Automatic welding apparatus for t-shaped welding rod and welding method thereof

Abstract

An automatic welding apparatus for T-shaped welding rod includes a welding gun and a feeding device for delivering the T-shaped welding rod. The welding gun comprises a gun body, a welding nozzle, and a press plate. The gun body extends to form the welding nozzle, which outputs hot air. The press plate is positioned at the front end of the welding nozzle and is connected to both the welding nozzle and the feeding device. The bottom of the press plate comprises a groove corresponding to the cross-sectional shape of the T-shaped welding rod. The feeding device includes a feeding conduit that transports the T-shaped welding rod to a welding groove for welding by the welding gun, wherein the feeding conduit includes an airflow passage.

Description

Technical Field

[0001] An automatic welding device, particularly an automatic welding device for T-shaped welding electrodes and its welding method. Prior Technology

[0002] In traditional plastic welding processes, a welding rod is pre-welded to the welding area. After it cools and solidifies and excess material is removed, a welding strip is used for secondary welding to complete the joint. However, traditional welding processes are not only cumbersome and time-consuming, but also require the removal of excess material after the welding rod is completed, resulting in unnecessary material loss and increased production costs. Furthermore, secondary welding or material trimming may lead to uneven stress in the weld, affecting the weld strength and stability.

[0003] In view of this, developing a welding method or equipment that reduces material waste, simplifies the welding process, thereby reducing production costs, and also ensures welding quality has become a highly desired goal in related fields. Summary of the Invention

[0004] To develop welding methods or equipment that reduce material waste, simplify welding processes, thereby lowering production costs while maintaining welding quality, this invention provides an automatic welding device for T-shaped welding rods. The device includes a hot air welding torch and a feeding device for conveying a T-shaped welding rod. The hot air welding torch includes a torch body, a welding nozzle, and a pressure plate. The welding nozzle extends from the end of the torch body to output hot air. The pressure plate is located at the front end of the welding nozzle and is connected to both the welding nozzle and the feeding device. A groove is recessed at the bottom of the pressure plate, corresponding to the cross-sectional shape of the T-shaped welding rod. The T-shaped welding rod includes a supporting end and a filling end. The supporting end is firmly attached to a plurality of adjacent plates. The filling end is used to fill a weld groove. The feeding device includes a feeding conduit that conveys the T-shaped welding rod to a weld groove for welding by the hot air welding torch. One of the feeding conduits has a conveying diameter larger than the cross-sectional size of the T-shaped welding rod.

[0005] The cross-sectional dimension of the groove is slightly smaller than that of the T-shaped welding rod.

[0006] At least one guide protrusion is provided on at least a portion of the bottom of the pressure plate, wherein the guide protrusion is confined within the weld groove.

[0007] Furthermore, the present invention also provides a welding method using the aforementioned automatic welding equipment with T-shaped welding rods, the steps of which include: step S1, bonding a plurality of the plates together, wherein each plate is bonded flush with the plane and an adjacent area is formed at the bonding location; step S2, etching the weld groove in the adjacent area; and step S3, welding the plurality of the plates through the automatic welding equipment.

[0008] In step S2, a cutting tool is used to apply force in one direction along the adjacent area to form the weld groove, and the cutting tool applies a fixed force angle to the adjacent area, wherein the force angle is between 30 and 45 degrees.

[0009] Furthermore, after step S1, the adjacent area is pre-treated by mechanical scraping, and after the surface pre-treatment is completed, the adjacent area is cleaned with a lint-free cloth and a solvent.

[0010] Furthermore, after step S2, the solder bath is also cleaned with the lint-free cloth and the solvent.

[0011] The solvent contains materials such as isopropanol (IPA), acetone, or methyl ethyl ketone (MEK).

[0012] The T-shaped welding rod contains thermoplastic materials such as polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), polyvinylidene fluoride (PVDF), polyethylene (PE), polypropylene (PP), or polyvinyl chloride (PVC).

[0013] The plurality of the sheet materials comprise one or a combination of polytetrafluoroethylene (PTFE), modified polytetrafluoroethylene (M-PTFE), perfluoroalkoxy polymer (PFA), and fluorinated ethylene propylene copolymer (FEP).

[0014] As can be seen from the above description, the present invention has the following characteristics:

[0015] 1. By mechanically scraping the adjacent area after multiple plates are laminated, a surface pretreatment is performed to increase the surface roughness of the adjacent area, thereby improving the welding strength and the adhesion performance of the welding material.

[0016] 2. After the surface pretreatment and the engraving of the weld pool are completed, the adjacent area or the weld pool is cleaned with the lint-free cloth and the solvent, which can effectively remove oil, fingerprints or organic contaminants, thereby reducing the potential risk of reduced welding strength.

