Welding device and method for a photovoltaic storage integrated machine support

Abstract

The application discloses a welding device and method for a light storage integrated machine support, the welding device comprising a mounting seat, a plurality of heating elements, each of the heating elements corresponding to a welding position of one of the support rods and the plate-shaped components to heat or keep warm the welding position, a moving mechanism, the heating elements being arranged on the mounting seat through the moving mechanism, a plurality of temperature measuring elements, each of the temperature measuring elements corresponding to one of the welding positions to detect the temperature of the welding position, and a controller electrically connected with the plurality of temperature measuring elements, used to heat the welding position when the temperature of the welding position decreases to a first set temperature, to increase the temperature of the welding position to a second set temperature, and to keep warm until the welding of other welding positions is completed and the keeping warm is stopped. The welding device can effectively reduce welding stress, avoid stress concentration, and improve the yield and service life of the support.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and specifically to a welding device and method for a photovoltaic storage integrated machine bracket. Background Technology

[0002] A photovoltaic (PV) and energy storage integrated unit can convert the DC power from photovoltaic panels or the DC power from the battery bank into 220V AC power for daily use. It has an internal battery bank that stores the electricity from the PV panels, providing 24-hour power to AC or electrical loads. During operation, the internal power devices of the integrated PV and energy storage unit generate a significant amount of heat due to the prolonged DC-DC conversion. Since the battery bank has a relatively low rated operating temperature, a support structure is needed to separate the integrated PV and energy storage unit into an inverter chamber and a battery chamber to prevent the battery bank from burning out.

[0003] The brackets for integrated photovoltaic and energy storage systems in the industry typically consist of plate-shaped components and support rods. The plate-shaped components have multiple welding points, and the plate-shaped components and support rods are fixedly connected using laser welding. Currently, during the welding process, variations in the welding sequence and instantaneous temperature at the welding points lead to varying degrees of stress concentration, resulting in significant shrinkage deformation of the bracket after cooling. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides a welding device and method for an integrated photovoltaic and energy storage unit bracket, which can effectively reduce welding stress, avoid stress concentration, and improve the yield and service life of the bracket.

[0005] The present invention adopts the following technical solution:

[0006] A welding device for a photovoltaic-storage integrated machine bracket, used to weld plate-shaped components of the bracket to multiple support rods, the welding device comprising:

[0007] Mounting base;

[0008] Multiple heating elements are movably disposed relative to the mounting base, each heating element corresponding to one of the welding points of the support rod and the plate-shaped component to heat or keep the welding point warm;

[0009] A moving mechanism for driving the heating element closer to or away from the welding area, wherein the heating element is mounted on the mounting base via the moving mechanism;

[0010] Multiple temperature measuring elements, each of which corresponds to one of the welding parts to detect the temperature of that welding part;

[0011] The controller, which is electrically connected to the plurality of temperature measuring elements, is used to control the heating element to heat the welding area when the temperature of a certain welding area drops to a first set temperature, raise its temperature to a second set temperature and then keep it at that temperature until the welding of other parts to be welded is completed, and then stop keeping it at that temperature.

[0012] In a preferred embodiment, the mounting base includes a base plate and a support frame. The base plate is provided with a plurality of lower limit members for the insertion of the support rod. The support frame includes a fixed plate and a movable plate. A hydraulic lifting column is provided between the fixed plate and the movable plate, and the hydraulic lifting column drives the movable plate to move up and down.

[0013] In a preferred embodiment, the plate-shaped component includes an upper partition plate and a lower partition plate; the movable plate is provided with a plurality of upper limit members, which can move up and down relative to the upper partition plate and are located above the upper partition plate.

[0014] In a preferred embodiment, the bracket is located between the base plate and the support frame.

[0015] In a more preferred embodiment, there are two upper limit positions; each upper limit position has a temperature measuring element on its front and rear sides, and the temperature measuring element includes an infrared temperature measuring camera.

[0016] In a preferred embodiment, the welding device further includes a support assembly located between the moving mechanism and the bracket; the support assembly includes a rotating shaft and a support plate integrally formed or fixedly connected to the rotating shaft, a handwheel is provided on one side of the rotating shaft, a ratchet and a snap-fit ​​component cooperating with the ratchet are provided on the other side, and the support plate is located below the upper partition plate.

[0017] In a more preferred embodiment, the latching member has a first working state and a second working state. In the first working state, the latching member rotates clockwise and is inserted into the root of the ratchet teeth. In the second working state, the latching member rotates counterclockwise and disengages from the root of the ratchet teeth.

