A wheel arch steering column welding equipment that requires no additional welding

Abstract

This invention relates to a welding device for wheel arch steering columns that requires no additional welding, belonging to the technical field of welding equipment. It includes an upper electrode, a lower electrode, and a transmission assembly. The transmission assembly moves the upper electrode closer to or away from the lower electrode. Several pressure sensors are disposed on the side of the upper electrode closest to the transmission assembly, and these pressure sensors abut against the transmission assembly. The pressure sensors measure the pressure data experienced by the upper electrode when it presses against the workpiece. The device also includes a control module. The pressure sensors are electrically connected to the control module and upload the pressure data. The control module is electrically connected to both the upper and lower electrodes and controls their operation based on the pressure data. By placing pressure sensors between the upper electrode and the transmission assembly to detect the pressure applied to the workpiece by different parts of the upper electrode, and by using a control module to calculate pressure uniformity based on the pressure data and adjust the electrode's power supply accordingly, the probability of needing additional welding is reduced.

Description

Technical Field

[0001] This invention belongs to the field of welding equipment technology, specifically relating to a wheel arch steering column welding device that eliminates the need for repair welding. Background Technology

[0002] Projection welding is a welding method that mainly involves pre-processing raised dots on the workpieces to be welded, then bringing the two workpieces together using the raised dots and applying current to them, so that the raised dots form a welding nucleus. It relies on the contact of the raised dots to increase the pressure and current density per unit area, which is beneficial for breaking the oxide film on the surface of the plate, concentrating the heat, reducing current shunting, reducing the center distance of the spot weld, and improving the welding effect and welding efficiency.

[0003] In projection welding, sometimes the mechanical weld is not strong enough, requiring manual repair welding after the mechanical weld is completed. To address this, a common improvement method is to use an upper electrode head for projection welding nuts, as disclosed in Chinese Patent CN201659380U. This electrode head body (1) has a cooling water hole (1c) in the middle, a receiving groove (1a) at the bottom of the electrode head body (1), the opening of the receiving groove (1a) being on the bottom surface of the electrode head body (1), and a positioning blind hole (1b) at the bottom of the receiving groove (1a). This method not only provides error prevention but also ensures a reliable projection weld nut, eliminating the need for CO2 shielded welding repair and wire cleaning, thus reducing manual labor. However, in welding... During the process, in addition to insufficient welding effect caused by the electrode not being able to properly engage with the nut to be welded, uneven pressure and uneven welding current flow will occur when the upper and lower electrodes are not parallel, resulting in a deterioration of the welding effect. In the above structure, it fails to determine whether the pressure applied to the workpiece after the upper electrode comes into contact with the workpiece is uniform, and it cannot automatically adjust whether to continue welding based on the pressure uniformity. At the same time, the welding effect is insufficient. Furthermore, when welding different workpieces, the required top pressure is different, and the judgment criteria for uniformity are different. The existing technology fails to adjust the judgment criteria based on the top pressure. Therefore, there is a need for a wheel cover steering column welding equipment that can automatically adjust the welding equipment conditions according to the top pressure of the upper electrode to ensure the welding effect without the need for re-welding. Summary of the Invention

[0004] To address the aforementioned problems in the prior art, this invention provides a wheel arch steering column welding device that eliminates the need for additional welding, featuring the ability to automatically adjust the welding device's operating conditions based on the upper electrode pressure.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] A wheel arch steering column welding device that does not require repair welding includes an upper electrode, a lower electrode, and a transmission assembly. The transmission assembly drives the upper electrode to move closer to or away from the lower electrode. Several pressure sensors are provided on the side of the upper electrode near the transmission assembly. The pressure sensors abut against the transmission assembly. The pressure sensors are used to measure the pressure data that the upper electrode experiences when it presses against the workpiece.

[0007] It also includes a control module, in which several pressure sensors are electrically connected to the control module and upload pressure data. The control module is electrically connected to the upper electrode and the lower electrode and controls the start and stop of the upper electrode and the lower electrode according to several pressure data.

[0008] As a preferred embodiment of the present invention, after receiving several pressure data p, the control module calculates the variance Sp of the pressure data. The control module has a pre-input variance threshold S0. The control module determines whether the variance exceeds the variance threshold S0. When the determination result is yes, the control module de-energizes the upper electrode.

[0009] As a preferred embodiment of the present invention, several pressure sensors are connected to the upper electrode via support rods, and the transmission assembly is provided with top pressure rods corresponding to several support rods. The top pressure rods and support rods are arranged in a one-to-one correspondence, and both the top pressure rods and support rods are made of plastic.

