Continuous high-stability high-speed ultrasonic welding automatic production line

Abstract

The application discloses a continuous high-stability high-speed ultrasonic welding automatic production line, which comprises a feeding conveying section, a rolling welding section and a discharging conveying section, the feeding conveying section is connected with the feeding end of the rolling welding section, and the discharging end of the rolling welding section is connected with the discharging conveying section; the rolling welding section comprises a welding conveying belt and a rolling welding mechanism, the rolling welding mechanism is installed on one side of the welding conveying belt, and the welding unit in the ultrasonic rolling welding mechanism is used for rolling welding of a workpiece to be welded on the welding conveying belt in conveying. The application has the advantages of improving the welding effect consistency and stability of the workpiece, and improving the production capacity and efficiency.

Description

A continuous, high-stability, high-speed automated ultrasonic welding production line Technical Field

[0001] This invention relates to the field of ultrasonic welding production line technology, specifically to a continuous, high-stability, high-speed automatic ultrasonic welding production line. Background Technology

[0002] With the rapid development of the new energy vehicle and electric bicycle market, lithium batteries, as a high-performance, high-energy-density power source, have become an indispensable part of the electric vehicle field. In the manufacturing process of lithium batteries, welding is a crucial step.

[0003] In existing technologies, lithium battery welding processes generally employ either resistance welding or laser welding. Resistance welding requires thorough cleaning of the welding surfaces to remove oxides and dirt; then, the welding parts are clamped in electrode clamps, and the electrodes are heated to their melting point by a heating coil within the clamps, while pressure is applied simultaneously to fuse them together; finally, cooling is performed. This process is complex, energy-intensive, and inefficient. Laser welding utilizes high-frequency pulses to apply a momentary high-temperature, high-pressure current to the surfaces of the electrodes to be welded, causing them to rapidly melt and form a strong connection. Laser welding offers advantages such as a simple process flow, high precision, high welding quality, and high efficiency, making it the current mainstream process. However, laser welding also has drawbacks, including high social security costs and higher overall operating costs.

[0004] Ultrasonic welding utilizes ultrasonic vibrations and the heat they generate to perform welding. The ultrasonic vibrations expel air between the metal surface and the substrate, forming a weld joint. Ultrasonic welding is relatively flexible, allowing for the tight bonding of two different material structures. The power of ultrasonic welding is low, minimizing its impact on batteries, making it commonly used in the production of battery modules and general batteries. While current ultrasonic welding processes are generally low-cost, they are slower and less efficient than laser welding, resulting in lower production line capacity and thus limiting their application.

[0005] Chinese invention patent application CN 114226945A discloses an ultrasonic welding apparatus and a continuous welding method. The ultrasonic welding apparatus includes a material transport component, two or more rolling welding machine components, and at least one bottom roller. The material transport component transports material to two or more welding stations, and the material has a width direction. The two or more rolling welding machine components are arranged sequentially in the material transport direction, each rolling welding machine component including a welding head, and the two or more welding heads are staggered along the width direction. At least one bottom roller is rotatably disposed in the ultrasonic welding apparatus, defining a welding station between the bottom roller and the welding head. This ultrasonic welding apparatus and continuous welding method can improve the welding efficiency for materials with a large width.

[0006] Chinese invention patent CN 216528958 U discloses an integrated composite material roll welding device, comprising a composite material unwinding mechanism, an upper foil unwinding mechanism, a lower foil unwinding mechanism, an unwinding and correction assembly, a roll welding machine, a rewinding and correction mechanism, an active drive mechanism, and a rewinding mechanism. The upper foil output from the upper foil unwinding mechanism, the composite material output from the composite material unwinding mechanism, and the lower foil output from the lower foil unwinding mechanism are aligned and corrected by the unwinding and correction assembly. The aligned three materials are then rolled and welded by the roll welding machine. The welded materials are then corrected by the rewinding and correction mechanism, which rewinds the welded materials. Tension control mechanisms and speed control mechanisms are respectively provided between the composite material unwinding mechanism and the unwinding and correction assembly, between the upper foil unwinding mechanism and the unwinding and correction assembly, and between the lower foil unwinding mechanism and the unwinding and correction assembly. This invention has a compact structure, which helps to ensure welding quality and improve welding speed.

[0007] In existing technologies, ultrasonic welding is generally used in the pre-welding and final welding processes of power batteries. However, the capacity of existing ultrasonic pre-welding equipment at pre-welding and final welding stations is relatively low, typically 12-15 PPM per minute. Production lines with more pre-welding and final welding stations can achieve a maximum of 20-30 PPM per minute, resulting in slow welding speed and low efficiency. The main reason is that existing ultrasonic pre-welding and final welding production lines use spot welding. Due to the limited welding area, ultrasonic spot welding typically employs a single-sided multi-welding-point process or a single-sided multi-station approach to meet the demands of large-capacity, large-area welding processes. This results in slow welding speed and low efficiency, severely impacting the production line's capacity.