[0017] 3. By using T-shaped welding rods for welding, the technical problems of reduced production efficiency, unnecessary material loss and low welding stability caused by the need for secondary welding in traditional processes are solved.

[0018] 4. By applying uniform force in one direction along the adjacent area with the engraving tool and engraving the weld groove at a fixed force angle, it is possible to ensure that the shape and size of the weld groove are consistent along the adjacent area, while reducing the possibility of material tearing or edge burrs on the plate, thereby avoiding the risk of inconsistent strength of the weld groove after welding.

[0019] 5. By setting the pressure plate in the hot air welding gun, and the fact that the cross-sectional dimension of the groove formed at the bottom of the pressure plate is smaller than the cross-sectional dimension of the T-shaped welding rod, it can not only apply appropriate pressure to the supporting end of the T-shaped welding rod during the welding process, ensuring that the filling end is tightly filled into the weld groove to improve the bonding strength between the plates, but also promote the uniformity of heat transfer between the T-shaped welding rod and the weld groove material, thereby improving the melting effect and welding density of the T-shaped welding rod. In addition, the setting of the groove can also effectively prevent the T-shaped welding rod from shaking or shifting during the feeding process, so as to ensure the accuracy of the welding position.

[0020] 6. By further providing at least one guide protrusion along the depth direction of the weld groove on at least a portion of the bottom of the pressure plate, the T-shaped welding rod can be precisely guided into the weld groove during the welding process, further preventing the feeding deviation of the T-shaped welding rod and thus ensuring the consistency and stability of the welding.

[0021] 7. The feed pipe has a feed port diameter larger than the cross-sectional size of the T-shaped welding electrode. The feed device allows hot air output from the welding nozzle to enter and preheat the T-shaped welding electrode. This not only reduces the temperature difference between the T-shaped welding electrode and the plate, making the heat transfer more uniform during the welding process, thereby reducing welding stress and improving the bonding strength and welding efficiency between the plates, but also effectively reduces the residual moisture and impurities inside the T-shaped welding electrode through preheating treatment, significantly reducing the generation of porosity and defects during the welding process and improving the welding quality. Simple Explanation of the Diagram

[0022] Figure 1 is a schematic diagram of a preferred process for the welding method of the T-shaped welding electrode of the present invention. Figure 2 is a schematic diagram of the preferred equipment for welding with T-shaped welding electrodes according to the present invention. Figure 3 is a cross-sectional schematic diagram of the pressure plate of the hot air welding torch of the present invention. Implementation

[0023] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of each embodiment are briefly introduced below. Obviously, the drawings described below are merely some examples or embodiments of the present invention. For those skilled in the art, these drawings can be used to apply the present invention to other similar scenarios without creative effort. Unless obvious from the context or otherwise specified, the same reference numerals in the drawings represent the same structures or operations.

[0024] As illustrated in this invention and the claims, unless the context clearly indicates otherwise, the words "a," "an," "an," or "the" do not specifically refer to the singular and may also include the plural. Generally speaking, the terms "comprising" and "including" only indicate the inclusion of explicitly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements.

[0025] This invention uses flowcharts to illustrate the operations performed by the system according to embodiments of the invention. It should be understood that the preceding or following operations are not necessarily performed precisely in sequence. Instead, the steps can be processed in reverse order or simultaneously. Furthermore, other operations can be added to these processes, or one or more steps can be removed from them.

[0026] Please refer to Figure 1, which is a preferred flowchart of the welding method of the T-shaped welding electrode of the present invention, the steps of which include:

[0027] Step S1: A plurality of plates 10 are laminated. Adjacent plates 10 are laminated flush with each other using an adhesive and joined at the bonding area between the plates 10 to form an adjacent area. The plurality of plates 10 are made by laminating one or a combination of powdered polytetrafluoroethylene (PTFE), modified polytetrafluoroethylene (M-PTFE), perfluoroalkoxy polymer (PFA), and fluorinated ethylene propylene copolymer (FEP). The adhesive includes materials such as two-component epoxy resin, cyanoacrylate, polyurethane, or silicone.

[0028] Furthermore, the adjacent area can be pre-treated by mechanical scraping to increase the surface roughness of the adjacent area, thereby improving the welding strength and the adhesion performance of the welding material. For example, a scraper can be used to roughen the surface of the adjacent area.

[0029] Preferably, after the surface pretreatment is completed, the adjacent area is cleaned with a lint-free cloth and a solvent to effectively remove oil, fingerprints or organic contaminants, thereby reducing the potential risk of decreased weld strength.

[0030] The solvent contains materials such as isopropanol (IPA), acetone, or methyl ethyl ketone (MEK).