[0010] As a preferred embodiment of the present invention, each of the aforementioned top pressure rods and bearing rods is fitted with a heat insulation sleeve, and the heat insulation sleeve is detachably connected to the corresponding top pressure rod or bearing rod.

[0011] As a preferred embodiment of the present invention, the control module is pre-inputting a pressure data range [A, B]. After receiving several pressure data p, the control module calculates the average value pn of the pressure data. The control module determines whether pn is within the pressure data range. If the determination result is no, the control module de-energizes the upper electrode.

[0012] As a preferred technical solution of the present invention, the control module is pre-inputting a pressure average reference value pn0, the control module calculates a correction coefficient A1 based on pn0 and pn, and the control module determines whether the variance exceeds S0×A1. When the determination result is yes, the control module de-energizes the upper electrode.

[0013] Where, A1 = 1 + pn / pn0.

[0014] As a preferred embodiment of the present invention, it further includes a control panel, which is electrically connected to the control module. The control panel is used to input the values ​​of pn0 and S0 and to instruct the transmission components to move.

[0015] As a preferred embodiment of the present invention, it also includes an alarm, which is electrically connected to the control module. The control module determines whether the variance exceeds the variance threshold S0. When the determination result is yes, the control module instructs the alarm to start.

[0016] The beneficial effects of this invention are as follows:

[0017] (1) By setting a pressure sensor between the upper electrode and the transmission assembly to detect the pressing pressure of each part of the upper electrode on the workpiece, and by setting a control module to calculate the pressure uniformity based on the pressure data, and forcibly de-energizing the electrode when the uniformity is lower than a certain value, the welding is avoided when the electrode fails to press the workpiece evenly and welding is carried out, resulting in poor welding effect of some protrusion welds that need to be repaired.

[0018] (2) By having the control module calculate the average pressure and determine whether the average pressure is within the range, and then deciding whether to continue the welding operation based on the judgment result, the welding operation is avoided if the overall pressure is too high or too low, which would result in poor overall welding effect or damage to the weld point.

[0019] (3) By adjusting the judgment criteria of whether the variance exceeds the threshold based on the overall pressure value, the frequency of cutting off welding operations is reduced when the pressure is relatively high and it is less likely to cause poor welding of the protrusion, thereby improving welding efficiency. When the pressure is low and it is easier to cause poor welding due to loose contact, the judgment criteria are tightened, thus completing the adjustment of the threshold based on the overall pressure. Attached Figure Description

[0020] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0021] Figure 1 This is a schematic diagram of the structure of the present invention;

[0022] Figure 2 This is a front view schematic diagram of the structure of the present invention;

[0023] Figure 3 This is a block diagram of the control loop of the present invention.

[0024] Explanation of key component symbols:

[0025] In the diagram: 1. Upper electrode; 11. Bearing rod; 2. Transmission assembly; 21. Top pressure rod; 22. Connecting column; 3. Lower electrode. Detailed Implementation

[0026] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided.

[0027] Please see Figure 1-3 A wheel arch steering column welding device that requires no additional welding includes an upper electrode 1, a lower electrode 3, and a transmission assembly 2. The transmission assembly 2 drives the upper electrode 1 to move closer to or away from the lower electrode 3. In this embodiment, the lower electrode 3 is fixed on the welding device, and the upper electrode 1 is located above and directly opposite the lower electrode 3. The transmission assembly 2 drives the upper electrode 1 to move closer to or away from the lower electrode 3 in a direction perpendicular to the ground. In use, the part of the workpiece to be welded is placed on the lower electrode 3, and the upper electrode 1 moves closer to the lower electrode 3 and abuts against the workpiece. At this time, the upper electrode 1, the workpiece, and the lower electrode 3 form a complete circuit. When the two electrodes are energized, the current is concentrated on the protrusions pre-processed on the workpiece, making the protrusions a weld point or weld nugget, thus completing the projection welding process.

