Resistance roll welding device and application thereof

Abstract

The invention provides a resistance roll welding device and application thereof, the core of the resistance roll welding device is that a split type design roll welding wheel assembly is adopted, the upper rim of an upper roll welding wheel is provided with unique pressing sheets arranged in a piano key mode, and the pressing sheets and adjacent grooves jointly form a concave-convex structure capable of rotating along with the upper roll welding wheel. The concave-convex structure and the fixedly-arranged spring ejector pin assembly have a synergistic effect, in the rotating process of the upper roll welding wheel, the end of the ejector pin is always kept in contact with the concave-convex structure, an electric contact at the tail of the ejector pin can be driven to make contact with or be separated from an electrifying terminal through axial displacement, and therefore precise programmed control over welding current is achieved. When the resistance roll welding device is applied to stitch welding of the multi-layer extremely-narrow-spacing thin plate girth, the device can effectively stretch into a narrow gap, accurate pressure application to an independent area is achieved, the technical bottleneck of welding of the multi-layer extremely-narrow-spacing thin plate girth is thoroughly broken through, and the welding efficiency is improved. And the welding quality, the process precision, the production efficiency and the reliability are remarkably improved.

Description

Technical Field

[0001] This invention belongs to the technical field of metal welding equipment, and in particular relates to a resistance roll welding device and its application. Background Technology

[0002] In the field of metal welding, resistance seam welding is a widely used welding method. Traditional resistance seam welding machines typically employ an edge-clamping structure, where the workpiece is placed between two rollers. Heat is generated by energizing the rollers, melting the edges of the workpiece, and then welding is completed under pressure. The roller axes in this structure are usually parallel or have an angle greater than 30°, primarily used for welding single-piece, single-layer welds.

[0003] However, when faced with precision seam welding of multi-layer thin plates with extremely narrow spacing (0.5-3mm), the technical shortcomings of traditional resistance roller welding machines gradually become apparent, specifically as follows: ① Inaccessible rim: When welding multi-layer thin plates with extremely narrow spacing, the overall structure of traditional rollers cannot reach the weld seam. Due to the poor fit between the roller and the workpiece surface, local pressure fluctuations can reach ±20%, which not only easily leads to incomplete welding, resulting in a decrease in welding strength of more than 30%, but may also cause plastic deformation of the plate, with deformation exceeding 0.1mm. This problem seriously affects the welding quality and structural integrity of the workpiece; ② Insufficient pressure application precision: The width of traditional integral rollers is usually ≥5mm, resulting in a large contact area with the thin plate. When welding in narrow areas with a spacing of less than 3mm, these rollers cannot apply targeted pressure, leading to weld width exceeding the standard, usually reaching 4-6mm. At the same time, the heat-affected zone spreads to the surrounding 0.8-1.2mm range, affecting the dimensional accuracy and overall quality of the workpiece. This limits the application of traditional resistance roller welding machines in welding multi-layer structures with extremely narrow spacing.

[0004] In summary, traditional resistance welding machines suffer from significant problems in welding multi-layered, extremely narrow-pitch thin sheet materials, including unreachable rims and insufficient pressure precision. These issues not only affect welding quality but can also lead to workpiece deformation and decreased dimensional accuracy, failing to meet the high-precision welding requirements of modern industry. Therefore, an improved technical solution is needed to address these shortcomings of existing technologies.

[0005] It should be noted that the above introduction to the technical background is only for the purpose of providing a clear and complete explanation of the technical solutions of this application and facilitating understanding by those skilled in the art. It should not be assumed that these technical solutions are known to those skilled in the art simply because they have been described in the background section of this application. Summary of the Invention

[0006] In view of the shortcomings of the prior art described above, the purpose of this invention is to provide a resistance rolling welding device and its application, which solves the problems in the prior art where the welding edge of the roller cannot reach the weld seam when the resistance rolling welding machine is used for the stacking of multi-layer ultra-narrow spacing thin plate materials, and the problems of uneven force and substandard weld quality caused by the inability to apply pressure independently to narrow areas.

[0007] To achieve the above and other related objectives, the present invention provides a resistance welding apparatus, which includes: a base, a workpiece rotation unit, and a welding unit;

[0008] The base is equipped with horizontal guide rails and vertical guide rails;

[0009] The workpiece rotation unit includes a workpiece rotary table mounted on the horizontal guide rail. The workpiece rotary table is used to clamp the workpiece to be welded and drive it to rotate.

[0010] The roll welding unit includes a roll welding head mounted on the longitudinal guide rail, and the roll welding head includes a roll welding wheel assembly and a pressure control mechanism;

[0011] The welding roller assembly includes a split upper welding roller and a lower welding roller. The rotation surfaces of the upper welding roller and the lower welding roller are arranged opposite to each other and rotate synchronously. Multiple sets of pressure plates arranged in a piano key pattern are cut out along the circumference of the upper rim of the upper welding roller. A groove is formed between two adjacent pressure plates. The groove and the pressure plate together form a concave-convex structure that rotates with the upper welding roller. The gap between the lower rim of the lower welding roller and the pressure plate of the upper rim forms a welding pressing zone. The welding pressing zone is used to accommodate the single-layer weld of the workpiece to be welded and to press and weld it.

