A split coil welding structure

Abstract

The present invention provides a split coil welding structure, which relates to the technical field of inductive coil welding equipment, and includes a mounting plate and two welding assemblies mounted on the mounting plate, each welding assembly including a pre-stress mechanism and a welding mechanism. The pre-stress mechanism includes a telescopic member and a connecting plate, and the telescopic end of the telescopic member is pressed against the connecting plate; the welding mechanism includes a pair of conductive columns mounted on the connecting plate and a welding head mounted at the end of the conductive column. The conductive column is mounted on the connecting plate by screws and is provided with a copper wing plate to increase the conductive area, reduce resistance and improve heat dissipation performance. The copper wing plate is perpendicular to the arrangement direction of the conductive column, which helps to maintain the compactness of the overall structure. By adopting a split welding head structure, the present invention can adapt to solder joints of different flatnesses, ensure that each solder joint can fully contact the welding head, significantly reduce welding defects, improve the quality of solder joints, and at the same time enhance conductivity and heat dissipation performance, ensure structural compactness, and improve production efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of induction coil welding equipment, and in particular to a split coil welding structure. Background Art

[0002] To achieve efficient welding of common-mode inductor coils, traditional coil winding machine welding devices typically use an integrated dual-head structure to simultaneously complete two solder joints. While this structure simplifies the operation process and improves production efficiency, it encounters some difficult-to-overcome challenges in practical applications.

[0003] As common-mode inductor products become increasingly miniaturized and sophisticated, ensuring that their solder joints are precisely aligned on the same surface becomes increasingly difficult. When two solder joints on a product are not precisely aligned, the integrated dual-tip welding head structure cannot adapt to the welding conditions and cannot ensure good contact between both welding heads and the solder joints simultaneously. This can lead to welding defects such as poor contact and insufficient solder joint strength. These issues not only affect the overall quality of the product but also significantly increase the defective product rate, thereby increasing production costs. Summary of the Invention

[0004] The purpose of the present invention is to provide a split coil welding structure. By adopting a split welding structure, the welding head at each welding point position can be precisely controlled to ensure that the welding head can fully contact welding points of different flatnesses, thereby improving the welding quality.

[0005] To achieve the above object, the present invention is implemented through the following technical solutions:

[0006] A split coil welding structure includes a mounting plate and two welding assemblies mounted on the mounting plate, the two welding assemblies being separated from each other, the welding assemblies including a pre-stressing mechanism mounted on the mounting plate and a welding mechanism mounted on the pre-stressing mechanism;

[0007] The pre-stress mechanism includes a telescopic member fixed vertically downward on the mounting plate and a connecting plate vertically slidably mounted on the mounting plate, wherein the telescopic end of the telescopic member is pressed against the connecting plate;

[0008] The welding mechanism includes a pair of conductive posts mounted on a connecting plate and a welding head mounted at the ends of the conductive posts, wherein the pair of conductive posts are conductive post 1 and conductive post 2, and the welding head is electrically connected to the conductive post 1 and the conductive post 2.

[0009] By adopting a split welding structure, the two welding components can adapt to welds with different flatness. The two pre-pressure mechanisms respectively drive the two separate welding heads to press on the welding points of the workpiece, thereby ensuring that each weld point can fully contact the welding head, thereby significantly reducing welding defects and improving the quality of the welds.

[0010] Furthermore: the conductive column is installed on the connecting plate by means of screws, and a number of copper wing plates are provided on the conductive column, and the copper wing plates are distributed on both sides of the screws. The screw-mounted connection form facilitates the disassembly, replacement, and maintenance of the device, and reduces the difficulty of designing and manufacturing the assembly parts. However, under the split welding structure design used in this device, the number of conductive columns increases, and the volume of the gaps between the conductive columns increases, while the volume of the conductive columns decreases, resulting in a decrease in the conductive volume at the screw installation location, which in turn causes an increase in the resistance of the conductive column at this location, and serious heat generation. This device further proposes a solution to this secondary problem, by adding copper wing plates on both sides of the screw installation location on the conductive column, which not only increases the conductive volume and reduces the overall resistance of the conductive column, but also reduces the heat generation of the conductive column and increases heat dissipation.