[0028] In the above process, when several protrusions to be welded need to be welded simultaneously, it is necessary to ensure that the pressure of the upper electrode 1 on each part of the workpiece remains as consistent as possible. Otherwise, the pressure will concentrate on a few protrusions, and some protrusions that are not fully pressed will not be able to tightly bond with the target location under the pressure of the electrode, resulting in insufficient welding effect in this part, requiring subsequent re-welding. To avoid this situation, several pressure sensors are provided on the side of the upper electrode 1 near the transmission component 2. The pressure sensors abut against the transmission component 2 and are used to measure the pressure data of the upper electrode 1 when it presses against the workpiece. In this embodiment, the upper electrode 1 is plate-shaped, and the lower end of the transmission component 2 is provided with a connecting post 22 and is connected to the upper surface of the upper electrode 1 through the connecting post 22. The contact point is located at the center of the upper surface of the plate-shaped upper electrode 1. There are four pressure sensors, which are arranged in a ring array around the connecting post 22 on the upper surface of the upper electrode 1. At the same time, the four pressure sensors abut against the transmission assembly 2. When the transmission assembly 2 presses the upper electrode 1 against the workpiece surface, the workpiece applies a reaction force to the upper electrode 1, causing the upper surface of the upper electrode 1 to press against the transmission assembly 2 in the opposite direction. The stronger the pressing force of a certain part of the upper electrode 1 on the workpiece, the stronger the reaction force applied by the workpiece to the upper electrode 1 and the stronger the pressing force of the upper electrode 1 on the transmission assembly 2. At this time, the pressure sensor located between the upper surface of the upper electrode 1 and the transmission assembly 2 can determine the pressing force of the upper electrode 1 around itself on the workpiece by measuring the pressure it receives.

[0029] Simultaneously, it also includes a control module. Four pressure sensors are electrically connected to the control module and upload pressure data. The control module is electrically connected to the upper electrode 1 and the lower electrode 3 and controls the start and stop of the upper electrode 1 and the lower electrode 3 according to several pressure data. When the control module receives four pressure data, it determines whether the four pressure data are uniform. When the degree of non-uniformity exceeds a certain value, the control module instructs the upper electrode 1 and the lower electrode 3 to be de-energized. In this embodiment, the upper electrode 1 or the lower electrode 3 is connected to the power supply through a switch. The switch is electrically connected to the control module and is turned on and off under the command of the control module. The power-off method is to disconnect the switch.

[0030] Preferably, in this embodiment, the connecting column 22 is a telescopic rod structure that can freely extend and retract within a certain stroke. At this time, the upper electrode 1 and the transmission assembly 2 form a floating connection through the connecting column 22. That is, when the upper electrode 1 is in a natural state without external force, the pressure sensor does not come into contact with the transmission assembly 2. When the transmission assembly 2 presses the upper electrode 1 onto the surface of the workpiece, the transmission assembly 2 continues to descend and squeeze the telescopic rod until it comes into contact with the pressure sensor.

[0031] By setting a pressure sensor between the upper electrode 1 and the transmission assembly 2 to detect the pressing pressure of each part of the upper electrode 1 on the workpiece, and by setting a control module to calculate the pressure uniformity based on the pressure data, and forcibly de-energizing the electrode when the uniformity is lower than a certain value, welding is not performed when the electrode fails to press the workpiece evenly, which would result in poor welding effect of some protrusion welds, thus ensuring the welding effect and eliminating the need for re-welding.

[0032] In the process of pressure uniformity judgment after receiving pressure data, the control module calculates the variance Sp of the pressure data after receiving several pressure data p. The control module has a pre-input variance threshold S0. The control module judges whether the variance exceeds the variance threshold S0. When the judgment result is yes, the control module de-energizes the upper electrode 1 and the lower electrode 3. The larger the variance, the greater the dispersion between the pressure data, the greater the difference in pressure applied to the workpiece by the upper electrode 1 around the four pressure sensors, the greater the inconsistency in the pressure on each protrusion weld point, and the greater the probability of some weld points being poorly welded and needing to be re-welded. When the variance exceeds the variance threshold, it means that the pressure inconsistency will significantly affect the welding quality. It is necessary to check the cause of the pressure inconsistency and reload the material. At this time, the control module commands the electrodes to de-energize to avoid welding when the pressure is not uniform.

[0033] During the welding process, a large current needs to flow through the upper electrode 1. There is a possibility that the current will flow to the pressure sensor and damage it. To avoid this, cylindrical support rods 11 are provided at several locations where pressure sensors are set on the upper electrode 1. Several pressure sensors are set on the upper surface of the support rods 11. At this time, several pressure sensors are connected to the upper electrode 1 through the support rods 11. The support rods 11 are made of plastic. When the current flows through the upper electrode 1 and tends to flow towards the pressure sensor, the insulated support rods 11 prevent the current from flowing to the pressure sensor, thus avoiding damage to the pressure sensor caused by the current from the upper electrode 1.

[0034] Meanwhile, during the welding process, some current may flow to the transmission component 2. When the pressure sensor directly contacts the transmission component 2, this current may also damage the pressure sensor. To address this, the transmission component 2 is equipped with a top pressure rod 21 corresponding to several bearing rods 11. Each top pressure rod 21 corresponds to one bearing rod 11. The top pressure rod 21 is also made of plastic. When the transmission component 2 presses the upper electrode 1 to the surface of the workpiece, the lower surface of the top pressure rod 21 contacts the upper surface of the bearing rod 11. At this time, the pressure sensor is surrounded by the plastic structure, which avoids damage caused by current flowing to the pressure sensor.