[0008] In summary, although the existing technologies mentioned above use rolling welding to replace spot welding to improve welding efficiency, the existing production lines stop when welding the next point, and cannot achieve the same continuous welding speed. Therefore, the corresponding production lines have shortcomings such as low overall working efficiency, limited welding to a single product, and difficulty in expanding production capacity. Summary of the Invention

[0009] The purpose of this invention is to address the shortcomings of the existing technology described above by providing a continuous, high-stability, high-speed automatic ultrasonic welding production line. This line improves the consistency and stability of ultrasonic welding of workpieces, greatly increases the welding capacity of the production line per unit time, and expands the types of products that can be welded by the production line.

[0010] The technical solution adopted by this invention to solve its technical problem is as follows: a continuous, high-stability, high-speed ultrasonic welding automatic production line, including a feeding conveying section, a rolling welding section, and an output conveying section. The feeding conveying section is connected to the feeding end of the rolling welding section, and the output end of the rolling welding section is connected to the output conveying section. The rolling welding section includes a welding conveyor belt and a rolling welding mechanism. The rolling welding mechanism is installed on one side of the welding conveyor belt, and the welding unit in the ultrasonic rolling welding mechanism is used to quickly roll and weld the workpiece (battery cell) to be welded on the welding conveyor belt during transportation.

[0011] The feeding conveying section includes a feeding robotic arm and a feeding conveyor belt. The feeding robotic arm is installed at the beginning of the feeding conveyor belt, and the end of the feeding conveyor belt is connected to the feeding end of the rolling welding section. The discharging conveying section includes a feeding robotic arm and a discharging conveyor belt. The feeding robotic arm is installed at the end of the discharging conveyor belt, and the beginning of the discharging conveyor belt is connected to the discharging end of the rolling welding section.

[0012] The rolling welding section also includes a housing, through which the welding conveyor belt passes. The ultrasonic rolling welding mechanism is respectively installed on opposite sides of the welding conveyor belt, or two sets of the ultrasonic rolling welding mechanism are installed on the same side of the welding conveyor belt.

[0013] Preferably, the rolling welding mechanism is provided in three sets, with two sets located on the same side of the welding conveyor belt and the other set located on the other side of the welding conveyor belt.

[0014] Preferably, the feeding and conveying section further includes a shaping and guiding device that is matched with the ultrasonic rolling welding mechanism. The shaping and guiding device is disposed on the side of the welding conveyor belt inside the box, the ultrasonic rolling welding mechanism is mounted on the base, and the welding unit is placed in the welding area of ​​the shaping and guiding device.

[0015] A conveying auxiliary mechanism is provided above the welding conveyor belt. The conveying auxiliary mechanism includes a drive motor set, a rotating belt pressing mechanism, a support frame, a mounting plate, pressure rollers, belt tensioning rollers, and a power synchronization roller. The support frame is installed on the lower part of the mounting plate, and belt tensioning rollers are respectively provided at both ends of the support frame. The power synchronization roller is installed at one end of the support frame, and a driven synchronization roller is provided at the other end of the support frame. Several pressure rollers are installed on pressure roller brackets at the bottom of the support frame. The rotating belt pressing mechanism is installed in the belt grooves of the belt tensioning roller, the power synchronization roller, the driven synchronization roller, and the pressure rollers. The power synchronization roller is fixed on a rotating shaft, and the rotating shaft is connected to the output shaft of the drive motor set.

[0016] The belt tensioning wheel is mounted on an adjustable frame, one end of which is fixed to a support frame. An adjustment groove is provided on the adjustable frame, and the belt tensioning wheel is mounted on a support shaft placed in the adjustment groove.

[0017] An adjustment device and a height adjustment device are provided between the support frame and the mounting plate.

[0018] The ultrasonic rolling welding mechanism includes a welding unit, which includes a first rolling welding mold (active roller) and a second rolling welding mold (driven roller) that cooperate with each other. The first rolling welding mold and the second rolling welding mold are located in the welding area of ​​the shaping and guiding device. The electrodes of the battery that have been clamped and shaped by the shaping and guiding device are rolled and welded in the welding area, which can effectively improve the welding efficiency and yield.

[0019] The ultrasonic rolling welding mechanism includes a welding unit, which includes a first rolling welding mold and a second rolling welding mold that cooperate with each other. The first rolling welding mold and the second rolling welding mold are located in the welding area of ​​the shaping and guiding device. The electrodes of the battery that have been clamped and shaped by the shaping and guiding device are rolled and welded in the welding area, which can effectively improve the welding efficiency and yield.

