Wire Harness Terminal Welding Method and Wire Harness Terminal Welded Part

Abstract

The object of the present invention is to provide a wire harness terminal welding method and a wire harness terminal welding part, which can effectively improve the overall efficiency of wire harness welding. The wire harness terminal welding method includes the following steps: providing two sets of ultrasonic welding systems; providing a wire, one end of the wire has a section to be welded, and the section to be welded is divided into two parts, forming an upper half section and a lower half section; providing a terminal, and placing the upper half section and the lower half section on the upper surface and the lower surface of the terminal respectively; starting the two sets of ultrasonic welding systems, so that the two sets of ultrasonic welding systems synchronously perform ultrasonic welding on the upper half section and the upper surface of the terminal, and perform ultrasonic welding on the lower half section and the lower surface of the terminal respectively.

Description

Technical Field

[0001] The present invention relates to the field of wire harness welding, and particularly to a wire harness terminal welding method and a wire harness terminal welding part. Background Art

[0002] Power ultrasound has been increasingly widely used in industrial production. It has played an increasingly important role in fields such as ultrasonic welding, ultrasonic cutting, ultrasonic machining, and ultrasonic cleaning. However, due to different application working conditions, the requirements for completing ultrasonic welding applications of large-square wire harnesses are very different. Among them, "large-square wire harness" generally refers to a wire harness with a total cross-sectional area exceeding 70 square millimeters.

[0003] In the wire harness industry, due to the rise of the new energy vehicle industry, the ultrasonic welding process is increasingly applied, especially for welding large-square terminal wire harnesses. However, in the existing ultrasonic welding process of large-square wire harness terminals, there are still the following three difficulties:

[0004] 1) Since the required welding square number is getting larger and larger, it poses a huge challenge to the entire ultrasonic system in ultrasonic welding. In order to complete the welding of large-square wire harness terminals, the required power of the ultrasonic system is getting larger and larger.

[0005] 2) Due to the increase in the required power of the ultrasonic system mentioned in point 1, in the prior art, when dealing with large-square welding, due to insufficient ultrasonic power, a step-by-step welding mode is adopted. However, in this welding mode, when the two weldings act on the same terminal, the second welding will have a huge impact on the first welding point. Since the power energy of large-square welding is relatively large, the second welding will break or even shake off the wire at the first welding point.

[0006] 3) In the prior art, when using a dual ultrasonic system to make up for insufficient welding power and performing synchronous welding of the dual systems, when the two sets of acoustic components are arranged in the same direction, the amplitudes of the two ultrasonic systems need to be asynchronous and in anti-phase. When the two sets of acoustic components are arranged in the opposite direction, the amplitudes of the two ultrasonic systems need to be synchronous and in the same phase. Otherwise, it will cause a certain degree of quality instability and also cause unnecessary damage to the ultrasonic system. And the process of arranging the two sets of acoustic components in the same direction is cumbersome, increasing the time cycle for debugging the equipment. Summary of the Invention

[0007] An object of the present invention is to provide a wire harness terminal welding method, which can effectively improve the overall efficiency of wire harness welding.

[0008] The wire harness terminal welding method for achieving the foregoing object includes the following steps:

[0009] Provide two sets of ultrasonic welding systems;

[0010] Provide a wire, one end of the wire has a section to be welded, and the section to be welded is divided into two, forming an upper half section and a lower half section;

[0011] Provide a terminal, and place the upper half section and the lower half section on the upper surface and the lower surface of the terminal respectively;

[0012] Start two sets of the ultrasonic welding systems, so that the two sets of ultrasonic welding systems synchronously perform ultrasonic welding on the upper half section and the upper surface of the terminal respectively, and perform ultrasonic welding on the lower half section and the lower surface of the terminal respectively.

[0013] In one or more embodiments, the method further includes:

[0014] Obtain a wire raw material, bisect one end of the wire raw material to obtain the section to be welded divided into two, so as to obtain the wire.

[0015] In one or more embodiments, the cross-sectional areas of the upper half section and the lower half section of the wire are 35 to 100 square millimeters.

[0016] In one or more embodiments, the method further includes:

[0017] Provide a fixture to clamp the terminal, and the upper surface and the lower surface of the terminal in the clamped state are open.