[0011] Furthermore, the copper wing plate is perpendicular to the arrangement direction of the conductive pillars, thereby ensuring the conductive performance of the conductive pillars while maintaining the compactness of the overall structure.

[0012] Furthermore, the copper wing plates are also distributed in the intervals between the screws, thereby further reducing the volume of the conductive column and increasing the heat dissipation of the conductive column.

[0013] Furthermore, the other ends of conductive pillars 1 and 2, where the welding heads are mounted, are respectively mounted with terminal blocks 1 and 2. Terminal blocks 1 and 2 are arranged in a staggered pattern, with the cross-sectional area of terminal block 1 being larger than that of conductive pillar 1, and the cross-sectional area of terminal block 2 being larger than that of conductive pillar 2. The staggered arrangement of terminal blocks 1 and 2 increases the contact area with the wires while maintaining a compact structure, reducing resistance at the connection point.

[0014] Furthermore, a cooling fan is installed on the conductive column, and a plurality of cooling slots are opened on at least one surface of the conductive column, and the cooling fan faces the cooling slots to further dissipate heat from the conductive column.

[0015] Furthermore: the heat dissipation fan is installed on the conductive column through a heat dissipation bracket.

[0016] Furthermore, an insulating layer is provided between the conductive column and the connecting plate to increase the electrical insulation safety of the device.

[0017] Furthermore, the insulating layer is a fluororubber pad, which has excellent insulation properties.

[0018] Furthermore, the preload mechanism also includes a contact stopper, comprising a first stud and a second stud, respectively threaded onto the mounting plate and the connecting plate, with the head of the first stud facing the head of the second stud. The head of the first stud presses against the head of the second stud, thereby limiting the position of the connecting plate under the pressure of the telescopic member. Rotating either the first stud or the second stud can adjust the limit stroke, facilitating device commissioning and achieving precise position limiting.

[0019] Furthermore, the telescopic member is a low-friction cylinder. The low-friction cylinder has low vibration and good impact resistance, and is suitable for use in precision welding scenarios.

[0020] Furthermore, a rubber top block is provided at the end of the top rod of the low-friction cylinder. The rubber top block acts as a buffer to increase the stability of the welding head.

[0021] Furthermore, the preload mechanism also includes a buffer mounted between the mounting plate and the connecting plate. The buffer comprises a spring and a spring mounting pin sleeved within the spring, which is mounted on the connecting plate. The spring's elastic force primarily offsets the weight of the connecting plate and its associated structures, reducing the unsprung mass of the compression member. This allows for more efficient and flexible control of the vertical movement of the welding mechanism, mitigating the impact of the inertia of the welding mechanism on the common-mode inductor product during downward movement and protecting product quality. Furthermore, the spring provides a certain amount of buffering force, preventing hard contact and impact between the mounting plate and the connecting plate.

[0022] Furthermore: the connecting plate is installed on the fixing plate through a guide rail mechanism.

[0023] Furthermore, the device further comprises a blowpipe directed to the welding head, which is used to connect to an air source and blow away welding dust from the welding head in a timely manner.

[0024] Furthermore, the conductive post is also equipped with a lateral stopper. This stopper is mounted on a side of the guide post perpendicular to the welding head. The stopper contacts the side of the welding head, and the surface of the side contacting the welding head aligns with the side surface of the welding head. The stopper is used to further limit the lateral position of the welding head, thereby further improving the installation accuracy of the welding head.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] First, this device utilizes a split welding structure. The two welding components can accommodate welds with varying flatness. Two pre-pressure mechanisms drive the two separate welding heads to press against the workpiece's weld points, ensuring full contact between each weld head and the welding head. This significantly reduces weld defects and improves weld quality. This effectively avoids welding defects, significantly reduces product rejection rates due to poor welding, and improves overall product quality.

[0027] Second, adding copper wing plates to the conductive columns not only increases the conductive area and reduces resistance, but also improves heat dissipation performance, allowing the welding head to maintain a stable temperature during long-term operation, ensuring the continuity of the welding process and the consistency of welding quality.