[0031] Step S2: A weld groove 11 is engraved in each of the adjacent areas. A scriber is used to engrave the weld groove 11 in the adjacent areas between the plates 10 for welding. The scriber applies force uniformly in one direction along the adjacent area, and the angle of force application (i.e., the angle between the scriber and the surface of the adjacent area) is fixed between 30 and 45 degrees to ensure that the weld groove 11 has a consistent shape and size along the adjacent area. At the same time, it reduces the possibility of material tearing or edge burrs on the plate 10, thereby avoiding the risk of inconsistent strength of the weld groove 11 after welding.

[0032] In this embodiment, the weld groove 11 is a V-shaped groove.

[0033] Furthermore, the lint-free cloth and the solvent can also be used to clean the solder bath 11 to effectively remove impurities such as oil, fingerprints, or organic contaminants.

[0034] Step S3: A plurality of the plates 10 are welded using an automatic welding device 20. The automatic welding device 20 heats a T-shaped welding rod to a melting temperature to achieve appropriate plasticity of the T-shaped welding rod, and fills the T-shaped welding rod into the weld groove 11 to firmly bond the plurality of plates 10. The T-shaped welding rod includes a support end and a filling end, ensuring that the T-shaped welding rod softens uniformly without degradation during the welding process. The filling end fully fills the weld groove 11; and the support end provides structural support on both sides of the weld groove 11. In other words, the support end acts like a bridge to firmly bond the adjacent plates 10, thereby improving the bonding stability between the plates 10.

[0035] The cross-section of the T-shaped welding electrode includes standard T-shape, symmetrical T-shape, and other T-shaped shapes.

[0036] The T-shaped welding rod contains thermoplastic materials such as polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), polyvinylidene fluoride (PVDF), polyethylene (PE), polypropylene (PP), or polyvinyl chloride (PVC).

[0037] Please refer to Figure 2, which is a schematic diagram of a preferred device for welding T-shaped welding rods according to the present invention. The automatic welding device 20 includes a hot air welding gun 21 and a feeding device 22. The feeding device 22 is used to transport the T-shaped welding rod to the welding tank 11 for welding by the hot air welding gun 21. The hot air welding gun 21 includes a welding gun body 211, a welding nozzle 212 and a pressure plate 213. The welding nozzle 212 extends from the end of the welding gun body 211 to output hot air to soften the T-shaped welding rod.

[0038] Further, please refer to Figure 3, which is a cross-sectional schematic diagram of the pressure plate of the hot air welding gun of the present invention. The pressure plate 213 is provided at the front end of the welding nozzle 212, and the pressure plate 213 is connected to the feeding device 22 to smoothly transport the T-shaped welding rod to the welding groove 11. The bottom of the pressure plate 213 is recessed to form a groove 2131, and the groove 2131 corresponds to the cross-sectional shape of the T-shaped welding rod.

[0039] Preferably, the cross-sectional dimension of the groove 2131 is slightly smaller than that of the T-shaped welding rod. This not only allows for appropriate pressure to be applied to the supporting end of the T-shaped welding rod during the welding process, ensuring that the filling end is tightly filled into the weld groove 11 to improve the bonding strength between the plates 10, but also promotes the uniformity of heat transfer between the T-shaped welding rod and the weld groove 11 material, thereby improving the melting effect and welding density of the T-shaped welding rod.

[0040] In addition, the groove 2131 can effectively prevent the T-shaped welding rod from shaking or shifting during the feeding process, so as to ensure the accuracy of the welding position.

[0041] More preferably, at least a portion of the bottom of the pressure plate 213 is provided with at least one guide protrusion 2132. When the automatic welding equipment 20 moves to perform welding, the guide protrusion 2132 moves along a running trajectory of the automatic welding equipment 20 and is confined within the weld groove 11. During the welding process, the guide protrusion 2132 can accurately guide the T-shaped welding rod into the weld groove 11, further preventing the feeding deviation of the T-shaped welding rod and thus ensuring the consistency and stability of the welding.

[0042] The feeding device 22 includes a feeding conduit 221 to deliver the T-shaped welding rod to the welding tank 11. In other words, the feeding conduit 221, the groove 2131, and the welding nozzle 212 are connected, so that the feeding device 22 further forms an airflow channel 222 that allows hot air output from the welding nozzle 212 to enter, thereby achieving the effect of preheating the T-shaped welding rod. This not only reduces the material temperature difference between the T-shaped welding rod and the plate 10, making the heat transfer during the welding process more uniform, thereby reducing welding stress and improving the bonding strength and welding efficiency between the plates 10, but also effectively reduces the residual moisture and impurities inside the T-shaped welding rod through preheating treatment, significantly reducing the generation of porosity and defects during the welding process and improving the welding quality.

[0043] Preferably, the feed conduit 221 has a feed port diameter slightly larger than the cross-sectional size of the T-shaped welding electrode.