[0018] In one or more embodiments, the fixture includes:

[0019] A first clamping group, including a first upper stop block and a first lower stop block that can move relative to or towards each other, and the first clamping group clamps the terminal on one side thereof;

[0020] A second clamping group, including a second upper stop block and a second lower stop block that can move relative to or towards each other, and the second clamping group clamps the terminal on the other side thereof;

[0021] Wherein, a first limiting space is formed between the first upper stop block and the second upper stop block, a second limiting space is formed between the first lower stop block and the second lower stop block, the first limiting space and the second limiting space respectively allow the upper surface and the lower surface of the terminal to be open, and during the welding process, the upper half section and the lower half section are respectively located in the first limiting space and the second limiting space, and the first limiting space and the second limiting space limit the welding width of the ultrasonic welding system for the upper half section and the lower half section.

[0022] In one or more embodiments, the ultrasonic welding system includes:

[0023] A first ultrasonic welding system, comprising a first ultrasonic generator, a first ultrasonic transducer, a first ultrasonic amplitude modulator, and a first ultrasonic welding head;

[0024] A second ultrasonic welding system, comprising a second ultrasonic generator, a second ultrasonic transducer, a second ultrasonic amplitude modulator, and a second ultrasonic welding head;

[0025] Wherein, the first ultrasonic welding head is located directly above the first limiting space and can move up and down. The second ultrasonic welding head is located directly below the second limiting space, and the ultrasonic welding head is fixed. The second limiting space and the ultrasonic welding head are fixed and can move relative to or towards each other.

[0026] In one or more embodiments, the method further comprises:

[0027] Lower the first ultrasonic welding head so that it contacts the upper half placed on the upper surface of the terminal;

[0028] Continue to lower the first ultrasonic welding head so that the entire fixture moves towards the second ultrasonic welding system until the second ultrasonic welding head contacts the lower half placed on the lower surface of the terminal;

[0029] Start the two ultrasonic welding systems and perform ultrasonic welding synchronously.

[0030] Another object of the present invention is to provide a wire harness terminal welding part, which is welded by the welding method described above.

[0031] The wire harness terminal welding part for achieving the aforementioned another object is made by the wire harness terminal welding method described above.

[0032] The wire harness terminal welding part for achieving the aforementioned another object comprises:

[0033] A wire, one end of the wire has a section to be welded, and the section to be welded is divided into two, forming an upper half and a lower half; and

[0034] A terminal, clamped between the upper half and the lower half;

[0035] Wherein, the upper surface of the terminal is welded and connected to the upper half, and the lower surface of the terminal is welded and connected to the lower half.

[0036] In one or more embodiments, the cross-sectional area of the wire of the upper half and the lower half is 35 to 100 square millimeters.

[0037] The progressive effects of the present invention include one or a combination of the following:

[0038] By using the wire harness terminal welding method of the present invention, during the welding process, the upper half of the wire 1 is friction-welded to the upper surface of the terminal, and the lower half is friction-welded to the lower surface of the terminal respectively, changing the application that originally required a high-power ultrasonic device into two sets of low-power devices. It solves the problem of lacking a high-power ultrasonic system for welding large cross-section wire harness terminals. At the same time, since the friction welding is carried out on the upper and lower surfaces respectively, the amplitude and phase of the welding system can be ignored, achieving a stable welding effect. At the same time, by using the simultaneous driving method of the dual ultrasonic system, the influence on the welded parts caused by step-by-step welding can be avoided. It can not only use an ultrasonic system with relatively low power, but also avoid multiple step-by-step weldings, accelerating the production speed. At the same time, there is no strict requirement for the phase of the ultrasonic system, ensuring the welding quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The above and other features, properties and advantages of the present invention will become more obvious through the following description in conjunction with the drawings and embodiments, wherein:

[0040] Figure 1 FIG. shows a schematic flow chart of the wire harness terminal welding method according to an embodiment;

[0041] Figure 2 FIG. shows a partial half-sectional schematic view of the welding section and the terminal according to an embodiment;

[0042] Figure 3 FIG. shows a three-dimensional schematic view of the clamping state of the fixture according to an embodiment;

[0043] Figure 4 FIG. shows a three-dimensional schematic view of the ultrasonic welding system according to an embodiment;

[0044] Figure 5 FIG. shows a side schematic view of the ultrasonic welding system according to an embodiment. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0045] The following discloses various embodiments or examples for implementing the subject technical solutions of the present invention. To simplify the disclosure content, specific examples of each element and arrangement are described below. Of course, these are only examples and do not limit the protection scope of the present application. In addition, the same reference numerals and / or letters may be repeated in different examples in these disclosures. This repetition is for the sake of brevity and clarity, and does not itself indicate the relationship between the various embodiments and / or structures to be discussed.