[0028] 3. Despite the split design, reasonable layout and optimized design, including the addition and reasonable layout of copper wing plates and staggered terminal blocks, ensure the compactness of the welding assembly and facilitate installation and maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic isometric view of the device of the present invention;

[0030] Figure 2 It is a schematic front view of the device of the present invention;

[0031] Figure 3 Schematic diagram of the left side view of the device of the present invention

[0032] In the picture:

[0033] 1. Mounting plate; 2. Connecting plate; 3. Low-friction cylinder; 3.1. Rubber top block; 4. Conductive column; 4.1. Conductive column 1; 4.11. Terminal block 1; 4.2. Conductive column 2; 4.21. Terminal block 2; 4.3. Copper wing plate; 4.4. Heat sink; 5. Welding head; 6. Cooling fan; 7. Cooling bracket; 8. Lateral limit block; 9. Guide rail mechanism; 10. Fluororubber pad; 11. Contact limiter; 12. Buffer; 13. Blowpipe. DETAILED DESCRIPTION

[0034] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0035] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0036] like Figure 1-Figure 3As shown: A split coil welding structure includes a mounting plate 1 and two welding assemblies mounted on the mounting plate 1, the two welding assemblies being separated from each other, the welding assemblies including a pre-stressing mechanism mounted on the mounting plate 1 and a welding mechanism mounted on the pre-stressing mechanism;

[0037] The prestressing mechanism includes a telescopic member fixed vertically downward on the mounting plate 1 and a vertical guide mechanism 9 slidably mounted on the connecting plate 2 on the mounting plate 1, with the telescopic end of the telescopic member pressed against the connecting plate 2. The welding mechanism includes a pair of conductive posts 4 mounted on the connecting plate 2 and a welding head 5 mounted at the end of the conductive posts 4. The pair of conductive posts 4 are conductive post 1 4.1 and conductive post 2 4.2, and the welding head 5 is electrically connected to the conductive post 1 4.1 and the conductive post 2 4.2. By adopting a split welding structure, the two welding assemblies can accommodate welds of different flatnesses. The two prestressing mechanisms respectively drive the two separate welding heads 5 to press against the weld points of the workpiece, thereby ensuring that each weld point can fully contact the welding head 5, thereby significantly reducing welding defects and improving the quality of the weld points.

[0038] The conductive posts 4 are mounted on the connecting plate 2 using screws. An insulating layer, consisting of a fluororubber pad 10, is provided between the posts 4 and the connecting plate 2. Several copper fins 4.3 are provided on the posts 4, located on either side of the screws. These fins 4.3 are perpendicular to the arrangement of the posts 4. This screw-mounted connection facilitates assembly, disassembly, replacement, and maintenance, reducing the design and manufacturing complexity of the assembly. However, the split-type welded design employed in this device increases the number of posts 4, increasing the volume of the gaps between them and reducing their volume. This reduces the conductive volume at the screw mounting locations, leading to increased resistance and significant heat generation. This device further addresses this secondary issue by adding copper fins 4.3 on either side of the screw mounting locations. This not only increases the conductive volume and reduces the overall resistance of the posts 4, but also reduces heat generation and improves heat dissipation. This ensures a compact overall structure while maintaining the conductive performance of the posts 4. The copper fins 4.3 are also located between the screws. The volume of the conductive column 4 is further reduced, and the heat dissipation of the conductive column 4 is increased.

[0039] The other ends of the conductive posts 1 4.1 and 2 4.2, on which the welding head 5 is mounted, are respectively mounted with terminal blocks 1 4.11 and terminal blocks 2 4.21. Terminal blocks 1 4.11 and 4.21 are interlaced with each other. The cross-sectional area of terminal block 1 4.11 is greater than that of conductive post 1 4.1, and the cross-sectional area of terminal block 2 4.21 is greater than that of conductive post 2 4.2. A lateral stopper 8 is also mounted on the conductive post 4. The lateral stopper 8 is mounted on a side of the guide post perpendicular to the welding head 5. The lateral stopper 8 contacts the side of the welding head 5, and the profile of the side of the lateral stopper 8 that contacts the welding head 5 matches the profile of the side of the welding head 5. The lateral stopper 8 is used to further limit the lateral position of the welding head 5, which can further improve the installation accuracy of the welding head 5.