[0012] The pressure control mechanism includes a spring-loaded pin assembly and an energized terminal. The spring-loaded pin assembly is fixedly disposed above the movement trajectory of the concave-convex structure. The spring-loaded pin assembly includes a pin and a spring. Under the action of the spring preload, the end of the pin is always in contact with the concave-convex structure as the upper welding roller rotates. An electrical contact is provided at the tail of the pin. The axial displacement of the pin drives the electrical contact to contact or separate from the energized terminal to control the on / off of the pressure plate welding current.

[0013] As an example, the angle between the rotation plane of the upper welding wheel and the rotation plane of the lower welding wheel is 0 to 10°.

[0014] As an example, both the upper and lower welding rollers are made of beryllium cobalt copper alloy, and the surfaces of the upper and lower welding rollers that contact the workpiece to be welded are coated with a hard tungsten layer.

[0015] As an example, the upper rim and the lower rim have the same radial width, both being 0.3 to 2 mm.

[0016] As an example, an insulating layer is provided between adjacent pressure plates, and the bushings of the upper and lower welding rollers are both made of alumina ceramic.

[0017] As an example, the resistance welding device further includes a water-cooling circulation system, which is interconnected with cooling water channels provided inside the shafts of the upper and lower welding rollers.

[0018] As an example, the resistance roll welding apparatus also includes a vision tracking system for accurately locating the welding pressing zone and the weld seam of the workpiece to be welded.

[0019] The present invention also provides an application of the above-mentioned resistance welding apparatus, wherein the resistance welding apparatus is used for the circumferential welding of multilayer ultra-narrow spacing thin plates, and the circumferential welding method specifically includes the following steps:

[0020] S1. Provide a workpiece to be welded, and press the workpiece to be welded onto the workpiece rotary table as a whole. The workpiece to be welded is composed of multiple layers of thin plates with extremely narrow spacing stacked together, and the edges of two adjacent layers of thin plate materials form a layer of circumferential seam to be welded.

[0021] S2. Adjust the horizontal position of the workpiece rotary table and the longitudinal position of the roller welding wheel assembly so that the circumferential seam of the lowest layer of the workpiece to be welded is moved to the welding pressing area of ​​the roller welding wheel assembly for welding.

[0022] S3. Turn on the welding roller assembly to make it rotate, turn on the workpiece rotary table to make the workpiece to be welded rotate at a certain speed, and after the spring pin assembly and the power terminal produce a clutch action, power is turned on to perform the welding of the circumferential seam.

[0023] S4. After welding is completed, adjust the horizontal position of the workpiece rotary table and the longitudinal position of the roller welding wheel assembly so that the circumferential seam of the adjacent upper layer moves to the welding pressing area of ​​the roller welding wheel assembly for welding.

[0024] S5. Turn on the welding roller assembly to make it rotate, turn on the workpiece rotary table to make the workpiece to be welded rotate at a certain speed, and after the spring pin assembly and the power terminal produce a clutch action, power is turned on to perform the welding of the circumferential seam.

[0025] S6. Repeat steps S4 and S5 to weld the multi-layered circumferential seams sequentially.

[0026] As an example, the spacing between the circumferential seams of two adjacent layers to be welded is 0.5 to 3 mm.

[0027] As an example, the welding pressing area is composed of a pressing plate of the upper rim and a lower rim, and the gap between the pressing plate of the upper rim and the lower rim is 0.1 to 0.3 mm larger than the thickness of the single-layer circumferential seam to be welded.

[0028] As an example, the total thickness of the welding area of ​​the upper and lower rims is not greater than the thickness of the single-layer circumferential seam to be welded.

[0029] As described above, the resistance roll welding apparatus and its application of the present invention have the following beneficial effects:

[0030] The core of the resistance welding device in this invention lies in the split-design welding wheel assembly. The upper rim of the upper welding wheel has unique pressure plates arranged in a piano key pattern. The pressure plates and adjacent grooves together form a concave-convex structure that can rotate with the upper welding wheel. This concave-convex structure works in conjunction with the fixedly installed spring pin assembly. During the rotation of the upper welding wheel, the end of the pin always maintains contact with the concave-convex structure. Axial displacement can drive the electrical contact at the tail of the pin to contact or separate from the energized terminal, thereby achieving precise programmed control of the welding current. The device in this invention integrates a water-cooling circulation system, which can stably control the working temperature of the welding wheel assembly at 80℃±5℃, ensuring its hardness and conductivity remain stable for a long time and significantly extending the equipment life. Combined with a vision tracking system, it realizes automatic identification and real-time tracking of the weld position, greatly improving the automation level and positioning accuracy of the entire welding process.

[0031] The resistance welding device of this invention is used for lap welding of circumferential seams in multi-layer thin plates with extremely narrow spacing (0.5-3mm). This device can effectively extend into the narrow gap to achieve precise pressure on independent areas. In addition, the welding wheel assembly of this invention combines beryllium cobalt copper alloy with roller material with hard tungsten coating, and double insulation composed of inter-plate insulation and ceramic bushing. This systematically solves the problems of incomplete welding, plate deformation and substandard weld quality caused by unreachable wheel rims, pressure fluctuations and lateral current shunting in traditional welding. This invention completely breaks through the technical bottleneck of circumferential welding of multi-layer thin plates with extremely narrow spacing, and achieves significant improvements in welding quality, process precision, production efficiency and reliability. Attached Figure Description

[0032] Figure 1 The diagram shown is a three-dimensional structural schematic of the resistance roll welding device in Embodiment 1 of the present invention.

[0033] Figure 2 The diagram shown is a three-dimensional structural schematic of the roll welding wheel assembly in Embodiment 1 of the present invention from one perspective.