[0046] In order to improve the overall efficiency of wire harness welding using ultrasonic welding, one aspect of the present invention provides a wire harness terminal welding method, as shown in Figure 1 FIG. shows a schematic flow chart of the wire harness terminal welding method according to an embodiment.

[0047] It is understandable that specific terms are used in this application to describe the embodiments of this application. For example, "one embodiment", "one or more embodiments", and / or "some embodiments" mean a certain feature, structure, or characteristic related to at least one embodiment of this application. Therefore, it should be emphasized and noted that the "one embodiment", "one or more embodiments", and / or "some embodiments" mentioned twice or more at different positions in this specification do not necessarily refer to the same embodiment.

[0048] One embodiment of the wire harness terminal welding method includes the following steps:

[0049] Step S1: Provide two sets of ultrasonic welding systems. Among them, the two sets of ultrasonic welding systems can be ultrasonic welding systems with their respective control units, or the two sets of ultrasonic welding systems can be welded simultaneously through the same control unit, so that ultrasonic waves are transmitted from two transducer vibration units to the upper and lower welding heads respectively, and the two welding heads can obtain ultrasonic energy simultaneously, that is, the two sets of ultrasonic welding systems can perform ultrasonic welding independently of each other or synchronously.

[0050] Step S2: Provide a wire. One end of the wire has a section to be welded, and the section to be welded is divided into two, forming an upper half section and a lower half section.

[0051] Step S3: Provide a terminal, and place the upper half section and the lower half section of the welding section on the upper surface and the lower surface of the terminal respectively.

[0052] Figure 2 A partial half-sectional schematic diagram of the welding section and the terminal in one embodiment is shown. It should be noted that these and other subsequent drawings are only examples, and they are not drawn under the condition of equal proportion, and should not be used to limit the actual protection scope required by the present invention. In addition, the transformation methods under different embodiments can be appropriately combined.

[0053] Combined Figure 2 to explain steps S2 and S3. Among them, the section to be welded 10 can be understood as a section extending inward from the end of the wire, which acts as the welded part in the wire during ultrasonic welding. The upper half section 101 and the lower half section 102 in the welding section 10 can be two parts evenly bisected as shown in the figure. Of course, in some other embodiments, the thicknesses of the upper half section 101 and the lower half section 102 can be approximately bisected, allowing for a certain error in thickness.

[0054] Before welding, the terminal 2 is clamped between the upper section 101 and the lower section 102, that is, the upper surface 21 of the terminal 2 is in contact with the upper section 101, and the lower surface 22 of the terminal 2 is in contact with the lower section 102. During welding, welding is performed between the upper surface 21 and the upper section 101, and welding is performed between the lower surface 22 and the lower section 102.

[0055] It should be noted that, when used, the terms "upper" and "lower" in the description herein are used only for convenience and do not imply any specific fixed direction. In fact, they are used to reflect the relative position and / or direction between the various parts of an object, such as "upper surface" and "lower surface". When the terminal 2 is turned over, the "upper surface" becomes the "lower surface".

[0056] Step S4: start the two ultrasonic welding systems so that the two ultrasonic welding systems synchronously ultrasonically weld the upper half 101 to the upper surface 21 of the terminal 2 and the lower half 102 to the lower surface 22 of the terminal 2, thereby obtaining the wiring harness terminal welded parts.

[0057] In one or more embodiments of the wiring harness terminal welding method, the following steps are also included:

[0058] Step S0: obtaining a conductor raw material, and bisecting one end of the conductor raw material to obtain a section 10 to be welded which is bisected to obtain a conductor.

[0059] Specifically, the wire with the welding section 10 can be obtained as in step S0, by cutting one end of the wire raw material including but not limited to using a cutter. Of course, in some other suitable embodiments, the wire with the welding section 10 can be a standard part, which is supplied in batches after production.