[0018] In a preferred embodiment, the moving mechanism includes an X-axis lead screw slide rail, a Y-axis lead screw slide rail, and a Z-axis lead screw slide rail. The X-axis lead screw slide rail is disposed above the Y-axis lead screw slide rail, and the Z-axis lead screw slide rail is disposed above the X-axis lead screw slide rail. A heating element is installed on one side of the Z-axis lead screw slide rail.

[0019] In a more preferred embodiment, the heating element includes a heat-conducting coil.

[0020] In a preferred embodiment, there is one X-axis lead screw guide rail, and two Y-axis and two Z-axis lead screw guide rails.

[0021] The present invention also adopts the following technical solution:

[0022] A welding method for a photovoltaic-storage integrated unit bracket, using the aforementioned welding device, the welding method comprising the following steps:

[0023] S1. Position the plate-shaped component;

[0024] S2. Weld each welding part of the plate-shaped component in sequence, and drive the heating element to approach the welding part through the moving mechanism. The temperature measuring element detects the temperature of the welding part. When the temperature of a certain welding part drops to the first set temperature, the controller controls the heating element to heat the welding part, raise its temperature to the second set temperature and then keep it warm until the welding of other parts to be welded is completed, and then stop keeping it warm.

[0025] S3. After the welded parts have completely cooled down, remove the bracket.

[0026] The present invention adopts the above solution, which has the following advantages compared with the prior art:

[0027] The welding device for the integrated photovoltaic and energy storage unit bracket of this invention uses a temperature sensor to detect the temperature of the welding area, and a controller to control the heating element to perform localized high-frequency induction heating and heat preservation treatment on the welding area. Utilizing the stress relaxation effect generated by localized heating, the welding stress at the welding area is reduced. The heat preservation treatment ensures a consistent temperature at the welding area of ​​the plate-shaped component, avoiding stress concentration due to instantaneous temperature differences, which helps improve the yield and service life of the bracket. Furthermore, the welding device of this invention has a high degree of automation during welding and is convenient to use. Attached Figure Description

[0028] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 This is a diagram showing the assembly of the welding apparatus and the support according to an embodiment of the present invention;

[0030] Figure 2 This is a schematic diagram of a mounting base according to an embodiment of the present invention;

[0031] Figure 3 This is a schematic diagram of a support component according to an embodiment of the present invention;

[0032] Figure 4This is a schematic diagram of the heating element and the moving mechanism according to an embodiment of the present invention;

[0033] Figure 5 This is a schematic diagram of a bracket according to an embodiment of the present invention.

[0034] in,

[0035] 1. Bracket; 11. Upper partition plate; 12. Lower partition plate; 13. Support rod; 14. Welding parts;

[0036] 2. Heating element; 21. Opening area; 22. Moving mechanism; 221. X-axis lead screw slide rail; 222. Y-axis lead screw slide rail; 223. Z-axis lead screw slide rail; 24. Motor;

[0037] 3. Mounting base; 31. Infrared temperature measurement camera; 32. Base plate; 33. Support frame; 331. Fixed plate; 332. Movable plate; 333. Hydraulic lifting column; 34. Lower limit component; 35. Upper limit component;

[0038] 4. Support assembly; 41. Rotating shaft; 42. Support plate; 43. Handwheel; 44. Ratchet; 45. Snap-fit ​​component. Detailed Implementation

[0039] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more readily understood by those skilled in the art. It should be noted that the description of these embodiments is for the purpose of aiding understanding the present invention, but does not constitute a limitation thereof.

[0040] Reference Figures 1 to 5 As shown, this embodiment provides a welding device for a photovoltaic storage integrated machine bracket, which is used to weld the plate-shaped components of the bracket 1 to multiple support rods 13. The plate-shaped components include an upper partition plate 11 and a lower partition plate 12. The upper partition plate 11 and the lower partition plate 12 are provided with multiple welding positions 14. Specifically, the upper partition plate 11 and the lower partition plate 12 each have four welding positions 14, and the number of support rods 13 is four. The support rods 13 are inserted into the welding positions 14 and welded to the lower partition plate 12 and the upper partition plate 11 respectively.