[0020] The shaping and guiding device includes a support plate, a first pressure band guiding unit, and a second pressure band guiding unit. A window is provided in the middle of the support plate to serve as a welding area for installing welding units. The first pressure band guiding unit and the second pressure band guiding unit are installed on the same side of the support plate. The guiding pressure bands of the first pressure band guiding unit and the second pressure band guiding unit move in opposite directions and are in surface contact with a certain pressure.

[0021] The first belt guiding unit includes a guiding belt, a tensioning pulley, an idler pulley, and a first pressing pulley. Two idler pulleys are provided, located on the upper sides of the first pressing pulley. The tensioning pulley is located above the first pressing pulley. The guiding belt is installed in the belt mounting grooves of the tensioning pulley, idler pulley, and first pressing pulley. The second belt guiding unit includes a guiding belt, a tensioning pulley, an idler pulley, and a second pressing pulley. Two idler pulleys are provided, located on the lower sides of the second pressing pulley. The tensioning pulley is located below the second pressing pulley. The guiding belt is installed in the belt mounting grooves of the tensioning pulley, idler pulley, and second pressing pulley. The first and second belt guiding units are arranged vertically and mutually supportive on the support plate, with the first pressing pulley contacting the second pressing pulley.

[0022] The tensioning wheel is mounted on a first adjustable base fixed on the support plate to adjust the position of the tensioning wheel, thereby adjusting the tension of the guide belt.

[0023] The inlet pressure band consists of a first pressure band and a second pressure band, wherein the second pressure band is located on the inner side near the support plate, and the second pressure band is wider than the first pressure band.

[0024] The width of the first pressure strip is 1-5mm, the width of the second pressure strip is 8-20mm, and the welding gap reserved between the first pressure strip and the second pressure strip is 2-8mm.

[0025] The first and second ultrasonic welding molds, which are matched with each other in the welding unit, are located on the upper and lower sides of the guide pressure belt, respectively, and the welding point is located in the welding gap reserved between the first and second pressure belts. This enables the two ultrasonic welding molds to perform ultrasonic welding from both the upper and lower sides at the same time, resulting in a more reliable and highly efficient welding process.

[0026] A shaping belt is provided between the pressure roller unit and the idler wheel at both ends. The shaping belt is located in the belt groove in the middle of the first pressure roller and the second pressure roller in the pressure roller unit. The shaping belt fills the welding gap reserved between the first pressure belt and the second pressure belt.

[0027] The first clamping wheel and the corresponding second clamping wheel form a clamping wheel unit. The clamping wheel unit includes a fixed carrier plate, a bearing seat, a first clamping wheel, a second clamping wheel, a first power synchronous wheel, and a second power synchronous wheel. The fixed carrier plate is provided with a mounting groove, and the two bearing seats are respectively installed in the mounting groove. The first clamping wheel and the first power synchronous wheel are respectively installed at both ends of the rotating shaft passing through the bearing seat, located on both sides of the fixed carrier plate.

[0028] Compared with existing technologies, the beneficial effects of this invention are: it solves the problems of slow production speed and low capacity of existing production lines, achieving a production speed of 60 PPM or more per minute, greatly increasing the capacity of a single production line; it adopts a continuous working mode, realizing continuous and uninterrupted production; it uses an upper and lower double rolling double ultrasonic welding method to solve the problem of unstable welding quality, improving the consistency and stability of welding effect while increasing speed; and it adopts an online assembly line working mode, reducing waiting time and improving production efficiency, thereby achieving the maximum capacity layout of a single production line. Attached Figure Description

[0029] Figure 1 is a perspective view of a continuous, high-stability, high-speed ultrasonic welding automatic production line according to the present invention.

[0030] Figure 2 is a perspective view of a continuous, high-stability, high-speed ultrasonic welding automatic production line according to the present invention.

[0031] Figure 3 is a perspective view of a continuous, high-stability, high-speed ultrasonic welding automatic production line according to the present invention.

[0032] Figure 4-6 is a three-dimensional structural diagram of the rolling welding section;

[0033] Figure 7 is a three-dimensional structural diagram of the conveying auxiliary mechanism;

[0034] Figure 8-13 is a structural diagram of the shaping and guiding device;

[0035] Figures 14-15 are structural diagrams of the pressure wheel unit;

[0036] Figure 16 is a three-dimensional structural diagram of the rolling welding section. Detailed Implementation

[0037] The technical solution of the present invention will be clearly and completely described below with reference to embodiments. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0038] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; and they may 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.