[0060] It is understandable that in the welding method in one or more embodiments as described above, steps S0 to S4 are not necessarily executed in sequence. For example, the execution order of step S0 and step S1 can be executed in parallel or one after the other, and the execution order of step S2 and step S3 can be executed in parallel or one after the other.

[0061] In one or more embodiments of the wiring harness terminal welding method, in the obtained wire, the upper half 101 and the lower half 102 of the welding section 10 respectively have a wire cross-sectional area of 35 to 100 square millimeters, that is, after one end of the wire is cut, the cross-sectional area of the upper half 101 and the cross-sectional area of the lower half 102 are equal and are between 35 and 100 square millimeters. The section 10 to be welded that meets the cross-sectional area can be well welded to the terminal 2.

[0062] In one or more embodiments of the wire harness terminal welding method, the wire harness terminal welding method further includes providing a fixture to clamp the terminal 2. As Figure 3 Fig. shows a three-dimensional schematic diagram of the clamping state of the fixture in an embodiment. Among them, the fixture 3 clamps the terminal 2, and the upper surface and the lower surface of the terminal 2 in the clamping state are open to allow the upper half 101 and the lower half 102 of the welding section 10 to contact it respectively for subsequent welding.

[0063] Further, in one embodiment of the fixture, it includes a first clamping group 31 and a second clamping group 32. The first clamping group 31 has a first upper stopper 311 and a first lower stopper 312 that can move relative to or towards each other, and the first upper stopper 311 and the first lower stopper 312 clamp the terminal 2 on one side thereof. The second clamping group 32 has a second upper stopper 321 and a second lower stopper 322 that can move relative to or towards each other, and the second upper stopper 321 and the second lower stopper 322 clamp the terminal 2 on the other side thereof.

[0064] Among them, a first limiting space 310 is formed between the first upper stopper 311 and the second upper stopper 321, and a second limiting space 320 is formed between the first lower stopper 312 and the second lower stopper 322. The first limiting space 310 and the second limiting space 320 define the welding space when the ultrasonic welding system performs welding. And in the clamping state, due to the existence of the first limiting space 310 and the second limiting space 320, the fixture 3 does not block the upper and lower surfaces of the clamped terminal 2, but is open to facilitate welding.

[0065] As Figure 3 As shown in, during welding, the upper half 101 of the welding section 10 is located in the first limiting space 310, and the lower half 102 of the welding section 10 is located in the second limiting space 320. The first limiting space 310 limits the welding width of the upper half 101 by the ultrasonic welding system, so that the wire to be welded is always within the effective welding area range, preventing the wire from overflowing due to welding, so as to prevent the wire to be welded from flying in the welding area. Similarly, the second limiting space 320 limits the welding width of the lower half 102 by the ultrasonic welding system, so that the wire to be welded is always within the effective welding area range, preventing the wire from overflowing due to welding, so as to prevent the wire to be welded from flying in the welding area.

[0066] Certain features, structures or characteristics in one or more of the above-described embodiments can be appropriately combined. In addition, using words such as "first" and "second" to limit components, such as "first upper stopper" and "second upper stopper", is only for facilitating the distinction of the corresponding components. Without otherwise stating, the above words have no special meaning, so they cannot be understood as a limitation on the protection scope of the present application.

[0067] As described above, in the fixture 3 in one or more embodiments, each clamping block in the first clamping group 31 and the second clamping group 32 can be arranged in a manner of being connected by a slide rail and a slider, so as to realize that the aforementioned first upper stop block 311 and the first lower stop block 312 can move relative to or towards each other, and the second upper stop block 321 and the second lower stop block 322 can move relative to or towards each other.