[0041] Furthermore, the welding apparatus includes a controller, multiple temperature sensors, such as... Figure 2 Mounting bracket 3 as shown Figure 3 Support component 4 shown, such as Figure 4The diagram shows multiple heating elements 2 and a moving mechanism 22. Furthermore, the multiple heating elements 2 are movably arranged relative to the mounting base 3. Each heating element 2 corresponds to one of the support rods 13 and the welding portion 14 of the plate-shaped component to heat or maintain the temperature of that welding portion 14. The moving mechanism 22 is used to drive the heating elements 2 closer to or further away from the welding portion 14. The heating elements 2 are mounted on the mounting base 3 via the moving mechanism 22. Each temperature sensor corresponds to one of the welding portions 14 to detect the temperature of that welding portion 14. The controller is electrically connected to the multiple temperature sensors and is used to control the heating elements 2 to heat the welding portion 14 when the temperature of a certain welding portion 14 drops to a first set temperature, raising its temperature to a second set temperature and maintaining it until the welding of other portions is completed, at which point the heat maintenance stops. Specifically, in this embodiment, the temperature sensor is an infrared temperature measuring camera 31; the first set temperature is 115-125℃, and the second set temperature is 185-195℃.

[0042] Reference Figure 1 As shown, the moving mechanism 22 is located on the left and right sides of the bracket 1, and the bracket 1 is located between the base plate 32 and the support frame 33, providing good protection for the bracket 1. The support assembly 4 is located between the moving mechanism 22 and the bracket 1. The bracket 1, the heating element 2, the moving mechanism 22 and the support assembly 4 are all located in the mounting base 3.

[0043] Furthermore, the heating element 2 is specifically an induction coil used for heating or heat preservation of the welding part 14. This induction coil is a contour-following induction coil, that is, an induction coil designed primarily to mimic the shape of the welding part 14. The shape of this induction coil is similar to a "U" shape and has an opening area 21. The support member 13 is located within the opening area 21, and the induction coil is wound around the welding part 14. The mounting base 3 includes a base plate 32 and a support frame 33. The base plate 32 is provided with multiple lower limiting members 34 for the insertion of the support rod 13. Furthermore, there are four lower limiting members 34. When the support rod 13 is inserted into the lower limiting member 34, the lower partition plate 12, the support rod 13, and the lower limiting members cooperate with each other to limit the lower partition plate 12 in the horizontal direction.

[0044] Furthermore, the support frame 33 includes a fixed plate 331 and a movable plate 332. A hydraulic lifting column 333 is provided between the fixed plate 331 and the movable plate 332, which drives the movable plate 332 to move up and down. Specifically, the lower end face of the fixed plate 331 is connected to the upper end face of the movable plate 332 through the hydraulic lifting column 333. The movable plate 332 is provided with multiple upper limit positions 35. The up and down movement of the movable plate 332 can drive the upper limit positions 35 to move up and down, and the upper limit positions 35 are located above the upper partition plate 11. More specifically, there are two upper limit positions 35, and each upper limit position 35 is provided with an infrared temperature measuring camera 31 on its front and rear sides. The infrared temperature measuring camera 31 can sense the welding temperature at the welding position 14, and there is no obstruction of the field of view during the lifting and lowering of the upper limit position 35. There are four infrared temperature measuring cameras 31, corresponding to the four welding positions 14 on the upper partition plate 11 and the lower partition plate 12, respectively.

[0045] Reference Figure 4 As shown, the moving mechanism 22 includes an X-axis lead screw slide rail 221, a Y-axis lead screw slide rail 222, and a Z-axis lead screw slide rail 223. The X-axis lead screw slide rail 221 is mounted above the Y-axis lead screw slide rail 222, and the Z-axis lead screw slide rail 223 is mounted above the X-axis lead screw slide rail 221. An induction coil is mounted on one side of the Z-axis lead screw slide rail 223. The X-axis lead screw slide rail 221, Y-axis lead screw slide rail 222, and Z-axis lead screw slide rail 223 are driven by a motor 24. There is one X-axis lead screw slide rail 221, and two Y-axis lead screw slide rails 222 and two Z-axis lead screw slide rails 223.

[0046] Reference Figure 3 As shown, the support assembly 4 includes a rotating shaft 41 and a support plate 42 integrally formed or fixedly connected to the rotating shaft 41. Specifically, in this embodiment, the rotating shaft 41 and the support plate 42 are integrally formed. A handwheel 43 is provided on one side of the rotating shaft 41, and a ratchet 44 and a snap-fit ​​member 45 cooperating with the ratchet 44 are provided on the other side. The support plate 42 is located below the upper partition plate 11.