[0034] Figure 3 The diagram shown is a top view of the upper welding wheel in Embodiment 1 of the present invention.

[0035] Figure 4This is a three-dimensional structural schematic diagram of the roll welding wheel assembly from another perspective in Embodiment 1 of the present invention.

[0036] Figure 5 The diagram shows the structure of the roll welding head and the weld seam of the workpiece to be welded in Embodiments 1 and 2 of the present invention.

[0037] Figure 6 The diagram shows a three-dimensional structure of the workpiece to be welded in Embodiment 2 of the present invention.

[0038] Figure 7 The diagram shown is a planar structural schematic of the workpiece to be welded in Embodiment 2 of the present invention.

[0039] Figure 8 Displayed as Figure 7 A magnified view of part A in the image.

[0040] Figure 9 Displayed as Figure 7 A magnified view of part B in the image.

[0041] Component designation explanation

[0042] 10 bases

[0043] 101 Horizontal Guide Rail

[0044] 102 pillars

[0045] 103 Longitudinal guide rail

[0046] 20 Workpiece Rotary Table

[0047] 30 Workpieces to be welded

[0048] 301 circumferential seam

[0049] 3011 Outer circumferential weld

[0050] 3012 Inner circumferential weld

[0051] 40 Roller Welding Wheel Assembly

[0052] 401 Upper Roller Welding Roller

[0053] 4011 tablets

[0054] 40121 Groove

[0055] 40122 Protrusion

[0056] 4012 Concave-convex structure

[0057] 4013 Upper Wheel Edge

[0058] 402 Lower Roller Welding Roller

[0059] 4021 Lower rim

[0060] 501 Spring Pin Assembly

[0061] 5011 thimble

[0062] 5012 Electrical Contact

[0063] 60 Water-cooled circulation system Detailed Implementation

[0064] The following description, in conjunction with the accompanying drawings of the embodiments of this application, outlines various embodiments of this application. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. This application can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed based on different viewpoints and applications without departing from the spirit of this application. For ease of explanation, when detailing the embodiments of this application, the cross-sectional views illustrating the device structure are partially enlarged, not according to general proportions, and the schematic diagrams are merely examples and should not limit the scope of protection of this application. Furthermore, in actual manufacturing, the three-dimensional spatial dimensions of length, width, and depth should be included.

[0065] In the description of the embodiments of this application, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, "connection" can be a detachable connection or a non-detachable connection; it can be a direct connection or an indirect connection through an intermediate medium. "Fixed connection" refers to a connection where the relative positional relationship remains unchanged after connection. It should be understood that when component A is fixedly connected to component C via component B, changes in the relative positional relationship due to deformation of components A, B, and C are permissible. "Rotary connection" refers to a connection where the components can rotate relative to each other after connection. "Sliding connection" refers to a connection where the components can slide relative to each other after connection. The phrase "two components forming an integrated structure through a one-piece molding process" means that during the formation of one of the two components, that component is connected to the other component, without requiring further processing (such as bonding, welding, snap-fit ​​connections, or screw connections) to connect the two components.

[0066] The directional terms mentioned in the embodiments of this application, such as "upper", "lower", "side", "top", "bottom", etc., are only for reference to the direction of the accompanying drawings. Therefore, the directional terms used are for better and clearer explanation and understanding of the embodiments of this application, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0067] The term "multiple" refers to at least two. The term "more than" includes the stated number. The term "and / or" describes a relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, or B alone. The terms "first," "second," etc., are used for descriptive purposes only and should not be construed as implying or suggesting relative importance or implicitly indicating the number of technical features indicated. Therefore, a feature specified as "first" or "second" may explicitly or implicitly include one or more of that feature.

[0068] Example 1

[0069] Please refer to the following: Figures 1-5 This embodiment provides a resistance welding device, which includes: a base 10, a workpiece rotation unit, and a welding unit;

[0070] The base 10 is provided with a horizontal guide rail 101 and a vertical guide rail 103;

[0071] The workpiece rotation unit includes a workpiece rotary table 20 mounted on the horizontal guide rail 101. The workpiece rotary table 20 is used to clamp the workpiece 30 to be welded and drive it to rotate.

[0072] The roll welding unit includes a roll welding head mounted on the longitudinal guide rail 103, and the roll welding head includes a roll welding wheel assembly 40 and a pressure control mechanism.

[0073] The welding roller assembly 40 includes a split upper welding roller 401 and a lower welding roller 402. The rotation surfaces of the upper welding roller 401 and the lower welding roller 402 are arranged opposite to each other and rotate synchronously. Multiple sets of pressure plates 4011 arranged in a piano key pattern are cut out circumferentially along the upper rim 4013 of the upper welding roller 401. A groove 40121 is formed between two adjacent pressure plates 4011. The groove 40121 and the pressure plates 4011 together constitute a concave-convex structure 4012 that rotates with the upper welding roller 401. The gap between the lower rim 4021 of the lower welding roller 402 and the pressure plates 4011 of the upper rim 4013 forms a welding pressing area. The welding pressing area is used to accommodate the single-layer weld of the workpiece to be welded and to press and weld it.