[0044] It should be noted that, based on the explanations and descriptions in the foregoing specification, those skilled in the art can make changes and modifications to the above embodiments. Therefore, this disclosure is not limited to the specific embodiments disclosed and described above, and some equivalent modifications and changes to this disclosure should also be within the scope of protection of the claims in this disclosure. Furthermore, although this specification uses some specific terms, these terms are only for convenience of explanation and do not constitute any limitation on the invention.

[0045] 10: Board material 11: Welding pool 20: Automatic welding equipment 21: Hot air welding torch 211: Welding torch body 212: Welding nozzle 213: Pressure Plate 2131: Groove 2132: Guide bump 22: Feeding device 221: Feed pipe 222: Airflow Channel S1-S3: Steps

Claims

1. An automatic welding device for T-shaped welding electrodes, comprising a hot air welding torch and a feeding device for conveying a T-shaped welding electrode, wherein: The hot air welding torch includes a torch body, a nozzle, and a pressure plate. The nozzle extends from the end of the torch body to output hot air. The pressure plate is located at the front end of the nozzle and is connected to both the nozzle and the feeding device. The bottom of the pressure plate has a recessed groove corresponding to the cross-sectional shape of the T-shaped welding rod. The T-shaped welding rod includes a supporting end and a filling end. The supporting end is firmly attached to a plate. The filling end is used to fill a weld groove. At least a portion of the bottom of the pressure plate has at least one guide protrusion that is confined within the weld groove. The feeding device includes a feeding conduit for conveying the T-shaped welding rod to the pressure plate. One of the feeding ports of the feeding conduit has a diameter larger than the cross-sectional size of the T-shaped welding rod.

2. The automatic welding equipment for the T-shaped welding electrode as described in claim 1, wherein the cross-sectional dimension of the groove is slightly smaller than the cross-sectional dimension of the T-shaped welding electrode.

3. A welding method using an automatic welding device with T-shaped welding electrodes, comprising the following steps: Step S1, laminating a plurality of plates, wherein, Each of the 10 plates is flush-mounted and bonded together, forming an adjacent area between them; Step S2, a weld groove is etched in the adjacent area; and Step S3, a plurality of the plates are welded using an automatic welding device, wherein the automatic welding device includes a hot air welding gun and a feeding device for conveying a T-shaped welding rod. The hot air welding gun includes a welding gun body, a welding nozzle, and a pressure plate. The welding nozzle extends from the end of the welding gun body to output hot air. The pressure plate is disposed at the front end of the welding nozzle and is connected to both the welding nozzle and the feeding device. The bottom of the pressure plate has a recessed groove corresponding to the cross-sectional shape of the T-shaped welding rod. The T-shaped welding rod includes a supporting end and a filling end. The supporting end is firmly attached to each of the plates. The filling end is used to fill the weld groove. At least a portion of the bottom of the pressure plate has at least one guide protrusion, which is confined within the weld groove. The feeding device includes a feeding conduit to deliver the T-shaped welding rod to a weld groove for welding by the hot air welding gun. One of the feeding conduits has a feeding port diameter larger than the cross-sectional size of the T-shaped welding rod.

4. The welding method of the automatic welding equipment for the T-shaped welding electrode as described in claim 3, wherein the cross-sectional dimension of the groove is slightly smaller than the cross-sectional dimension of the T-shaped welding electrode.

5. The welding method of the automatic welding equipment for the T-shaped welding electrode as described in claim 3, wherein in step S2, a cutting tool applies force unidirectionally along the adjacent area to form the weld groove, and the cutting tool applies a fixed force angle to the adjacent area, wherein, The angle at which the force is applied is between 30 and 45 degrees.

6. The welding method of the automatic welding equipment for the T-shaped welding electrode as described in claim 3, further comprising, after step S1, performing a surface pretreatment on the adjacent area by mechanical scraping, and after the surface pretreatment is completed, cleaning the adjacent area with a lint-free cloth and a solvent.

7. The welding method of the automatic welding equipment for the T-shaped welding electrode as described in claim 6, further comprising cleaning the weld tank with the lint-free cloth and the solvent after step S2.

8. The welding method of the automatic welding equipment for the T-shaped welding electrode as described in claim 7, wherein the solvent comprises materials such as isopropanol (IPA), acetone, or methyl ethyl ketone (MEK).

9. A welding method for an automatic welding apparatus for a T-shaped welding electrode as described in any one of claims 3 to 8, wherein the T-shaped welding electrode comprises a thermoplastic material such as polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), polyvinylidene fluoride (PVDF), polyethylene (PE), polypropylene (PP), or polyvinyl chloride (PVC).

10. The welding method of the automatic welding equipment for the T-shaped welding electrode as described in claim 9, wherein the plurality of the plates comprise one or a combination of polytetrafluoroethylene (PTFE), modified polytetrafluoroethylene (M-PTFE), perfluoroalkoxy polymer (PFA), and fluorinated ethylene propylene copolymer (FEP).

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