[0047] The snap-fit ​​component 45 has a first working state and a second working state. In the first working state, the snap-fit ​​component 45 rotates clockwise and is inserted into the root of the ratchet 44 teeth. In the second working state, the snap-fit ​​component 45 rotates counterclockwise and disengages from the root of the ratchet 44 teeth.

[0048] Further, before welding the upper partition plate 11 and the support rod 13, turn the handwheel 43 to rotate the support plate 42 until it is parallel to the horizontal plane under the drive of the rotating shaft 41. Rotate the locking piece 45 downward to insert it into the root of the ratchet 44, preventing the ratchet 44 from rotating counterclockwise. Place the upper partition plate 11 above the support plate 42, and the support plate 42 supports the upper partition plate 11. The hydraulic lifting column 333 drives the movable plate 332 downward until the upper limit piece 35 presses against the upper partition plate 11. After the welded part 14 has completely cooled down, i.e., after welding is completed, the hydraulic lifting column 333 drives the movable plate 332 upward, and the upper limit piece 35 returns to the initial position. Rotate the locking piece 45 upward to disengage it from the root of the ratchet 44. Turn the handwheel 43 to make the support plate 13 perpendicular to the horizontal plane and remove the bracket 1.

[0049] This embodiment also provides a welding method for a photovoltaic-storage integrated machine bracket, using the above-mentioned welding device, and the welding method includes the following steps:

[0050] S1. Position the plate-shaped component;

[0051] S2. Weld each welding part 14 of the plate-shaped component in sequence, and drive the heating element 2 to approach the welding part 14 through the moving mechanism 22. The temperature measuring element detects the temperature of the welding part 14. When the temperature of a certain welding part 14 drops to the first set temperature, the controller controls the heating element 2 to heat the welding part 14, raise its temperature to the second set temperature and keep it warm until the other welding parts 14 are completed and the heat preservation is stopped.

[0052] S3. After the welded part 14 has completely cooled down, remove the bracket 1.

[0053] Furthermore, in this embodiment, during the welding process, the upper partition plate 11 of the plate-shaped component is first positioned and the four welding parts 14 of the upper partition plate 11 are welded, and then the lower partition plate 12 is positioned and the four welding parts 14 of the lower partition plate 12 are welded.

[0054] In step S2, when the temperature of the welded part 14 that has been welded drops to 115-125°C, the heating element starts to heat it, raising the temperature to 185-195°C, and holds it at that temperature until the remaining welded parts are finished. Then, the holding is stopped, and the welded parts 14 on the upper partition plate 11 or the lower partition plate 12 are allowed to cool naturally to room temperature.

[0055] In this embodiment, during welding, the lower partition plate 12 is first placed above the lower limiting member 34, and the support rod 13 is inserted into the lower limiting member 34 to completely limit the lower partition plate 12 in the horizontal direction. Then, the four welding parts 14 on the lower partition plate 12 are welded. The infrared temperature measuring camera 31 detects the temperature of the welding parts 14 and transmits the temperature data to the computer. The computer can drive the X-axis lead screw slide rail 221, Y-axis lead screw slide rail 222, and Z-axis lead screw slide rail 223 to move the heating element 2 to the welding parts 14 according to the temperature data, and adjust the heating power of the heating element 2 through the controller to regulate the temperature of the welding parts 14. Next, the handwheel 43 is rotated to make the support plate 42 rotate on the shaft 41. Rotate downwards until parallel to the horizontal plane, then rotate the locking piece 45 downwards to insert it into the root of the ratchet 44, preventing the ratchet 44 from rotating counterclockwise. Place the upper partition plate 11 above the support plate 42. The hydraulic lifting column 333 drives the movable plate 332 downwards until the upper limit piece 35 presses against the upper partition plate 11. Weld the four welding parts 14 of the upper partition plate 11. Finally, after all the welding parts 14 have cooled down, i.e., after the welding is completed, the hydraulic lifting column 333 drives the movable plate 332 upwards, the upper limit piece 35 returns to the initial position, rotate the locking piece 45 upwards to disengage it from the root of the ratchet 44, rotate the handwheel 43 to make the support plate 13 perpendicular to the horizontal plane, and remove the bracket 1.

[0056] The welding apparatus of this embodiment has at least the following advantages:

[0057] (1) By setting up multiple sets of induction coils to perform local high-frequency induction heating on the welding part 14 where welding stress concentration exists, the material stress relaxation effect generated by the heat source heating in a local area can be used to reduce the welding stress at the weld and avoid the influence of a higher temperature field on the part 14 far away from the weld.