[0035] By setting up several support rods 11 and top pressure rods 21, the pressure sensor is surrounded by a plastic structure during operation, thus avoiding damage to the pressure sensor from the welding current during welding.

[0036] The welding process generates heat, which may damage the plastic top pressure rod 21 and the support rod 11. To address this, several top pressure rods 21 and support rods 11 are fitted with heat insulation sleeves. The heat insulation sleeves can be detachably connected to the corresponding top pressure rod 21 or support rod 11. When welding heat is transferred to the vicinity of the top pressure rod 21 and support rod 11, the heat insulation sleeves prevent the heat from being transferred to the top pressure rod 21 and support rod 11, thus reducing the impact of welding heat on the plastic structure.

[0037] During the welding process, in addition to the uniformity of pressure of the upper electrode 1 on the workpiece, the overall pressure also affects the welding effect. When the overall pressure is too low, there is a probability that all the protrusion welds will not be tightly joined. When the overall pressure is too high, there is a probability that the upper electrode 1 will be damaged in the shape of the protrusion. Therefore, in addition to the excessive variance of some pressure values, the welding process also needs to be cut off to check the situation when the overall pressure is too high or too low. For this purpose, the control module is pre-inputted with a pressure data range [A,B]. After receiving several pressure data p, the control module calculates the average value pn of the pressure data. The control module determines whether pn is within the pressure data range. When the determination result is no, the control module de-energizes the upper electrode 1 and the lower electrode 3.

[0038] Specifically, after the control module receives four pressure data points each time, it first determines whether the variance exceeds the threshold. If the result is no, it calculates the mean and determines whether the mean is within the range. If it is too large or too small, the control module instructs the upper electrode 1 and the lower electrode 3 to be de-energized.

[0039] By having the control module calculate the average pressure and determine whether the average pressure is within the range, and then deciding whether to continue welding based on the judgment result, the system avoids situations where the overall pressure is too high or too low, leading to poor overall welding results or damaged weld points.

[0040] When the overall pressure is high, even if the pressure applied to the protrusions in the upper electrode 1 area is relatively small compared to the other protrusions, the tight connection of the protrusions can still be guaranteed. When the overall pressure changes, the criteria for judging whether the pressure is uniform also need to change. In the above structure, the variance threshold is set to a fixed value. When the threshold is too large, the control module may cut off the welding when it could meet the normal welding requirements, resulting in a decrease in welding efficiency. When the threshold is too large, there is a probability that the welding operation cannot be planted in time when the protrusions are not tightly connected, and the adjustment of the working conditions to cut off abnormal welding will not be possible. Therefore, the control module is pre-inputting a pressure average reference value pn0. The control module calculates the correction coefficient A1 based on pn0 and pn. The control module judges whether the variance exceeds S0×A1. When the judgment result is yes, the control module de-energizes the upper electrode 1 and the lower electrode 3, where A1=1+pn / pn0;

[0041] When pn is relatively large compared to pn0, it indicates that the overall pressure is large. Even if the pressure applied to the protrusions in the electrode area is relatively small compared to the other protrusions, the tight connection of the protrusions can still be guaranteed. In this case, the judgment standard for non-uniformity needs to be appropriately relaxed. At this time, the output value of A1 is greater than 1, making the value of A1×S0 used for judgment greater than the value of S0. When the variance is large, it is relatively less likely to exceed A1×S0, thus completing the relaxation of the judgment standard. Similarly, when pn is relatively small compared to pn0, it indicates that the overall pressure is small. The relatively small pressure applied to the electrode area is more likely to cause this part to fail to press the protrusions. The judgment standard for non-uniformity needs to be tightened. At this time, the output value of A1 is less than 1, making the value of A1×S0 used for judgment less than the value of S0. When the variance is large, it is relatively easier to exceed A1×S0, thus completing the tightening of the judgment standard.

[0042] The timing control module adjusts the judgment criteria based on the overall pressure value to determine whether the variance exceeds the threshold. When the pressure is high and it is relatively less likely to cause poor welds, the frequency of cutting off welding operations is reduced to improve welding efficiency. When the pressure is low and it is easier to cause poor welds due to loose contact, the judgment criteria are tightened to complete the adjustment of the threshold according to the overall pressure.

