A welding apparatus and method for a multi-component contact assembly

Abstract

The present application belongs to the technical field of contact assembly welding, and particularly relates to a welding device and a welding method for a multi-component contact assembly. The welding device comprises a welding support tool, a welding pressure head tool and an induction brazing device. The welding support tool comprises a base, and the base is fixed with a support ceramic rod, a first limiting ceramic rod and an arc leading piece support rod. The welding pressure head tool comprises an upper support frame, and the lower end of the upper support frame is fixed with a first upper pressure rod and a second upper pressure rod. The induction brazing device comprises an induction coil, and the induction coil is arranged around the welding part of the multi-component contact assembly. The welding device with a special structure can simultaneously realize the welding of multiple components, solve the influence of the welding of the last welding point on the strength of the previous welding point during step-by-step welding, improve the welding quality and the welding efficiency, and realize large-scale stable production by using the welding process of the present application. The welding process is easy to operate, low in cost, high in welding efficiency and good in welding quality consistency.

Description

Technical Field

[0001] This invention belongs to the field of welding technology for contact assemblies, and specifically relates to a welding device and welding method for a multi-component contact assembly. Background Technology

[0002] As a critical point contact component in a switch, the welding quality of the contact assembly largely determines the service life of the switch. Therefore, improving the welding quality of the contact assembly is the primary issue to address.

[0003] Figure 1 The contact assembly shown is welded from multiple dissimilar material parts, specifically including two arc-starting plates 1, a support 2, and two contacts 3. The support 2 has an upper welding plane 202 and side welding bevels 201 located on both sides of the upper welding plane 202, with their planes forming an obtuse angle with the plane of the upper welding plane 202. The two contacts 3 are welded to both sides of the upper welding plane 202. The arc-starting plates 1 include a bottom support plate 101 and a welding connecting plate 102. The welding connecting plate 102 is welded to the surface of the side welding bevels 201, and a certain included angle is provided between the bottom support plate 101 and the welding connecting plate 102. The arc-starting plates 1 are made of stainless steel, the support 2 is made of copper, and the contacts 3 are made of silver tin oxide. Generally speaking, welding between two dissimilar materials is relatively conventional. However, for the contact assembly made of multiple dissimilar material parts, the current welding method is step-by-step welding, which has low welding efficiency. Furthermore, in step-by-step welding, the strength of the previous weld point is affected by the subsequent weld point, resulting in unstable welding quality. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings and deficiencies of the existing technology and to provide a welding device and welding method for a multi-component contact assembly.

[0005] The technical solution adopted by the present invention is as follows: a welding device for a multi-component contact assembly, wherein the multi-component contact assembly includes two arc-starting plates, a bracket, and two contacts;

[0006] The bracket has an upper welding plane and side welding slopes located on both sides of the upper welding plane along the second direction, with the planes of the slopes forming an obtuse angle with the plane of the upper welding plane. Two contact points are welded to both sides of the upper welding plane along the second direction. The arc-starting plate includes a bottom support plate and a welding connecting plate. The welding connecting plate is welded to the surface of the side welding slopes. A certain included angle is provided between the bottom support plate and the welding connecting plate.

[0007] The welding apparatus includes:

[0008] The welding support fixture includes a base, on which a support ceramic rod, a first limiting ceramic rod, and an arc-starting plate support rod are fixed;

[0009] Among them, the supporting ceramic rod is used to support the bottom of the bracket;

[0010] The first limiting ceramic rod is provided in two sets, and the two sets of first limiting ceramic rods are respectively located on both sides of the supporting ceramic rod along the first direction. The height of the first limiting ceramic rod relative to the base is greater than the height of the supporting ceramic rod relative to the base, and the spacing between the two sets of first limiting ceramic rods is adapted to the width of the bracket. The first limiting ceramic rod is used to limit the two sides of the bracket along the first direction.

[0011] Among them, there are two arc-inducing plate support rods, and the two arc-inducing plate support rods are respectively located on both sides of the supporting ceramic rod along the second direction. The arc-inducing plate support rods are used to support the bottom of the bottom support plate.

[0012] The welding pressure head fixture includes an upper support frame, and a first upper pressure rod and a second upper pressure rod are fixed at the lower end of the upper support frame;

[0013] The first upper pressure rod is used to apply downward pressure to the upper surface of the contact point;

[0014] The second upper pressure bar has a lower pressure slope corresponding to the side welding slope, and the second upper pressure bar is used to exert a downward pressure on the upper surface of the welding connection plate through the lower pressure slope;

[0015] The welding pressure head fixture and the welding support fixture are arranged vertically, and the welding pressure head fixture can move vertically relative to the welding support fixture.