[0074] The pressure control mechanism includes a spring-loaded pin assembly 501 and an energized terminal. The spring-loaded pin assembly 501 is fixedly disposed above the movement trajectory of the concave-convex structure 4012. The spring-loaded pin assembly 501 includes a pin 5011 and a spring. Under the action of the spring preload, the end of the pin 5011 is always in contact with the concave-convex structure 4012 as the upper welding roller 401 rotates. An electrical contact 5012 is provided at the tail of the pin 5011. The axial displacement of the pin 5011 drives the electrical contact 5012 to contact or separate from the energized terminal to control the on / off of the welding current of the pressure plate 4011.

[0075] For details, please refer to Figure 1 A horizontal guide rail 101 is provided on the base 10. The workpiece rotary table 20 is mounted on the horizontal guide rail 101 via a horizontal slider. The drive motor drives the horizontal slider to move in the horizontal direction, thereby moving the workpiece rotary table 20 in the horizontal direction. A column 102 is provided in the longitudinal direction of the base 10. A longitudinal guide rail 103 is provided on the column 102. The roll welding head is mounted on the longitudinal guide rail 103 via a longitudinal slider. Similarly, the drive motor drives the longitudinal slider to move in the longitudinal direction, thereby moving the roll welding head in the longitudinal direction.

[0076] See Figure 2 This is a three-dimensional structural diagram of the welding roller assembly 40. The upper welding roller 401 and the lower welding roller 402 are separate, oppositely arranged, and rotate synchronously. The upper welding roller 401 and the lower welding roller 402 can be installed coaxially or non-coaxially, as long as the upper wheel rim 4013 and the lower wheel rim 4021 can ensure synchronous pressing and welding of the workpiece 30 to be welded when rotating synchronously. (See reference...) Figure 2 The upper roller welding wheel 401 includes an upper roller body and an upper rim 4013 located at the circumferential edge of the upper roller body. The upper rim 4013 is formed by radially extending the trapezoidal side of the upper roller body, and the upper roller body and the upper rim 4013 are integrally formed. Multiple sets of pressure plates 4011 arranged in a piano key pattern are cut circumferentially from the upper rim 4013. The multiple sets of pressure plates 4011 are evenly distributed along the circumference of the upper rim 4013, and each set of plates is radially cut from the end face of the upper roller body towards the upper rim 4013. (See reference...) Figure 2 and Figure 3To ensure the overall rotational stability of the upper welding roller 401, one cut of each set of slices extends radially downward from the end face of the upper roller body to the upper rim 4013, and the other cut extends radially downward only from the edge of the upper roller body to the upper rim 4013. The lower welding roller 402 has the same shape as the upper welding roller 401, but no pressure plates 4011 are cut out. The gap between the multiple sets of pressure plates 4011 on the upper rim 4013 and the lower rim 4021 forms a welding pressing zone. The welding pressing zone is used for pressing and welding the single-layer weld of the workpiece to be welded. When pressing and welding is performed, the area where the welding pressing zone contacts and welds with the workpiece to be welded is the welding area. Preferably, the number of pressure plates 4011 arranged in a piano key pattern is not less than 2.

[0077] See Figure 3 A groove 40121 is provided between adjacent pressure plates 4011. The groove 40121 and the adjacent pressure plates 4011 form a set of concave and convex structures 4012. Each set of concave and convex structures 4012 includes a protrusion 40122 and a groove 40121. Relative to the groove 40121, the protrusion 40122 is the end face of the pressure plate 4011.

[0078] See Figure 5 This is a schematic diagram of the structure for press welding between the roller welding head and the workpiece 30. The single-layer circumferential seam 301 of the workpiece 30 is press welded within the welding pressing zone formed by the roller welding wheel assembly 40. A spring ejector assembly 501 is vertically fixed above the upper roller welding wheel 401. When the upper roller welding wheel 401 rotates, the end of the ejector pin 5011 of the spring ejector assembly 501 always presses against the concave-convex structure 4012 of the upper roller welding wheel 401, causing the pressure plate 401 to... 1. Moving up and down; when the end of the ejector pin 5011 enters the groove 40121, the electrical contact 5012 at the tail of the ejector pin 5011 separates from the energized terminal, and the pressure plate 4011 does not press or discharge the workpiece 30 to be welded; when the end of the ejector pin 5011 contacts the protrusion 40122 of the concave-convex structure 4012, the electrical contact 5012 at the tail of the ejector pin 5011 contacts the energized terminal, and the pressure plate 4011 presses and discharges the workpiece 30 to be welded.

[0079] In addition, in a specific embodiment of the present invention, the spring pin assembly 501 can be adjusted up and down to contact the upper welding wheel 401, and the spring preload length can also be adjusted to change the elastic force. The spring pin 5011 connected to the spring also changes accordingly to meet the force of pressing the workpiece 30 to be welded. The specific structure of the spring pin assembly 501 is not excessively limited here.

[0080] Preferably, the pressure plate 4011 will wear down over a long period of use, with a certain degree of wear at the bottom. The spring pin assembly 501 can automatically press down a certain distance so that the pressure plate 4011 can still be used for welding, that is, automatic compensation is achieved. The upper wheel rim 4013 automatically compensates for wear through the spring pin assembly 501, with a compensation stroke of 0.2mm.

[0081] As an example, the angle between the rotation plane of the upper welding roller 401 and the rotation plane of the lower welding roller 402 is 0 to 10°.