[0039] A continuous, high-stability, high-speed ultrasonic welding automated production line, as shown in Figures 1-3, includes a feeding conveying section, a rolling welding section 5, and an output conveying section. The feeding conveying section is connected to the feeding end of the rolling welding section, and the output end of the rolling welding section is connected to the output conveying section. The feeding conveying section includes a loading robotic arm 3 and a feeding conveyor belt 2. The loading robotic arm 3 is installed at the beginning of the feeding conveyor belt. The workpieces 8 (battery cells) to be welded are conveyed within the working range of the loading robotic arm 3 via a feeding device 1. The mechanical gripper on the loading robotic arm 3 can automatically grab the workpieces 8 to be welded from the feeding device 1 and place them on the loading bin of the feeding conveyor belt 2, which then transports them to the feeding end of the rolling welding section 5 and transfers them to the loading bin of the welding conveyor belt of the rolling welding section 5.

[0040] Preferably, a first rotary conveyor robot 4 can be installed between the feeding conveyor belt 2 and the feeding end of the rolling welding section 5. The first rotary conveyor robot 4 is equipped with suction cups, which adsorb the workpiece 8 to be welded and transport it to the loading bin of the welding conveyor belt at the feeding end of the rolling welding section 5.

[0041] The discharge conveying section includes a loading robotic arm 3 and a discharge conveyor belt 7. The loading robotic arm 3 is installed at the end of the discharge conveyor belt 7. The beginning of the discharge conveyor belt 7 is connected to the discharge end of the rolling welding section 5. The end of the welding conveyor belt of the rolling welding section 5 transfers the welded workpiece to the discharge conveyor belt 7, and then the discharge conveyor belt 7 transports it to its end. The mechanical gripper on the loading robotic arm 3 automatically grabs the delivered welded workpiece and stacks it on the feeding device 1 to transport it to the next section.

[0042] Preferably, a second rotary conveyor robot 6 can be installed between the discharge end of the rolling welding section 5 and the discharge conveyor belt 7. The second rotary conveyor robot 6 is equipped with suction cups, which adsorb the welded workpieces and transport them to the loading bin at the beginning of the discharge conveyor belt 7. The feeding device 1 can be a transport vehicle such as a feeding cart.

[0043] The rolling welding section 5, as shown in Figures 4-6 and 16, includes a housing 51, a welding conveyor belt 55 passing through the housing 51, and ultrasonic rolling welding mechanisms (52, 53, 54). The ultrasonic rolling welding mechanisms (52, 53, 54) are installed on one side of the welding conveyor belt 55 inside the housing 51. The welding units of the ultrasonic rolling welding mechanisms (52, 53, 54) rapidly complete the rolling welding of the workpieces 8 to be welded on the welding conveyor belt during transport. Preferably, the ultrasonic rolling welding mechanisms are respectively arranged on opposite sides of the welding conveyor belt inside the housing 51, allowing two sets of ultrasonic rolling welding mechanisms (53, 52) to weld simultaneously on the same welding conveyor belt 55, effectively doubling the welding efficiency. More preferably, two sets of ultrasonic rolling welding mechanisms (53, 54) are arranged on the same side of the welding conveyor belt 55 inside the housing 51. When one set is under maintenance or the mold is replaced, the other set is in operation, ensuring uninterrupted operation of the production line and improving work continuity and efficiency. The ultrasonic rolling welding mechanism (52, 53, 54) is installed on the base on the side of the housing 51.

[0044] As shown in Figures 5-7, a conveying auxiliary mechanism is provided above the welding conveyor belt 55 to fix the workpiece 8 to be welded on the welding conveyor belt 55 for conveying and welding, so as to avoid vibration or displacement during conveying and welding, which would affect the welding effect and effectively improve the yield and welding speed. The conveying auxiliary mechanism includes a drive motor set 547, a rotating pressure belt 545, a support frame, a mounting plate 541, a pressure roller 546, a pressure belt tensioning roller 544, and a power synchronous roller 548. The support frame is installed on the lower part of the mounting plate 541, and pressure belt tensioning rollers 544 are respectively provided at both ends of the support frame to adjust the tension of the rotating pressure belt 545. The pressure belt tensioning rollers 544 are installed on an adjustable frame, one end of which is fixed to the support frame. An adjustment groove is provided on the adjustable frame, and the pressure belt tensioning rollers 544 are installed on a support shaft placed in the adjustment groove. Preferably, the adjustable frame can be a "U"-shaped structure, with the rotating pressure belt 545 located inside the pressure belt tensioning wheel 544 within the "U"-shaped groove of the adjustable frame. This provides excellent protection for the rotating pressure belt 545, improves reliability, and reduces installation space. The power synchronous wheel 548 is mounted at one end of the support frame, and a driven synchronous wheel is located at the other end of the support frame. Several pressure rollers 546 are mounted on a pressure roller bracket at the bottom of the support frame. The rotating pressure belt 545 is installed in the belt grooves of the pressure belt tensioning wheel 544, the power synchronous wheel 548, the driven synchronous wheel, and the pressure rollers 546. The power synchronous wheel 548 is fixed to a rotating shaft, which is connected to the output shaft of the drive motor assembly 547. The drive motor assembly 547 drives the power synchronous wheel 548 to rotate the rotating pressure belt 545. An elastic element is provided between the pressure roller bracket and the pressure rollers 546, allowing the pressure rollers 546 to have a certain amount of elastic expansion and contraction, which helps protect the workpiece 8 to be welded.