[0016] An induction brazing apparatus includes an induction coil arranged around the welding area of ​​a multi-component contact assembly.

[0017] Furthermore, the outer end of the bottom support plate has two bevels, and two second limiting ceramic rods are fixed on one of the arc-guiding plate support rods. The upper end face of the second limiting ceramic rod protrudes relative to the upper end face of the arc-guiding plate support rod, and the second limiting ceramic rod is used to limit the two bevels of the bottom support plate.

[0018] Furthermore, the arc-starting plate support rod is provided with a limiting hole groove for the second limiting ceramic rod to extend into, and the second limiting ceramic rod is connected to the arc-starting plate support rod by being inserted into the limiting hole groove.

[0019] Furthermore, both the first and second upper pressure rods can slide up and down and be connected to the upper support frame, and springs are provided between the first and second upper pressure rods and the upper support frame, the springs being used to generate downward pressing force.

[0020] A welding method for welding the multi-component contact assembly using the welding apparatus described above includes the following steps:

[0021] 1. Assemble the parts to be welded on the welding support fixture, in the following specific order:

[0022] (a) Place the bracket to be welded on the support ceramic rod, and its position is fixed by the limiting ceramic rod. During assembly, it is necessary to confirm that the lower surface of the bracket is flush with the upper surface of the support ceramic rod and the side is in contact with the first limiting ceramic rod.

[0023] (b) Apply flux evenly to the side welding bevel of the bracket, place the arc-starting piece to be welded on the arc-starting piece support rod, and make the bottom support plate completely fit the top surface of the arc-starting piece support rod. The welding connection plate is completely fitted with the side welding bevel of the bracket.

[0024] (c) Apply flux evenly to the contact welding area of ​​the bracket;

[0025] (d) Place the silver-based solder on the contact soldering area of ​​the support that has been coated with flux;

[0026] (e) Apply flux evenly to the soldering surface of the contact and place the contact on the contact soldering area of ​​the bracket;

[0027] 2. The welding head fixture presses down to fix the arc-starting plate and contacts, and the induction brazing equipment works to weld the induction coil product.

[0028] Furthermore, the silver-based brazing filler metal is made of BAgCuZn solder sheet with dimensions of 5mm×6mm×0.1mm.

[0029] Furthermore, the flux is prepared by boiling silver solder and water in a volume ratio of 3:2 to form a paste.

[0030] Furthermore, the side end face of the contact is in contact with the upper end face of the welding connection plate, so that the molten silver-based brazing filler metal between the contact and the bracket can penetrate into the side welding slope between the welding connection plate and the bracket through capillary action.

[0031] Furthermore, the induction brazing equipment adopts high-precision, high-frequency induction brazing equipment with a power of 50-80kW.

[0032] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0033] This invention employs a specially structured welding device that can simultaneously weld multiple components, resolving the impact of subsequent welds on the strength of previous welds during step-by-step welding. This improves both welding quality and efficiency. Welding using this invention's process allows for stable, large-scale production; it is easy to operate, low-cost, highly efficient, and produces consistent weld quality. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, obtaining other drawings based on these drawings without creative effort still falls within the scope of the present invention.

[0035] Figure 1 A perspective view (a) and an exploded view (b) of a welding apparatus for a multi-component contact assembly;

[0036] Figure 2 This is a structural schematic diagram of the welding pressure head tooling;

[0037] Figure 3 This is a structural schematic diagram of the welding support fixture;

[0038] Figure 4 A perspective view of a multi-component contact assembly being welded using welding fixtures;

[0039] Figure 5 A front view of a multi-component contact assembly being welded using welding fixtures;

[0040] Figure 6 The results of the brazing rate test for the multi-component contact assembly obtained by welding according to the present invention;

[0041] Figure 7 The shear surface morphology of the multi-component contact assembly obtained by welding according to the present invention;

[0042] Figure 8 The shear force results of the multi-component contact assembly obtained by welding according to the present invention;

[0043] In the figure, 1 is the arc-initiating plate; 101 is the bottom support plate; 1011 is the inclined side; 102 is the welding connection plate; 2 is the bracket; 201 is the side welding inclined surface; 202 is the upper welding plane; 3 is the contact point; 4 is the base; 5 is the supporting ceramic rod; 6 is the first limiting ceramic rod; 7 is the second limiting ceramic rod; 8 is the arc-initiating plate support rod; 9 is the induction coil; 10 is the first upper pressure rod; 11 is the second upper pressure rod; 1101 is the lower pressure inclined surface; 12 is the spring; 13 is the upper support frame; and 14 is the arc-initiating plate limiting rod. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings.