[0043] To facilitate the input of the values ​​of S0 and pn0, a control panel is also included. The control panel is electrically connected to the control module and is used to input the values ​​of pn0 and S0 and to instruct the transmission component 2 to move.

[0044] When the control module disconnects the electrode, without additional reminders, operators cannot determine whether the power outage is due to failure to meet welding standards or a malfunction in the welding equipment. To provide reminders, an alarm is also included. The alarm is electrically connected to the control module. The control module determines whether the variance exceeds the variance threshold S0. If the result is yes, the control module instructs the alarm to start. By setting the alarm, operators can determine whether the current power outage is due to failure to meet welding standards, without having to spend time troubleshooting.

[0045] Working principle and usage process of this invention:

[0046] The part of the workpiece to be welded is placed on the lower electrode 3, and the upper electrode 1 is close to the lower electrode 3 and abuts against the workpiece. At this time, the upper electrode 1, the workpiece and the lower electrode 3 form a complete circuit. The two electrodes are energized, and the current is concentrated on the protrusions pre-processed on the workpiece, so that the protrusions become weld points or weld nuggets, and the projection welding process is completed.

[0047] When the transmission assembly 2 presses the upper electrode 1 onto the surface of the workpiece, the workpiece applies a reaction force to the upper electrode 1, causing the upper surface of the upper electrode 1 to press against the transmission assembly 2 in the opposite direction. The stronger the pressing force of a certain part of the upper electrode 1 on the workpiece, the stronger the reaction force applied by the workpiece to the upper electrode 1 and the stronger the pressing force of the upper electrode 1 on the transmission assembly 2. At this time, the pressure sensor located between the upper surface of the upper electrode 1 and the transmission assembly 2 can determine the pressing force of the upper electrode 1 around itself on the workpiece by measuring the pressure it receives and upload the data to the control module.

[0048] After the control module receives four pressure data points, it determines whether the four pressure data points are uniform. When the degree of non-uniformity exceeds a certain value, the control module instructs the upper electrode 1 and the lower electrode 3 to be de-energized.

[0049] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A welding device for wheel arch steering columns that requires no additional welding, characterized in that: It includes an upper electrode, a lower electrode, and a transmission assembly. The transmission assembly drives the upper electrode to move closer to or away from the lower electrode. Several pressure sensors are provided on the side of the upper electrode near the transmission assembly. The pressure sensors abut against the transmission assembly. The pressure sensors are used to measure the pressure data that the upper electrode experiences when it presses against the workpiece. It also includes a control module, in which several pressure sensors are electrically connected to the control module and upload pressure data. The control module is electrically connected to the upper electrode and the lower electrode and controls the start and stop of the upper electrode and the lower electrode according to several pressure data. The pressure sensors are arranged in a ring array on the upper surface of the upper electrode, around the connecting post. After receiving several pressure data p, the control module calculates the variance Sp of the pressure data. The control module has a pre-input variance threshold S0. The control module determines whether the variance exceeds the variance threshold S0. If the determination result is yes, the control module de-energizes the upper electrode. The control module is pre-inputted with a pressure data range [A,B]. After receiving several pressure data p, the control module calculates the average value pn of the pressure data. The control module determines whether pn is within the pressure data range. If the determination result is no, the control module de-energizes the upper electrode. The control module is pre-inputting a pressure average reference value pn0. The control module calculates a correction coefficient A1 based on pn0 and pn. The control module determines whether the variance exceeds S0×A1. If the determination result is yes, the control module de-energizes the upper electrode. Where A1 = 1 + pn / pn0.

2. The wheel arch steering column welding equipment without the need for repair welding according to claim 1, characterized in that: Several pressure sensors are connected to the upper electrode via support rods. The transmission assembly is provided with top pressure rods corresponding to several support rods. Several top pressure rods are provided in one-to-one correspondence with the support rods. Both the top pressure rods and the support rods are made of plastic.

3. The wheel arch steering column welding equipment without the need for repair welding according to claim 2, characterized in that: Several of the aforementioned top pressure rods and bearing rods are fitted with heat insulation sleeves, and the heat insulation sleeves can be detachably connected to the corresponding top pressure rods or bearing rods.

4. The wheel arch steering column welding equipment without the need for repair welding according to claim 1, characterized in that: It also includes a control panel, which is electrically connected to the control module. The control panel is used to input the values ​​of pn0 and S0 and to instruct the transmission components to move.

5. The wheel arch steering column welding equipment according to claim 1, characterized in that: It also includes an alarm, which is electrically connected to the control module. The control module determines whether the variance exceeds the variance threshold S0. If the determination result is yes, the control module instructs the alarm to start.

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