[0082] Specifically, the side of the upper welding wheel 4013 that contacts the workpiece 30 to be welded is on the same plane as the rotation plane of the upper welding wheel 401. Similarly, the rotation plane of the lower welding wheel 402 is on the same plane as the side of the lower welding wheel 4021 that contacts the workpiece 30 to be welded. The included angle between the rotation plane of the upper welding wheel 401 and the rotation plane of the lower welding wheel 402 includes values ​​within any range such as 0°, 1°, 2°, 4°, 6°, 8°, and 10°. (See also...) Figure 2 As shown, the angle between the rotation plane of the upper welding wheel 401 and the rotation plane of the lower welding wheel 402 is 0°. The upper welding wheel 401 and the lower welding wheel 402 are assembled in parallel. At this time, the two can be installed coaxially or non-coaxially.

[0083] In a specific embodiment of the present invention, the upper welding wheel 401 and the lower welding wheel 402 are coaxially mounted, and the included angle between their rotation planes is 0°. A gap is left between the upper wheel rim 4013 and the lower wheel rim 4021, and the gap is 0.1 to 0.3 mm larger than the thickness of the single-layer weld of the workpiece 30 to be welded.

[0084] As an example, both the upper welding wheel 401 and the lower welding wheel 402 are made of beryllium cobalt copper alloy, and the surfaces of the upper welding wheel 401 and the lower welding wheel 402 that contact the workpiece 30 to be welded are coated with a hard tungsten layer.

[0085] Specifically, the beryllium cobalt copper alloy upper welding wheel 401 and lower welding wheel 402 possess both high conductivity and high strength and resistance to softening. During continuous welding, the rollers accumulate a large amount of heat, and the beryllium cobalt copper alloy maintains its strength and shape at the high welding temperature, thus ensuring the long-term accuracy of the piano key-arranged pressure plate 4011. The surfaces of the upper welding wheel 401 and lower welding wheel 402 that contact the workpiece 30 to be welded are plated with a hard tungsten layer, which greatly extends the working life of the rollers. The combination of beryllium cobalt copper alloy and hard tungsten layer produces a synergistic effect, giving the upper welding wheel 401 and lower welding wheel 402 higher wear resistance. Preferably, the thickness of the hard tungsten layer is 0.05 mm, which improves the wear resistance of the upper welding wheel 401 and lower welding wheel 402 by 200%.

[0086] Preferably, the parts of the upper welding wheel 401 and the lower welding wheel 402 that contact the workpiece 30 to be welded are made of beryllium cobalt copper alloy and are plated with a hard tungsten layer. They adopt a line contact design structure, which is equivalent to forming a contact line at the point where the upper wheel rim 4013 and the lower wheel rim 4021 contact the workpiece 30 to be welded and apply pressure. The contact pressure applied on the contact line is 50 to 80 N, and the contact resistance is controlled at 30 to 50 μΩ to achieve reliable welding quality.

[0087] As an example, the upper rim 4013 and the lower rim 4021 have the same radial width, both being 0.3 to 2 mm.

[0088] Specifically, the radial widths of the upper flange 4013 and the lower flange 4021 are the same, and can include any value within the range of 0.3mm, 0.5mm, 1mm, 1.5mm, 2mm, etc. The appropriate specification can be selected according to the spacing between the two adjacent weld seams of the workpiece 30 to be welded.

[0089] In a specific embodiment of the present invention, the diameters of the upper welding roller 401 and the lower welding roller 402 are 100-200mm (including any value within the range of 100mm, 120mm, 140mm, 160mm, 180mm, 200mm, etc.).

[0090] As an example, an insulating layer is provided between adjacent pressure plates 4011, and the bushings of the upper welding roller 401 and the lower welding roller 402 are both made of alumina ceramic material.

[0091] Specifically, an insulating layer is provided between adjacent pressure plates 4011, ensuring that each pressure plate 4011 arranged in a piano key pattern has an independent and non-interfering side length. This prevents current from flowing between adjacent pressure plates 4011 during welding, thus preventing lateral current shunting and enabling precise and independent control of each welding point, reducing the likelihood of incomplete soldering. Preferably, the insulating layer is a polyimide insulating layer, preferably 0.05mm thick and heat-resistant up to 300℃.

[0092] Specifically, the bushings of both the upper welding roller 401 and the lower welding roller 402 are made of alumina ceramic, which is also an insulating material to prevent current from leaking through the bushings to the roller frame. The insulation resistance of the alumina ceramic is >10 ohms. 12 Ω.

[0093] As an example, the resistance welding device further includes a water cooling circulation system 60, which is interconnected with the cooling water channels provided inside the shafts of the upper welding wheel 401 and the lower welding wheel 402.

[0094] For details, please refer to Figure 1A water cooling circulation system 60 is provided above the upper welding roller 401 and below the lower welding roller 402. At the same time, a cooling water channel is provided inside the shaft of the upper welding roller 401 and the shaft of the lower welding roller 402. Room temperature deionized water is introduced into the cooling water channel through the water cooling circulation system 60. Through heat exchange, the working temperature of the upper welding roller 401 and the lower welding roller 402 is controlled at 80℃±5℃ to avoid the hardness of the upper welding roller 401 and the lower welding roller 402 decreasing due to high temperature.

[0095] In a specific embodiment of the present invention, the cooling water channel is spiral-shaped, the diameter of the spiral cooling water channel is 2mm, and the flow rate of deionized water is 0.5L / min.

[0096] As an example, the resistance roll welding apparatus also includes a vision tracking system for accurately locating the welding pressing zone and the weld seam of the workpiece 30 to be welded.

[0097] Specifically, the vision tracking system can accurately locate the positions of the workpiece rotary table 20 and the welding wheel assembly 40, and adjust the longitudinal position of the welding wheel assembly 40 so that its welding pressing area is positioned at the weld seam of the workpiece 30 to be welded, thereby ensuring the accuracy of the weld seam position.