[0040] The split-type coil welding structure also includes a cooling fan 6 mounted on the conductive column 4 via a heat dissipation bracket 7. The conductive column 4 has a plurality of heat dissipation slots 4.4 formed on at least one surface. The cooling fan 6 faces the heat dissipation slots 4.4, further dissipating heat from the conductive column 4. The split-type coil welding structure also includes a blowpipe 13 directed toward the welding head 5. This blowpipe 13 is connected to an air source to promptly remove welding dust from the welding head 5.

[0041] The pre-stress mechanism also includes a contact limiter 11, which includes a stud 1 and a stud 2 respectively threadedly connected to the mounting plate 1 and the connecting plate 2, with the head of stud 1 facing the head of stud 2. The head of stud 1 is pressed against the head of stud 2, that is, the connecting plate 2 under the pressure of the telescopic part is limited; the limit stroke can be adjusted by rotating stud 1 or stud 2, which facilitates the debugging of the device and performs precise limiting. In addition, both stud 1 and stud 2 are made of copper. Stud 1 and stud 2 are electrically connected to the PLC controller of the coil winding machine respectively. When the welding structure is pressed down to the welding point, the low-friction cylinder 3 in the pre-stress mechanism is compressed. At this time, stud 1 and stud 2 are disconnected, and the PLC controller can receive a disconnection signal to indicate that the welding head stroke is in place. When the welding head strokes on the two welding components are in place, it means that the downward stroke of the entire welding structure is in place, and the PLC controller can perform the next step of control.

[0042] The telescopic part is a low-friction cylinder 3. The low-friction cylinder 3 has low vibration and good impact resistance, and is suitable for use in precision welding scenarios. A rubber top block 3.1 is provided at the end of the push rod of the low-friction cylinder 3. The rubber top block 3.1 acts as a buffer to increase the movement stability of the welding head 5. The pre-stressing mechanism also includes a buffer 12 installed between the mounting plate 1 and the connecting plate 2. The buffer 12 includes a spring 12.2 and a spring mounting pin 12.1 sleeved in the spring 12.2. The spring mounting pin 12.1 is installed on the connecting plate 2. The elastic force of the spring 12.2 is mainly used to offset the gravity of the connecting plate 2 and its ancillary structures, reduce the unsprung mass of the low-friction cylinder 3, and can more effectively and flexibly control the up and down movement of the welding mechanism, reduce the impact of the welding mechanism on the common-mode inductor coil product due to inertia during the downward movement of the entire welding structure, and protect the product quality; in addition, the spring 12.2 also provides a certain buffering force to prevent hard contact between the mounting plate 1 and the connecting plate 2, which causes impact.

[0043] The working principle of the present invention is as follows:

[0044] Installation and Positioning: Install the device on the coil winding machine's welding arm using the mounting plate 1. Connect all terminal blocks to the power supply wires. The lateral stoppers 8 on the conductive posts 4 contact the sides of the welding head 5, limiting the side position of the welding head 5 and improving installation accuracy.

[0045] When welding begins, the robotic arm drives the device to the welding point and moves the two welding heads 5 toward the welding point respectively. Since the pre-stress mechanism is separated, the two welding heads 5 move independently within the travel range of the pre-stress mechanism. If one of the welding heads 5 contacts the welding point first, the other welding head 5 that has not yet contacted the welding point can still continue to press down until it also contacts the welding point. In the process of the two welding heads 5 pressing down respectively, the rubber top block 3.1 provided at the end of the top rod of the telescopic part plays a buffering role, increasing the movement stability of the welding head 5. In addition, adjusting the contact limiter 11 (rotating stud one or stud two) in the pre-stress mechanism can adjust the limit stroke to ensure that the contact pressure between the welding head 5 and the welding point is moderate, and the travel freedom of the two pre-stress mechanisms can also be adjusted separately.

[0046] During welding, a cooling fan 6 faces the heat sink 4.4, further dissipating heat from the conductive posts 4 to maintain a stable temperature for the welding head 5 during extended operation. A blowpipe 13, directed to the welding head 5, connects to an air source to promptly remove welding dust from the welding head 5, keeping the welding area clean. Copper wing plates 4.3 are provided on the conductive posts 4. These plates are located on both sides of the screw, increasing the conductive area and reducing resistance while also improving heat dissipation. The copper wing plates 4.3 are perpendicular to the arrangement of the conductive posts 4, ensuring the conductive performance of the conductive posts 4 while maintaining the compactness of the overall structure.