[0045] A welding device for a multi-component contact assembly.

[0046] like Figure 1 As shown, the multi-component contact assembly includes two arc-inducing plates 1, a bracket 2, and two contacts 3;

[0047] The bracket 2 has an upper welding plane 202 and side welding slopes 201 located on both sides of the upper welding plane 202 along the second direction, with their planes forming an obtuse angle with the plane of the upper welding plane 202. Two contacts 3 are welded to both sides of the upper welding plane 202 along the second direction. The arc-starting plate 1 includes a bottom support plate 101 and a welding connecting plate 102. The welding connecting plate 102 is welded to the surface of the side welding slope 201. A certain angle is provided between the bottom support plate 101 and the welding connecting plate 102. The arc-starting plate 1 is made of stainless steel, the bracket 2 is made of copper, and the contacts 3 are made of silver tin oxide. The welding device in this embodiment specifically achieves welding between the lower end face of the contacts 3 and the upper welding plane 202 and between the side welding slope 201 and the welding connecting plate 102 through one-step welding. This involves welding between silver tin oxide and copper, and welding between stainless steel and copper.

[0048] Specifically, such as Figure 2-5 As shown, the welding apparatus includes:

[0049] Welding support fixtures, such as Figure 3 As shown, it includes a base 4, on which a supporting ceramic rod 5, a first limiting ceramic rod 6, and an arc-inducing plate support rod 8 are fixed.

[0050] Among them, the supporting ceramic rod 5 is used to support the bottom of the bracket 2. There are at least two supporting ceramic rods 5, and the specific number is set according to the length of the bracket 2. The height of each supporting ceramic rod 5 should be the same to stably support the copper bracket. The height setting can avoid the coil heating the base during welding.

[0051] The first limiting ceramic rod 6 is provided in two sets, and the two sets of first limiting ceramic rod 6 are respectively located on both sides of the supporting ceramic rod 5 along the first direction. The height of the first limiting ceramic rod 6 relative to the base 4 is greater than the height of the supporting ceramic rod 5 relative to the base 4, and the distance between the two sets of first limiting ceramic rod 6 is adapted to the width of the bracket 2. The first limiting ceramic rod 6 is used to limit the two sides of the bracket 2 along the first direction. In this embodiment, the first limiting ceramic rod 6 is a cylindrical ceramic rod with a diameter of φ10mm, which is used to prevent the bracket 2 from shifting after being placed on the supporting ceramic rod 5.

[0052] Among them, there are two arc-inducing plate support rods 8, and the two arc-inducing plate support rods 8 are respectively located on both sides of the supporting ceramic rod 5 along the second direction. The arc-inducing plate support rods 8 are used to support the bottom of the bottom support plate 101.

[0053] Welding pressure head tooling, such as Figure 2 As shown, it includes an upper support frame 13, and a first upper pressure rod 10 and a second upper pressure rod 11 are fixed at the lower end of the upper support frame 13;

[0054] The first upper pressure rod 10 is used to exert a downward pressure on the upper surface of the contact point 3;

[0055] The second upper pressure rod 11 has a lower pressure slope 1101 corresponding to the side welding slope 201. The second upper pressure rod 11 is used to exert a downward pressure on the upper surface of the welding connection plate 102 through the lower pressure slope 1101.

[0056] like Figure 4-5 As shown, the welding pressure head fixture and the welding support fixture are arranged vertically, and the welding pressure head fixture can move vertically relative to the welding support fixture.

[0057] An induction brazing device includes an induction coil 9, which is arranged around the welding area of ​​a multi-component contact assembly.

[0058] Specifically, such as Figure 1 As shown in (b), the outer end of the bottom support plate 101 has two inclined sides 1011, as follows: Figure 4 As shown, two second limiting ceramic rods 7 are fixed on an arc-starting plate support rod 8. The upper end face of the second limiting ceramic rod 7 protrudes relative to the upper end face of the arc-starting plate support rod 8. The second limiting ceramic rod 7 is used to limit the two inclined sides 1011 of the bottom support plate 101. In this embodiment, the second limiting ceramic rod 7 is a cylindrical ceramic rod with a diameter of φ4mm. The second limiting ceramic rod 7 limits the two inclined sides 1011 of the bottom support plate 101, and can simultaneously position the arc-starting plate 1 in the first direction and the second direction, ensuring that the side welding inclined surface 201 and the welding connecting plate 102 maintain a completely fitted relationship to ensure the post-weld dimensions.