[0045] An adjustment device 542 is provided between the support frame and the mounting plate 541 for adjusting the left and right positions, thereby achieving precise positioning of the rotating pressure belt 545. Preferably, the adjustment device 542 can be a hand-cranked adjustment device, which adjusts the relative position of the rotating pressure belt 545 and the loading bin on the welding conveyor belt by cranking the handle of the hand-cranked adjustment device.

[0046] A height adjustment device is provided between the support frame and the mounting plate 541 to adjust the vertical position between the rotating pressure belt 545 and the welding conveyor belt 55. Preferably, the height adjustment device can be a stepping electric cylinder for adjusting the vertical position, thereby achieving precise positioning of the rotating pressure belt 545.

[0047] Preferably, the rotating pressure belt 545 and the welding conveyor belt 55 operate synchronously at the same speed, which can effectively avoid instability during the conveying and welding of the workpieces 8 to be welded in the loading bin, and improve the yield and welding reliability.

[0048] Preferably, the rotating pressure belt 545 is a soft-surfaced pressure belt to avoid damage to the surface of the workpiece 8 to be welded. The outer surface of the rotating pressure belt 545 contacts the surface of the workpiece 8 to be welded on the welding conveyor belt 55 and applies a certain pressure to fix it to the loading bin on the welding conveyor belt for transportation, avoiding displacement during transportation, thereby effectively ensuring the yield rate during rapid welding.

[0049] The ultrasonic rolling welding mechanism (52, 53, 54), as shown in Figures 5 and 16, is installed on the base at the bottom side of the welding conveyor belt 55 inside the housing 51. It includes a welding unit, which includes a first rolling welding mold (active roller) and a second rolling welding mold (driven roller) that cooperate with each other. The first rolling welding mold and the second rolling welding mold are located in the welding area of ​​the shaping and guiding device. The electrodes of the battery that have been clamped and shaped by the shaping and guiding device are rolled and welded in the welding area, which can effectively improve the welding efficiency and yield.

[0050] The shaping and guiding device, as shown in Figures 8-13, includes a support plate 511, a first pressure band guiding unit, a second pressure band guiding unit, and a motor 504. The first and second pressure band guiding units are mounted on the same side of the support plate 511, and the guiding pressure bands of the first and second pressure band guiding units move in opposite directions, forming a surface contact with a certain pressure. A window 510 is provided in the middle of the support plate 511 to serve as a welding area for installing welding units.

[0051] The first belt guiding unit includes a belt guiding unit, a tensioning wheel 501, an idler wheel 505, and a first pressing wheel 506. There are two idler wheels 505, which are located on the upper sides of the first pressing wheel 506 respectively. The tensioning wheel 501 is located in the middle of the upper side of the first pressing wheel 506. The belt guiding unit is installed in the belt mounting groove of the tensioning wheel 501, the idler wheel 505, and the first pressing wheel 506.

[0052] The second belt guiding unit includes a belt guiding unit, a tensioning wheel 501, an idler wheel 505, and a second pressing wheel 507. There are two idler wheels 505, which are located on the lower sides of the second pressing wheel 507 respectively. The tensioning wheel 501 is located in the middle of the lower side of the second pressing wheel 507. The belt guiding unit is installed in the belt mounting groove of the tensioning wheel 501, the idler wheel 505, and the second pressing wheel 507.

[0053] The first and second pressure belt guiding units are arranged vertically on the support plate 511. The first pressure roller 506 contacts and applies pressure to the second pressure roller 507, and the rollers are symmetrically arranged with respect to the contact tangents of the first and second pressure rollers 506 and 507. The contact line between the first and second pressure rollers 506 and 507 is on the same plane as the travel line of the welding portion of the workpiece 8 to be welded on the welding conveyor belt.

[0054] The tensioning wheel 501, idler wheel 505, first clamping wheel 506, and second clamping wheel 507 are fixed to the support plate 511 via bearing seats. Side plates 503 are respectively provided on both sides of the support plate 511 to facilitate fixing the support plate 511 inside the housing 51. Angle plate reinforcements are provided between the support plate 511 and the side plates 503 to enhance the structural strength between them.