[0098] Example 2

[0099] This embodiment provides an application of the resistance welding device in Embodiment 1 above. The resistance welding device is applied to the lap welding of the circumferential seam 301 of multilayer ultra-narrow spacing thin plates. The lap welding method specifically includes the following steps:

[0100] S1. Provide a workpiece 30 to be welded, and press the workpiece 30 to be welded onto the workpiece rotary table 20 as a whole. The workpiece 30 to be welded is made of multiple layers of thin plates with extremely narrow spacing circumferential seams 301 stacked together, and the edges of two adjacent layers of thin plate materials form a layer of circumferential seams 301 to be welded.

[0101] S2. Adjust the horizontal position of the workpiece rotary table 20 and the longitudinal position of the roller welding wheel assembly 40 so that the circumferential seam 301 of the bottom layer of the workpiece 30 to be welded is moved to the welding pressing area of ​​the roller welding wheel assembly 40 for welding.

[0102] S3. Turn on the welding roller assembly 40 to make it rotate, turn on the workpiece rotary table 20 to make the workpiece 30 to be welded rotate at a certain speed, and after the spring pin assembly 501 and the power terminal produce a disengagement action, power is turned on to perform welding of the circumferential seam 301.

[0103] S4. After welding is completed, adjust the horizontal position of the workpiece rotary table 20 and the longitudinal position of the roller welding wheel assembly 40 so that the circumferential seam 301 of the adjacent upper layer moves to the welding pressing area of ​​the roller welding wheel assembly 40 for welding.

[0104] S5. Turn on the welding roller assembly 40 to make it rotate, turn on the workpiece rotary table 20 to make the workpiece 30 to be welded rotate at a certain speed, and after the spring pin assembly 501 and the power terminal produce a disengagement action, power is turned on to perform welding of the circumferential seam 301.

[0105] S6. Repeat steps S4 and S5 to weld the multi-layered circumferential seam 301 sequentially.

[0106] The following is in conjunction with the appendix Figures 1-9 The resistance roll welding device in Example 1 is applied to the lap welding method of the circumferential seam 301 of multilayer ultra-narrow spacing thin plates.

[0107] First, step S1 is performed, providing a workpiece 30 to be welded, and pressing the workpiece 30 to be welded onto the workpiece rotary table 20. The workpiece 30 to be welded is composed of multiple layers of thin plates with extremely narrow spacing circumferential seams 301 stacked together, and the edges of two adjacent thin plate materials form a layer of circumferential seams 301 to be welded.

[0108] Specifically, the workpiece 30 to be welded is made up of multiple layers of thin plate circumferential seams 301 with extremely narrow spacing. Each layer of circumferential seam 301 is made up of the edges of two layers of thin plate material stacked together, and the spacing between adjacent layers of circumferential seams 301 to be welded is very narrow.

[0109] As an example, the spacing between two adjacent layers of the circumferential seam 301 to be welded is 0.5 to 3 mm.

[0110] Specifically, the spacing between two adjacent layers of the circumferential seam 301 to be welded can be any value within the range of 0.5mm, 1mm, 1.5mm, 2mm, 2.5mm, 3mm, etc.

[0111] In a specific embodiment of the present invention, see [reference]. Figure 6-9 The workpiece 30 to be welded is cylindrical and is made up of 400 layers of thin plate circumferential seams 301. Each layer of thin plate circumferential seam 301 is formed by the edges of two layers of thin plate material. The workpiece 30 to be welded includes an inner ring and an outer ring. The radius of the inner ring is 0.5m and the radius of the outer ring is 1m. The circumferential seam 301 includes an inner ring weld 3012 and an outer ring weld 3011. The distance between two adjacent layers of circumferential seams 301 is 1.2mm. The thin plate material is 316 stainless steel with a thickness of 0.1mm.

[0112] Next, proceed to step S2, see [link / reference] Figure 5Adjust the horizontal position of the workpiece rotary table 20 and the longitudinal position of the roller welding wheel assembly 40 so that the circumferential seam 301 of the bottom layer of the workpiece 30 to be welded is moved to the welding pressing area of ​​the roller welding wheel assembly 40 for welding.

[0113] Specifically, the horizontal position of the workpiece rotary table 20 is adjusted by the horizontal guide rail 101, the longitudinal position of the welding roller assembly 40 is adjusted by the longitudinal guide rail 103, and the position of the welding pressing area and the weld of the workpiece 30 to be welded is accurately located by the vision tracking system. In a specific embodiment of the present invention, the outer ring weld 3011 of the workpiece 30 to be welded is welded first, and the overlapping welding is carried out from bottom to top. The bottommost outer ring weld 3011 is moved to the welding pressing area to be welded.

[0114] As an example, the welding pressing area is composed of the pressing plate 4011 of the upper wheel rim 4013 and the lower wheel rim 4021. The gap between the pressing plate 4011 of the upper wheel rim 4013 and the lower wheel rim 4021 is 0.1 to 0.3 mm larger than the thickness of the single layer of the circumferential seam 301 to be welded.

[0115] Specifically, the gap between the pressure plate 4011 of the upper rim 4013 and the lower rim 4021 is larger than the thickness of the single-layer circumferential seam 301 to be welded by any value within any range such as 0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm, so as to move the circumferential seam 301 to the welding pressing area in advance.