[0047] The above embodiments are intended only to illustrate the technical concepts and features of the present invention. Their purpose is to enable those skilled in the art to understand the contents of the present invention and implement them accordingly. They are not intended to limit the scope of protection of the present invention. Any equivalent changes or modifications made in accordance with the spirit of the present invention are intended to be covered by the scope of protection of the present invention.

Claims

1. A split coil welding structure, characterized in that: It includes a mounting plate and two welding assemblies mounted on the mounting plate, the two welding assemblies are separated from each other, and the welding assembly includes a pre-pressure mechanism mounted on the mounting plate and a welding mechanism mounted on the pre-pressure mechanism; The pre-stress mechanism includes a telescopic member fixed vertically downward on the mounting plate and a connecting plate vertically slidably mounted on the mounting plate, the telescopic end of the telescopic member is pressed tightly against the connecting plate, and the telescopic member is a low-friction cylinder; The welding mechanism includes a pair of conductive posts mounted on the connecting plate and a welding head mounted at the ends of the conductive posts, the pair of conductive posts being a first conductive post and a second conductive post, the welding head being electrically connected to the first conductive post and the second conductive post; The conductive column is mounted on the connecting plate by screws, and a plurality of copper wing plates are provided on the conductive column. The copper wing plates are distributed on both sides of the screws; the copper wing plates are perpendicular to the arrangement direction of the conductive column; The pre-stress mechanism also includes a contact limiter, which includes a stud 1 and a stud 2 threadedly connected to the mounting plate and the connecting plate respectively, and the head of the stud 1 and the head of the stud 2 are opposite to each other; the stud 1 and the stud 2 are both made of copper, and the stud 1 and the stud 2 are electrically connected to a PLC controller. When the welding structure is pressed down to the welding point, the low-friction cylinder in the pre-stress mechanism is compressed, and at this time the stud 1 and the stud 2 are disconnected. The PLC controller can then receive a disconnection signal to indicate that the welding head has reached its stroke.

2. The split coil welding structure according to claim 1, characterized in that: The copper wings are also distributed in the intervals between the screws.

3. The split coil welding structure according to claim 1, characterized in that: The other ends of the conductive pillars 1 and 2 on which the welding heads are mounted are respectively mounted with terminal blocks 1 and 2, and the terminal blocks 1 and 2 are staggered. The cross-sectional area of the terminal block 1 is larger than the cross-sectional area of the conductive pillar 1, and the cross-sectional area of the terminal block 2 is larger than the cross-sectional area of the conductive pillar 2.

4. The split coil welding structure according to claim 1, characterized in that: It also includes a heat dissipation fan installed on the conductive column. A plurality of heat dissipation slots are opened on at least one surface of the conductive column, and the heat dissipation fan is directly facing the heat dissipation slots.

5. The split coil welding structure according to claim 4, characterized in that: The heat dissipation fan is installed on the conductive column through a heat dissipation bracket.

6. The split coil welding structure according to claim 1, characterized in that: An insulating layer is provided between the conductive column and the connecting plate.

7. The split coil welding structure according to claim 6, characterized in that: The insulating layer is a fluororubber pad.

8. The split coil welding structure according to claim 7, characterized in that: The end of the push rod of the low-friction cylinder is provided with a rubber push block.

9. The split coil welding structure according to claim 1, characterized in that: The pre-stress mechanism further comprises a buffer installed between the mounting plate and the connecting plate, wherein the buffer comprises a spring and a spring mounting pin sleeved in the spring, and the spring mounting pin is installed on the connecting plate.

10. The split coil welding structure according to claim 1, characterized in that: The connecting plate is mounted on the fixing plate through a guide rail mechanism.

11. The split coil welding structure according to claim 1, characterized in that: Also included is a blowpipe that guides the welding head.

12. The split coil welding structure according to claim 1, characterized in that: A lateral limit block is also installed on the conductive column. The lateral limit block is installed on a side of the guide column perpendicular to the welding head. The lateral limit block contacts the side of the welding head, and the surface of the side of the lateral limit block in contact with the welding head matches the side surface of the welding head.

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