[0055] The tensioning wheel 501 is mounted on a first adjustable base 514 fixed to the support plate 511 to facilitate adjustment of its position, thereby adjusting the tension of the guide belt. The first adjustable base 514 includes a fixed block, a movable groove on the fixed block, and a movable block movably mounted within the movable groove. The tensioning wheel 501 is mounted on the movable block. The movable block and the fixed block are connected by adjusting bolts. By cooperating with the fixed block, the adjusting bolts allow for vertical adjustment of the tensioning wheel 501, thus adjusting the tension of the guide belt.

[0056] Preferably, the guide pressure band consists of a first pressure band 509 and a second pressure band 508, wherein the second pressure band 508 is located on the inner side near the support plate 511. The second pressure band 508 is wider than the first pressure band 509. The width of the first pressure band 509 is set according to the front position of the workpiece 8 to be welded and the welding position. The width of the second pressure band 508 is set according to the position of the welding unit surrounding the outer cover and the ultrasonic rolling welding mechanism. Preferably, the width of the first pressure band 509 is 3mm, and the width of the second pressure band 508 is 10mm. The first and second rolling welding molds, which are mutually matched in the welding unit, are located on the upper and lower sides of the guide pressure band, respectively, and the welding point is located in the pre-reserved welding gap between the first and second pressure bands 509 and 508, realizing simultaneous ultrasonic welding from both upper and lower sides by the two ultrasonic rolling welding molds, resulting in a more reliable and highly efficient weld. The gap between the first pressure band 509 and the second pressure band 508 is set to 4mm according to the welding position and the welding part thickness of the first and second rolling welding molds in the welding unit. The workpieces to be welded are clamped by two mutually cooperating first pressure bands 509 and second pressure bands 508, achieving stable welding during transportation. The welding quality is reliable, the speed is fast, and there are almost no welding defects.

[0057] The output shaft of the motor 504 is connected to the drive assembly via a belt. The drive assembly includes a drive wheel set and a power steering wheel set, which are connected by gear meshing to achieve synchronous counter-rotation of the power steering wheel set. The drive wheel set includes a meshing gear, a first pulley, and a second pulley fixed on a rotating shaft; the power steering wheel set includes a steering meshing gear and a third pulley fixed on a rotating shaft; wherein the meshing gear and the steering meshing gear are meshed to achieve synchronous steering operation. The first pulley of the drive wheel set is connected to the drive wheel fixed on the output shaft of the motor 504 via a belt. The motor 504 drives the drive wheel set to rotate through the drive wheel, and simultaneously drives the power steering wheel set. The drive wheel set and the power steering wheel set are mounted on a carrier plate, which is fixed to a support plate 511.

[0058] The second pulley of the drive wheel assembly is connected to the second power synchronous pulley 569 on the second pressure wheel 507 via a synchronous belt; the third pulley of the power steering wheel assembly is connected to the first power synchronous pulley 568 on the first pressure wheel 506 via a synchronous belt, driving the first pressure wheel 506 and the second pressure wheel 507 to rotate synchronously in opposite directions.

[0059] Preferably, the drive assembly is provided in two sets, including a first drive assembly and a second drive assembly, which are respectively disposed at both ends of the pressure wheel unit. The first drive assembly and the second drive assembly have the same structure, and the connection between them and the pressure wheel unit is as described above.

[0060] The first pulley of the second drive assembly is connected to the intermediate drive wheel, which is fixed on the intermediate shaft. An intermediate pulley is mounted on the intermediate shaft and connected to the drive wheel on the output shaft of motor 504 via a belt. Motor 504 drives the intermediate drive wheel on the intermediate shaft to rotate via the drive wheel, and the intermediate drive wheel drives the first pulley. Both the first and second belt pressing and guiding units are driven by a single motor 504. That is, each shaping and guiding device is driven by a single motor, which effectively saves energy consumption, and the above structure is more reliable and has less error.

[0061] A shaping belt is provided between the clamping wheel unit at both ends and the idler wheel 505. The shaping belt is located in the belt groove in the middle of the first clamping wheel 506 and the second clamping wheel 507 in the clamping wheel unit. The shaping belt fills the welding gap reserved between the first pressure belt 509 and the second pressure belt 508, and forms a "trumpet mouth" shaped inlet at the end. It can shape and clamp the part of the workpiece to be welded, and avoid the welding part of the workpiece to be welded from being stuck in the gap due to irregularity, which would cause damage to the workpiece. At the same time, as a pre-welding treatment, it can improve the welding reliability and ensure the yield rate.