[0059] Specifically, the arc-starting plate support rod 8 is provided with a limiting hole groove for the second limiting ceramic rod 7 to extend into, and the second limiting ceramic rod 7 is connected to the arc-starting plate support rod 8 by being inserted into the limiting hole groove.

[0060] Both the first upper pressure rod 10 and the second upper pressure rod 11 can slide up and down and be connected to the upper support frame 13. Springs 12 are provided between the first upper pressure rod 10 and the second upper pressure rod 11 and the upper support frame 13. The springs 12 are used to generate downward pressing force.

[0061] This embodiment further provides a welding method for welding the multi-component contact assembly using the welding device described above, including the following steps:

[0062] 1. Assemble the parts to be welded on the welding support fixture, in the following specific order:

[0063] (a) Place the bracket 2 to be welded on the support ceramic rod 5. Its position is fixed by the limiting ceramic rod 5. During assembly, it is necessary to confirm that the lower surface of the bracket 2 is flush with the upper surface of the support ceramic rod 5 and the side is in contact with the first limiting ceramic rod 6.

[0064] (b) Apply flux evenly to the side welding slope 201 of the bracket 2, place the arc-starting piece 1 to be welded on the arc-starting piece support rod 8, and make the bottom support plate 101 completely fit the top surface of the arc-starting piece support rod 8. The welding connection plate 102 is completely fitted with the side welding slope 201 of the bracket 2.

[0065] (c) Apply flux evenly to the contact welding area of ​​bracket 2;

[0066] (d) Place the silver-based solder on the contact soldering area of ​​the support 2, which has been coated with flux;

[0067] (e) Apply flux evenly to the welding surface of contact 3 and place contact 3 on the contact welding area of ​​bracket 2;

[0068] 2. The welding head fixture presses down to fix the arc-starting plate 1 and contact 3, and the induction brazing equipment works to make the induction coil 9 product welded.

[0069] Specifically, the silver-based brazing filler metal is a BAg56CuZn solder sheet with dimensions of 5mm × 6mm × 0.1mm.

[0070] Specifically, the flux is prepared by boiling silver solder and water in a volume ratio of 3:2 to form a paste.

[0071] Specifically, the side end face of the contact 3 is in contact with the upper end face of the welding connection plate 102, allowing the molten silver-based brazing filler metal between the contact 3 and the bracket 2 to penetrate through capillary action between the welding connection plate 102 and the side welding slope 201 of the bracket 2. This embodiment fully utilizes... Figure 1 The multi-component contact assembly shown has its own structural features. Only the silver-based brazing filler metal is placed between the contact 3 and the support 2. The capillary effect is used to allow the silver-based brazing filler metal that melts between the contact 3 and the support 2 to penetrate into the side welding slope 201 between the welding connection plate 102 and the support 2, and to weld the arc-starting piece 1 to the support 2, which can avoid overflow.

[0072] Specifically, the induction brazing equipment uses high-precision, high-frequency induction brazing equipment with a power of 50-80kW.

[0073] like Figure 6-8As shown, the welding method of the present invention can realize the one-time welding of three different materials of multi-component contact assembly, including two stainless steel arc-starting plates, a copper bracket, and two silver tin oxide contacts. The operation is simple, the welding quality is high (brazing rate is greater than 85%, residual area is greater than 80%), and the dimensional consistency is good. The welding yield of the contact assembly welded by this embodiment is 100%.

[0074] The above description discloses only preferred embodiments of the present invention and should not be construed as limiting the scope of the present invention. Therefore, equivalent variations made in accordance with the claims of the present invention are still within the scope of the present invention.