[0116] As an example, the total thickness of the welding areas of the upper rim 4013 and the lower rim 4021 is not greater than the thickness of the single layer of the circumferential seam 301 to be welded.

[0117] In a specific embodiment of the present invention, the width of the welding area of ​​the upper rim 4013 and the lower rim 4021 is 2mm, and the total thickness of the welding area of ​​the upper rim 4013 and the lower rim 4021 is 0.2mm less than the thickness of the single-layer circumferential seam 301.

[0118] Next, step S3 is executed: the welding roller assembly 40 is turned on to rotate, and the workpiece rotary table 20 is turned on to rotate the workpiece 30 to be welded at a certain speed. After the spring ejector pin assembly 501 engages and disengages with the energized terminal, power is applied to perform welding of the circumferential seam 301. (See reference...) Figure 5 .

[0119] Specifically, the rotational speed of the workpiece rotary table 20 is 0.3 to 5 m / min (e.g., 0.3 m / min, 0.5 m / min, 1 m / min, 2 m / min, 3 m / min, 4 m / min, 5 m / min, etc.).

[0120] Next, step S4 is executed. After welding is completed, the horizontal position of the workpiece rotary table 20 and the longitudinal position of the roller welding wheel assembly 40 are adjusted so that the circumferential seam 301 of the adjacent upper layer is moved to the welding pressing area of ​​the roller welding wheel assembly 40 for welding.

[0121] In a specific embodiment of the present invention, after the bottom outer ring weld 3011 is welded, the workpiece rotary table 20 moves horizontally between the horizontal guide rails 101 by a drive motor, so that the position of the outer ring weld 3011 of the workpiece 30 to be welded is separated from the rim of the welding roller assembly 40 by about 5mm. The welding roller assembly 40 is driven by the drive motor to move upward 1.4mm on the longitudinal guide rail 103, and the horizontal position of the workpiece rotary table 20 is adjusted so that the outer ring weld 3011 of the adjacent upper layer moves to the welding pressing area to be welded.

[0122] Next, step S5 is executed, the welding roller assembly 40 is turned on to rotate, the workpiece rotary table 20 is turned on to make the workpiece 30 to be welded rotate at a certain speed, and after the spring pin assembly 501 and the power terminal produce a disengagement action, the power is turned on to perform the welding of the circumferential seam 301.

[0123] Next, repeat steps S4 and S5 to weld the multi-layered circumferential seam 301 in sequence.

[0124] In a specific embodiment of the present invention, steps S4 and S5 are repeated to sequentially weld the 400-layer superimposed outer ring weld 3011. After the outer ring weld 3011 is completed, the inner ring weld 3012 is welded. (See reference...) Figure 8 for Figure 7 The enlarged view of section A shows that the edges of two layers of thin plate material are stacked together to form the outer ring weld 3011 to be welded. The spacing between two adjacent outer ring welds 3011 is 1.2 mm, and the width of the outer ring weld 3011 to be welded is 1.5 mm. (See reference...) Figure 9 for Figure 7 The enlarged view in section B shows the inner ring weld 3012, which has a width of 1.5 mm and a spacing of 1.2 mm between two adjacent inner ring welds 3012.

[0125] In other embodiments, when both the outer ring weld 3011 and the inner ring weld 3012 of the workpiece 30 to be welded need to be welded, the resistance rolling welding device may include two longitudinally arranged longitudinal guide rails 103, and each of the two longitudinal guide rails 103 is provided with a corresponding rolling welding wheel assembly 40. The two sets of rolling welding wheel assemblies 40 can simultaneously perform overlapping welding on the inner ring weld 3012 and the outer ring weld 3011. When welding the inner ring weld 3012, the column 102 with the longitudinal guide rails 103 is placed in the inner ring. The working principle is the same as the overlapping welding of the outer ring weld 3011, which will not be described in detail here.

[0126] In summary, the core of the resistance welding device in this invention lies in the split-design welding wheel assembly. The upper rim of the upper welding wheel has unique pressure plates arranged in a piano key pattern. These pressure plates, together with adjacent grooves, form a convex-concave structure that rotates with the upper welding wheel. This convex-concave structure works in conjunction with the fixedly mounted spring pin assembly. During the rotation of the upper welding wheel, the pin end remains in contact with the convex-concave structure. Axial displacement can drive the electrical contacts at the pin tail to contact or separate from the energized terminals, thereby achieving precise programmed control of the welding current. The device in this invention integrates a water-cooling circulation system, which can stably control the working temperature of the welding wheel assembly at 80℃±5℃, ensuring its hardness and conductivity remain stable over time and significantly extending the equipment's lifespan. Combined with a vision tracking system, it achieves automatic identification and real-time tracking of the weld position, greatly improving the automation level and positioning accuracy of the entire welding process. The resistance welding device of this invention is applied to the circumferential welding of multi-layer thin plates with extremely narrow spacing (0.5-3mm). This device can effectively penetrate the narrow gaps to achieve precise pressure application to independent areas. Furthermore, the welding wheel assembly of this invention, combining beryllium cobalt copper alloy with a hard tungsten-plated roller material, and double insulation consisting of inter-plate insulation and a ceramic bushing, systematically solves the problems of incomplete welding, plate deformation, and substandard weld quality caused by unreachable wheel rims, pressure fluctuations, and lateral current shunting in traditional welding. This invention completely breaks through the technical bottleneck of multi-layer thin plate circumferential welding, achieving significant improvements in welding quality, process precision, production efficiency, and reliability. Therefore, this invention effectively overcomes the various shortcomings of existing technologies and has high industrial application value.

