the driven wheel moves toward or away from the driving wheel.

8. The modular booster according to claim 1, characterized in that: The booster is rotatably connected to the welding cable via the rotatable connection portion, and the rotatable connection portion includes: a third connecting member fixed to the housing and having a rotation interface; a fourth connector fixed to the welding cable, having a mating interface adapted to the rotation interface; an adjusting assembly configured to adjust the degree of coupling between the third connecting member and the fourth connecting member to change the rotational resistance therebetween; The rotation interface and the mating interface are configured to allow the booster to rotate in multiple directions relative to the welding cable, and the adjustment component achieves coordinated adjustment of the resistance in each rotation direction by changing the normal force or contact characteristics between the rotation interfaces.

9. A modular booster welding gun, characterized in that: The booster comprises the booster according to any one of claims 1 to 7, wherein the welding gun comprises a wire push welding gun, a robot welding gun and a collaborative robot welding gun.

10. A modular booster welding gun according to claim 9, wherein the angle between the straight line where the welding wire in the booster is located and the straight line where the welding wire in the welding gun handle is located is 0-30 degrees.

Images