[0068] Figure 4 A three-dimensional schematic diagram of an ultrasonic welding system in an embodiment is shown. Figure 5 A side schematic diagram of an ultrasonic welding system in an embodiment is shown. Among them, as described above, the two sets of ultrasonic welding systems in one or more embodiments include a first ultrasonic welding system 4 and a second ultrasonic welding system 5. The first ultrasonic welding system 4 has a first ultrasonic generator (not shown in the figure), a first ultrasonic transducer 41, a first ultrasonic amplitude modulator 42, and a first ultrasonic welding head 43. The second ultrasonic welding system 5 has a second ultrasonic generator (not shown in the figure), a second ultrasonic transducer 51, a second ultrasonic amplitude modulator 52, and a second ultrasonic welding head 53. Among them, the first ultrasonic welding head 43 is located directly above the first limiting space 310 and can move up and down to move towards or away from the first limiting space 310, so as to be movable to a position aligned with the first limiting space 310. The second ultrasonic welding head 53 is located directly below the second limiting space 320, and the second ultrasonic welding head 53 is fixed. A second limiting space 320 is formed between the first lower stop block 312 and the second lower stop block 322, and they can move relative to or towards each other relative to the second ultrasonic welding head 53, so that the second ultrasonic welding head 53 and the second limiting space 320 can move relative to each other to a position where they are aligned with each other.

[0069] Furthermore, in one or more embodiments of the wire harness terminal welding method, the welding process includes:

[0070] Press down the first ultrasonic welding head 53 to make it contact the upper half section 101 placed on the upper surface of the terminal 2;

[0071] Continue to press down the first ultrasonic welding head 53, so that the whole fixture 3 moves towards the second ultrasonic welding system 5 until the second ultrasonic welding head 53 contacts the lower half section 102 placed on the lower surface of the terminal 2;

[0072] Start two ultrasonic welding systems and perform ultrasonic welding synchronously. Specifically, the vibration energy generated by the first ultrasonic transducer 41 is transmitted to the first ultrasonic horn 43 via the first ultrasonic amplitude modulator 42, and the vibration energy radiated by the transducer is conducted to the welding surface, causing the working surface of the first ultrasonic horn 43 opposite to the upper half 101 to generate high-frequency vibration friction, resulting in the reorganization of the metal lattice structure on the surface of the workpiece to be welded, thereby realizing the welding connection between the upper half 101 and the upper surface of the terminal 2. Similarly, the vibration energy generated by the second ultrasonic transducer 51 is transmitted to the second ultrasonic horn 53 via the second ultrasonic amplitude modulator 52, and the vibration energy radiated by the transducer is conducted to the welding surface, causing the working surface of the second ultrasonic horn 53 opposite to the lower half 102 to generate high-frequency vibration friction, resulting in the reorganization of the metal lattice structure on the surface of the workpiece to be welded, thereby realizing the welding connection between the lower half 102 and the lower surface of the terminal 2.

[0073] During the welding process, since the wire 1 is friction-welded to the upper surface of the terminal 2 through the upper half 101 and to the lower surface of the terminal 2 through the lower half 102 respectively, two ultrasonic systems with relatively small power can be used to meet the welding application of large cross-section wire harnesses during the welding process. And because the upper and lower parts are friction-welded separately, during the layout of the two ultrasonic systems, the phase requirements of the amplitude can be ignored, and multiple step-by-step weldings can be avoided to avoid the influence on the workpiece to be welded during step-by-step welding, and welding can be carried out stably to meet the production requirements.

[0074] At the same time, during the welding process, while the terminal 2 is fixed by the fixture 3, it is equivalent to being clamped by the first ultrasonic horn 53 and the second ultrasonic horn 53 for welding, ensuring that the terminal 2 remains stationary throughout the welding process and guaranteeing the welding quality.

[0075] Another aspect of the present invention also provides a wire harness terminal welding part, which is made by using the wire harness terminal welding method described in one or more of the foregoing embodiments.

[0076] Yet another aspect of the present invention also provides a wire harness terminal welding part, which is easily made by a welding method that can effectively improve the overall efficiency of wire harness welding. As Figure 2 shown, the wire harness terminal welding part includes a wire, one end of which has a section to be welded 10. The section to be welded 10 is divided into two parts, forming an upper half 101 and a lower half 102. The terminal 2 is clamped between the upper half 101 and the lower half 102. Among them, the upper surface 21 of the terminal 2 is welded to the upper half 101, and the lower surface of the terminal 2 is welded to the lower half 102.