[0062] Each first clamping roller 506 and its corresponding second clamping roller 507 form a clamping roller unit. The clamping roller unit comprises at least two sets, located on opposite sides of the welding area. As shown in Figures 13-15, each clamping roller unit includes a fixed carrier plate 566, bearing seats 567, a first clamping roller 506, a second clamping roller 507, a first power synchronous roller 568, and a second power synchronous roller 569. The fixed carrier plate 566 has mounting grooves, and the two bearing seats 567 are respectively installed within these grooves. The first clamping roller 506 and the first power synchronous roller 568 are respectively mounted at both ends of a rotating shaft passing through the bearing seats 567, located on opposite sides of the fixed carrier plate 566. Each bearing seat 567 is equipped with an adjustment mechanism to adjust the relative distance between the two bearing seats 567, thereby adjusting the vertical engagement and positioning of the first clamping roller 506 and the second clamping roller 507.

[0063] Preferably, the adjustment mechanism includes a fixing block 565 and an adjusting bolt 564. The fixing block 565 is fixed on the fixing plate 566. The adjusting bolt 564 is connected to the bearing seat 567 through the bolt hole that mates with the fixing block 565. The adjusting bolt 564 and the fixing block 565 mate with each other, and the position of the bearing seat 567 can be adjusted slightly up and down by adjusting the adjusting bolt 564, thereby achieving the function of the first clamping wheel 506 and the second clamping wheel 507 engaging and positioning up and down.

[0064] The fixed carrier plate 566 has left and right adjustment mechanisms at its upper and lower ends for adjusting the tension of the synchronous belt of the power synchronous pulley. Each adjustment mechanism includes a second fixed block 562 and a sliding block 561. The fixed carrier plate 566 is fixed to the sliding block 561. The second fixed block 562 has bolt holes, and the sliding block 561 is connected via adjusting bolts through matching bolt holes. The adjusting bolts, in conjunction with the second fixed block 562, allow for slight left and right adjustments to the fixed carrier plate 566, thereby adjusting the tension of the synchronous belt of the power synchronous pulley.

[0065] Preferably, at least two clamping roller units are respectively arranged on both sides of the opening 510 portion of the support plate 511. The first power synchronizing wheel 568 and the second power synchronizing wheel 569 of adjacent clamping roller units are connected by a synchronous belt, which can realize that each pair of clamping roller units is in a state of speed synchronization, ensuring the consistency and stability of welding. Most preferably, three clamping roller units are respectively arranged on both sides of the opening 510 portion of the support plate 511. The first power synchronizing wheel 568 and the second power synchronizing wheel 569 of adjacent clamping roller units are connected by a synchronous belt. A fan filter unit (FFU) is arranged above the housing 51 to create positive pressure inside the housing and reduce dust pollution inside the housing 51.

[0066] The performance parameters achievable by the above technical solution of the present invention are shown in the table below:

[0067] Item No. Name Requirements 1. Conveyor belt mechanical speed ≥ 12 m / min 2. Stable equipment operating speed ≥ 6 m / min 3. Equipment welding efficiency ≥ 24 PPM 4. Welding yield ≥ 99.5% 5. Residue ≥ 60% 6. Tensile strength depends on specific product (reference: 40*10mm weld mark, straight pull, positive electrode ≥ 100N, negative electrode ≥ 90N) 7. Equipment large plate flatness ≤ ±0.05mm / m 2 8. Laser Welding Specifications (Reference Evaluation): Positive electrode: penetration depth 0.3-1 mm, weld width ≥ 2 mm, tensile strength ≥ 100 N; Negative electrode: penetration depth 0.16-0.6 mm, weld width ≥ 2 mm, tensile strength ≥ 150 N surface

[0068] The welding efficiency of this invention can reach up to 60 PPM, and the welding yield can be guaranteed to be greater than 99.5%, thus greatly improving the capacity of a single production line.

[0069] The above description is merely a preferred embodiment of the present invention and should not be construed as limiting the scope of the present invention. Any simple equivalent changes and modifications made in accordance with the scope of the patent application and the description of the invention shall still fall within the scope of the patent of the present invention.