[0127] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Where there is no conflict, the embodiments and features in the embodiments of this application can be combined with each other. The structural materials, dimensions, shapes, etc., mentioned in the embodiments of this application are all illustrative descriptions and do not constitute strict or absolute limitations. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A resistance welding apparatus, characterized in that, The resistance roll welding device includes: a base, a workpiece rotation unit, and a roll welding unit; The base is equipped with horizontal guide rails and vertical guide rails; The workpiece rotation unit includes a workpiece rotary table mounted on the horizontal guide rail. The workpiece rotary table is used to clamp the workpiece to be welded and drive it to rotate. The roll welding unit includes a roll welding head mounted on the longitudinal guide rail, and the roll welding head includes a roll welding wheel assembly and a pressure control mechanism; The welding roller assembly includes a split upper welding roller and a lower welding roller. The rotation surfaces of the upper welding roller and the lower welding roller are arranged opposite to each other and rotate synchronously. Multiple sets of pressure plates arranged in a piano key pattern are cut out along the circumference of the upper rim of the upper welding roller. A groove is formed between two adjacent pressure plates. The groove and the pressure plate together form a concave-convex structure that rotates with the upper welding roller. The gap between the lower rim of the lower welding roller and the pressure plate of the upper rim forms a welding pressing zone. The welding pressing zone is used to accommodate the single-layer weld of the workpiece to be welded and to press and weld it. The pressure control mechanism includes a spring-loaded pin assembly and an energized terminal. The spring-loaded pin assembly is fixedly disposed above the movement trajectory of the concave-convex structure. The spring-loaded pin assembly includes a pin and a spring. Under the action of the spring preload, the end of the pin is always in contact with the concave-convex structure as the upper welding roller rotates. An electrical contact is provided at the tail of the pin. The axial displacement of the pin drives the electrical contact to contact or separate from the energized terminal to control the on / off of the pressure plate welding current.

2. The resistance welding apparatus according to claim 1, characterized in that: The angle between the rotation plane of the upper welding wheel and the rotation plane of the lower welding wheel is 0 to 10°.

3. The resistance welding apparatus according to claim 1, characterized in that: Both the upper and lower welding rollers are made of beryllium cobalt copper alloy, and the surfaces of the upper and lower welding rollers that contact the workpiece to be welded are coated with a hard tungsten layer.

4. The resistance welding apparatus according to claim 1, characterized in that: The upper rim and the lower rim have the same radial width, both being 0.3 to 2 mm.

5. The resistance welding apparatus according to claim 1, characterized in that: An insulating layer is provided between adjacent pressure plates, and the bushings of the upper and lower welding rollers are both made of alumina ceramic.

6. The resistance welding apparatus according to claim 1, characterized in that: The resistance welding device also includes a water-cooling circulation system, which is connected to the cooling water channels provided inside the shafts of the upper and lower welding rollers.

7. The resistance welding apparatus according to claim 1, characterized in that: The resistance roll welding device also includes a vision tracking system, which is used to accurately locate the position of the welding pressing zone and the weld seam of the workpiece to be welded.

8. An application of the resistance roll welding apparatus according to any one of claims 1 to 7, characterized in that: The resistance welding device is used for lap welding of circumferential seams in multi-layered thin plates with extremely narrow spacing. The lap welding method specifically includes the following steps: S1. Provide a workpiece to be welded, and press the workpiece to be welded onto the workpiece rotary table as a whole. The workpiece to be welded is composed of multiple layers of thin plates with extremely narrow spacing stacked together, and the edges of two adjacent layers of thin plate materials form a layer of circumferential seam to be welded. S2. Adjust the horizontal position of the workpiece rotary table and the longitudinal position of the roller welding wheel assembly so that the circumferential seam of the lowest layer of the workpiece to be welded is moved to the welding pressing area of ​​the roller welding wheel assembly for welding. S3. Turn on the welding roller assembly to make it rotate, turn on the workpiece turntable to make the workpiece to be welded rotate at a certain speed, and after the spring pin assembly and the power terminal produce a clutch action, power is turned on to perform the welding of the circumferential seam. S4. After welding is completed, adjust the horizontal position of the workpiece rotary table and the longitudinal position of the roller welding wheel assembly so that the circumferential seam of the adjacent upper layer moves to the welding pressing area of ​​the roller welding wheel assembly for welding. S5. Turn on the welding roller assembly to make it rotate, turn on the workpiece rotary table to make the workpiece to be welded rotate at a certain speed, and after the spring pin assembly and the power terminal produce a disengagement action, power is turned on to perform the welding of the circumferential seam. S6. Repeat steps S4 and S5 to weld the multi-layered circumferential seams sequentially.

9. The application of the resistance roll welding apparatus according to claim 8, characterized in that: The spacing between the circumferential seams of two adjacent layers to be welded is 0.5 to 3 mm.

10. The application of the resistance roll welding apparatus according to claim 8, characterized in that: Includes one or a combination of the following conditions: The welding pressing zone is composed of the pressing plate of the upper wheel rim and the lower wheel rim. The gap between the pressing plate of the upper wheel rim and the lower wheel rim is 0.1 to 0.3 mm larger than the thickness of the single-layer circumferential seam to be welded. The total thickness of the welding area of ​​the upper and lower rims is not greater than the thickness of the single-layer circumferential seam to be welded.

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