[0077] In one or more embodiments of the wiring harness terminal welding part, the upper half 101 and the lower half 102 of the welding section 10 respectively have a conductor cross-sectional area of 35 to 100 square millimeters, that is, after one end of the conductor is cut, the cross-sectional area of the upper half 101 and the cross-sectional area of the lower half 102 are equal and are between 35 and 100 square millimeters. The section 10 to be welded that meets this cross-sectional area can be well welded to the terminal 2.

[0078] Although the present invention is disclosed as above with preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications without departing from the spirit and scope of the present invention. Therefore, any modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention shall fall within the protection scope defined by the claims of the present invention.

Claims

1. A wire harness terminal welding method, characterized in that, It includes the following steps: Provide two sets of ultrasonic welding systems; Provide a wire, one end of the wire has a section to be welded, and the section to be welded is divided into two in the thickness direction to form an upper half section and a lower half section; Provide terminals, and place the upper half section and the lower half section on the upper surface and the lower surface of the terminals respectively; Start the two sets of ultrasonic welding systems, so that the two sets of ultrasonic welding systems synchronously perform ultrasonic welding on the upper half section and the upper surface of the terminal, and perform ultrasonic welding on the lower half section and the lower surface of the terminal respectively.

2. The wire harness terminal welding method according to claim 1, characterized in that, The method further includes: Obtain the original wire material, bisect one end of the original wire material to obtain the section to be welded that is divided into two, so as to obtain the wire.

3. The wire harness terminal welding method according to claim 1, wherein The cross-sectional areas of the upper half section and the lower half section of the wire are 35 to 100 square millimeters.

4. The wire harness terminal welding method according to claim 1, characterized in that It further includes: Provide a fixture to clamp the terminal, and the upper surface and the lower surface of the terminal in the clamped state are open.

5. The wire harness terminal welding method according to claim 4, characterized in that, The fixture includes: A first clamping group, including a first upper stopper and a first lower stopper that can move relative to or towards each other, and the first clamping group clamps the terminal on one side thereof; A second clamping group, including a second upper stopper and a second lower stopper that can move relative to or towards each other, and the second clamping group clamps the terminal on the other side thereof; Wherein, a first limiting space is formed between the first upper stopper and the second upper stopper, a second limiting space is formed between the first lower stopper and the second lower stopper, the first limiting space and the second limiting space respectively allow the upper surface and the lower surface of the terminal to be open, and during the welding process, the upper half section and the lower half section are respectively located in the first limiting space and the second limiting space, and the first limiting space and the second limiting space limit the welding width of the ultrasonic welding system for the upper half section and the lower half section.

6. The wire harness terminal soldering method according to claim 5, characterized in that, The ultrasonic welding system includes: A first ultrasonic welding system, having a first ultrasonic generator, a first ultrasonic transducer, a first ultrasonic amplitude modulator and a first ultrasonic welding head; A second ultrasonic welding system, having a second ultrasonic generator, a second ultrasonic transducer, a second ultrasonic amplitude modulator and a second ultrasonic welding head; Wherein, the first ultrasonic welding head is located directly above the first limiting space, the first ultrasonic welding head can move up and down, the second ultrasonic welding head is located directly below the second limiting space, the ultrasonic welding head is fixed, and the second limiting space and the ultrasonic welding head are fixed and can move relative to or towards each other.

7. The wire harness terminal welding method according to claim 6, characterized in that It further includes: Press down the first ultrasonic welding head to make it contact the upper half section placed on the upper surface of the terminal; Continue to press down the first ultrasonic welding head, so that the whole fixture moves towards the second ultrasonic welding system until the second ultrasonic welding head contacts the lower half section placed on the lower surface of the terminal; Start the two ultrasonic welding systems and perform ultrasonic welding synchronously.

8. A wire harness terminal welding part, characterized in that, It is made by using the wire harness terminal welding method according to any one of claims 1 to 7.

9. A wire harness terminal welding part, characterized in that, It includes: A wire, one end of the wire has a section to be welded, and the section to be welded is divided into two in the thickness direction to form an upper half section and a lower half section; And A terminal, clamped between the upper half section and the lower half section; Wherein, the upper surface of the terminal is welded and connected to the upper half section, and the lower surface of the terminal is welded and connected to the lower half section.

10. The wire harness terminal welding part according to claim 9, characterized in that, The cross-sectional area of the wire of the upper half section and the lower half section is 35 to 100 square millimeters.

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