Claims

1. A continuous, high-stability, high-speed ultrasonic welding automated production line, characterized in that, The system includes a feeding conveyor section, a rolling welding section, and a discharging conveyor section. The feeding conveyor section is connected to the feeding end of the rolling welding section, and the discharging end of the rolling welding section is connected to the discharging conveyor section. The rolling welding section includes a welding conveyor belt and an ultrasonic rolling welding mechanism. The ultrasonic rolling welding mechanism is installed on one side of the welding conveyor belt, and the welding unit in the ultrasonic rolling welding mechanism is used to roll and weld the workpiece to be welded on the welding conveyor belt during conveying. The ultrasonic rolling welding mechanism includes a shaping and guiding device and an ultrasonic rolling welding device. The ultrasonic rolling welding mold is placed between two contacting guide pressure bands of the shaping and guiding device. The shaping and guiding device includes a support plate, a first pressure band guiding unit, and a second pressure band guiding unit. A window is provided in the middle of the support plate to serve as a welding area for installing the welding unit. The first pressure band guiding unit and the second pressure band guiding unit are installed on the same side of the support plate, and the guide pressure bands of the first pressure band guiding unit and the second pressure band guiding unit move in opposite directions and are in surface contact. The first belt guiding unit includes a belt guide, a tensioning pulley, an idler pulley, and a first pressing pulley. Two idler pulleys are provided, located on the upper sides of the first pressing pulley. The tensioning pulley is located above the first pressing pulley. The belt guide is installed in the belt mounting grooves of the tensioning pulley, idler pulley, and first pressing pulley. The second belt guiding unit includes a belt guide, a tensioning pulley, an idler pulley, and a second pressing pulley. Two idler pulleys are provided, located on the lower sides of the second pressing pulley. The tensioning pulley is located below the second pressing pulley. The belt guide is installed in the belt mounting grooves of the tensioning pulley, idler pulley, and second pressing pulley.

2. The continuous, high-stability, high-speed ultrasonic welding automatic production line according to claim 1, characterized in that, The feeding conveying section includes a feeding robotic arm and a feeding conveyor belt. The feeding robotic arm is installed at the beginning of the feeding conveyor belt, and the end of the feeding conveyor belt is connected to the feeding end of the rolling welding section. The discharging conveying section includes a feeding robotic arm and a discharging conveyor belt. The feeding robotic arm is installed at the end of the discharging conveyor belt, and the beginning of the discharging conveyor belt is connected to the discharging end of the rolling welding section.

3. The continuous high-stability high-speed ultrasonic welding automatic production line according to claim 1, wherein the rolling welding section includes a box, a conveyor belt passing through the box, and an ultrasonic rolling welding mechanism, wherein three sets of the ultrasonic rolling welding mechanism are provided, two sets being located on the same side of the conveyor belt, and the other set being located on the other side of the conveyor belt; the shaping and guiding device is provided inside the box, and the ultrasonic rolling welding device is installed on the outside of the box.

4. The continuous, high-stability, high-speed ultrasonic welding automatic production line according to claim 3, characterized in that, The rolling welding section also includes a housing, through which the welding conveyor belt passes. The ultrasonic rolling welding mechanism is respectively installed on opposite sides of the welding conveyor belt, or two sets of the ultrasonic rolling welding mechanism are installed on the same side of the welding conveyor belt.

5. The continuous, high-stability, high-speed ultrasonic welding automatic production line according to claim 4, characterized in that, The ultrasonic rolling welding mechanism is provided in three sets, with two sets located on the same side of the welding conveyor belt and the other set located on the other side of the welding conveyor belt.

6. The continuous, high-stability, high-speed ultrasonic welding automatic production line according to claim 4, characterized in that, The feeding and conveying section also includes a shaping and guiding device that is matched with the ultrasonic rolling welding mechanism. The shaping and guiding device is set on the side of the welding conveyor belt inside the box, the ultrasonic rolling welding mechanism is installed on the base, and the welding unit is placed in the welding area of ​​the shaping and guiding device.

7. The continuous, high-stability, high-speed ultrasonic welding automatic production line according to claim 4, characterized in that, A conveying auxiliary mechanism is provided above the welding conveyor belt. The conveying auxiliary mechanism includes a drive motor set, a rotating belt pressing mechanism, a support frame, a mounting plate, pressure rollers, belt tensioning rollers, and a power synchronization roller. The support frame is installed on the lower part of the mounting plate, and belt tensioning rollers are respectively provided at both ends of the support frame. The power synchronization roller is installed at one end of the support frame, and a driven synchronization roller is provided at the other end of the support frame. Several pressure rollers are installed on pressure roller brackets at the bottom of the support frame. The rotating belt pressing mechanism is installed in the belt grooves of the belt tensioning roller, the power synchronization roller, the driven synchronization roller, and the pressure rollers. The power synchronization roller is fixed on a rotating shaft, and the rotating shaft is connected to the output shaft of the drive motor set.

8. The continuous, high-stability, high-speed ultrasonic welding automatic production line according to claim 7, characterized in that, The ultrasonic rolling welding mechanism includes a welding unit, which includes a first rolling welding mold and a second rolling welding mold that cooperate with each other. The first rolling welding mold and the second rolling welding mold are located in the welding area of ​​the shaping and guiding device.

9. The continuous, high-stability, high-speed ultrasonic welding automatic production line according to claim 1, characterized in that, The first pressure belt guide unit and the second pressure belt guide unit are arranged in a vertically cooperating manner on the support plate, and the first pressure roller is in contact with the second pressure roller.

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