[0058] (2) By setting up multiple sets of induction coils with different heating powers, the welding parts 14 are heated and kept warm in sequence according to the welding order, so that the temperature of the welding parts 14 on the same plane is consistent, avoiding stress concentration of different degrees due to different instantaneous temperatures, which helps to improve the yield and service life of aluminum alloy brackets.

[0059] (3) Currently, most bracket welding methods are handheld welding, where an assistant holds the workpiece while the welder performs the welding operation. Because the components are not restrained during welding, the aluminum alloy bracket exhibits significant dimensional deviations after welding. The welding device in this embodiment can restrain the aluminum alloy bracket during welding, effectively reducing dimensional deviations and eliminating the safety hazard of assistant personnel being burned by sparks.

[0060] In the description of this invention, it should be noted that the terms "upper", "lower", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not 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 this invention.

[0061] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0062] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0063] The above embodiments are merely illustrative of the technical concept and features of the present invention, and are preferred embodiments. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly, and they should not be construed as limiting the scope of protection of the present invention. All equivalent transformations or modifications made according to the principles of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A welding device for a photovoltaic-storage integrated machine bracket, used to weld plate-shaped components of the bracket onto a plurality of support rods, characterized in that, The welding apparatus includes: Mounting base; Multiple heating elements are movably disposed relative to the mounting base, each heating element corresponding to one of the welding points of the support rod and the plate-shaped component to heat or keep the welding point warm; A moving mechanism for driving the heating element closer to or away from the welding area, wherein the heating element is mounted on the mounting base via the moving mechanism; Multiple temperature measuring elements, each of which corresponds to one of the welding parts to detect the temperature of that welding part; The controller, which is electrically connected to the plurality of temperature measuring elements, is used to control the heating element to heat the welding area when the temperature of a certain welding area drops to a first set temperature, raise the temperature to a second set temperature and then keep it at that temperature until the welding of other parts to be welded is completed, and then stop keeping it at that temperature. The mounting base includes a base plate and a support frame. The base plate is provided with multiple lower limit members for the insertion of the support rod. The support frame includes a fixed plate and a movable plate. A hydraulic lifting column is provided between the fixed plate and the movable plate. The hydraulic lifting column drives the movable plate to move up and down. The plate-shaped component includes an upper partition plate and a lower partition plate; the movable plate is provided with a plurality of upper limit members, which can move up and down relative to the upper partition plate and are located above the upper partition plate; The welding device further includes a support assembly located between the moving mechanism and the bracket; the support assembly includes a rotating shaft and a support plate integrally formed or fixedly connected to the rotating shaft, a handwheel is provided on one side of the rotating shaft, a ratchet is provided on the other side and a snap-fit ​​component cooperating with the ratchet, and the support plate is located below the upper partition plate; The latching member has a first working state and a second working state. In the first working state, the latching member rotates clockwise and is inserted into the root of the ratchet teeth. In the second working state, the latching member rotates counterclockwise and disengages from the root of the ratchet teeth.

2. The welding apparatus according to claim 1, characterized in that, The bracket is located between the base plate and the support frame.

3. The welding apparatus according to claim 1, characterized in that, The number of upper limit positioners is two; each upper limit positioner has a temperature measuring element on its front and rear sides, and the temperature measuring element includes an infrared temperature measuring camera.

4. The welding apparatus according to claim 1, characterized in that, The moving mechanism includes an X-axis lead screw slide rail, a Y-axis lead screw slide rail, and a Z-axis lead screw slide rail. The X-axis lead screw slide rail is located above the Y-axis lead screw slide rail, and the Z-axis lead screw slide rail is located above the X-axis lead screw slide rail. A heating element is installed on one side of the Z-axis lead screw slide rail.

5. The welding apparatus according to claim 4, characterized in that, The heating element includes a heat-conducting coil; there is one X-axis lead screw slide rail, and two Y-axis and two Z-axis lead screw slide rails.

6. A welding method for a photovoltaic-storage integrated machine bracket, characterized in that, Using the welding apparatus as described in any one of claims 1 to 5, the welding method comprises the following steps: S1. Position the plate-shaped component; S2. Weld each welding part of the plate-shaped component in sequence, and drive the heating element to approach the welding part through the moving mechanism. The temperature measuring element detects the temperature of the welding part. When the temperature of a certain welding part drops to the first set temperature, the controller controls the heating element to heat the welding part, raise its temperature to the second set temperature and then keep it warm until the welding of other parts to be welded is completed, and then stop keeping it warm. S3. After the welded parts have completely cooled down, remove the bracket.

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