Claims

1. A welding apparatus for a multi-component contact assembly, the multi-component contact assembly comprising two arc-starting plates (1), a bracket (2), and two contacts (3); The bracket (2) has an upper welding plane (202) and side welding slopes (201) located on both sides of the upper welding plane (202) along the second direction, and the planes thereon form an obtuse angle with the planes of the upper welding plane (202). Two contact points (3) are welded to both sides of the upper welding plane (202) along the second direction. The arc-starting plate (1) includes a bottom support plate (101) and a welding connecting plate (102). The welding connecting plate (102) is welded to the surface of the side welding slope (201). A certain angle is provided between the bottom support plate (101) and the welding connecting plate (102). Its features are, The welding apparatus includes: The welding support fixture includes a base (4), on which a support ceramic rod (5), a first limiting ceramic rod (6), and an arc-starting plate support rod (8) are fixed. Among them, the supporting ceramic rod (5) is used to support the bottom of the bracket (2); Among them, the first limiting ceramic rod (6) is provided in two sets and the two sets of first limiting ceramic rods (6) are respectively located on both sides of the supporting ceramic rod (5) along the first direction. The height of the first limiting ceramic rod (6) relative to the base (4) is greater than the height of the supporting ceramic rod (5) relative to the base (4), and the distance between the two sets of first limiting ceramic rods (6) is adapted to the width of the bracket (2). The first limiting ceramic rod (6) is used to limit the two sides of the bracket (2) along the first direction. Among them, there are two arc-starting plate support rods (8), and the two arc-starting plate support rods (8) are respectively located on both sides of the supporting ceramic rod (5) along the second direction. The arc-starting plate support rods (8) are used to support the bottom of the bottom support plate (101). The welding pressure head fixture includes an upper support frame (13), and a first upper pressure rod (10) and a second upper pressure rod (11) are fixed at the lower end of the upper support frame (13). The first upper pressure rod (10) is used to exert a downward pressure on the upper surface of the contact point (3); The second upper pressure bar (11) has a lower pressure slope (1101) corresponding to the side welding slope (201), and the second upper pressure bar (11) is used to exert a downward pressure on the upper surface of the welded connecting plate (102) through the lower pressure slope (1101); The welding pressure head fixture and the welding support fixture are arranged vertically, and the welding pressure head fixture can move vertically relative to the welding support fixture. An induction brazing apparatus includes an induction coil (9) arranged around the welding area of ​​a multi-component contact assembly.

2. The welding apparatus for a multi-component contact assembly according to claim 1, characterized in that: The bottom support plate (101) has two inclined sides (1011) at its outer end. Two second limiting ceramic rods (7) are fixed on one of the arc-guiding plate support rods (8). The upper end face of the second limiting ceramic rod (7) protrudes relative to the upper end face of the arc-guiding plate support rod (8). The second limiting ceramic rod (7) is used to limit the two inclined sides (1011) of the bottom support plate (101).

3. The welding apparatus for a multi-component contact assembly according to claim 2, characterized in that: The arc-starting plate support rod (8) is provided with a limiting hole groove for the second limiting ceramic rod (7) to extend into. The second limiting ceramic rod (7) is connected to the arc-starting plate support rod (8) by being inserted into the limiting hole groove.

4. The welding apparatus for a multi-component contact assembly according to claim 1, characterized in that: The first upper pressure rod (10) and the second upper pressure rod (11) can slide up and down and be connected to the upper support frame (13). A spring (12) is provided between the first upper pressure rod (10) and the second upper pressure rod (11) and the upper support frame (13). The spring (12) is used to generate a downward pressing force.

5. A welding method for welding the multi-component contact assembly using the welding apparatus as described in any one of claims 1-4, characterized in that, Includes the following steps:

1. Assemble the parts to be welded on the welding support fixture, in the following specific order: (a) Place the bracket (2) to be welded on the support ceramic rod (5), and its position is fixed by the limiting ceramic rod (5). During assembly, it is necessary to confirm that the lower surface of the bracket (2) is flush with the upper surface of the support ceramic rod (5) and the side is in contact with the first limiting ceramic rod (6). (b) Apply flux evenly to the side welding slope (201) of the bracket (2), place the arc-starting piece (1) to be welded on the arc-starting piece support rod (8), the bottom support plate (101) is completely attached to the top surface of the arc-starting piece support rod (8), and the welding connection plate (102) is completely attached to the side welding slope (201) of the bracket (2); (c) Apply flux evenly to the contact welding area of ​​the bracket (2); (d) Place the silver-based solder on the contact soldering area of ​​the support (2) that has been coated with flux; (e) Apply flux evenly to the welding surface of the contact (3) and place the contact (3) on the contact welding area of ​​the bracket (2); 2. The welding head fixture presses down to fix the arc-starting plate (1) and the contact (3), and the induction brazing equipment works to make the induction coil (9) product welded.

6. The welding method according to claim 5, characterized in that: The silver-based brazing filler metal is made of BAg56CuZn solder sheet, with dimensions of 5mm×6mm×0.1mm.

7. The welding method according to claim 5, characterized in that: The flux is prepared by boiling silver solder and water in a volume ratio of 3:2 to form a paste.

8. The welding method according to claim 5, characterized in that: The side end face of the contact (3) is in contact with the upper end face of the welding connection plate (102), so that the silver-based brazing filler metal melted between the contact (3) and the bracket (2) can penetrate between the side welding slope (201) of the welding connection plate (102) and the bracket (2) through capillary action.

9. The welding method according to claim 5, characterized in that: The induction brazing equipment uses high-precision, high-frequency induction brazing technology with a power of 50-80kW.

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