A conductive layer welding device for preparing composite busbars

Abstract

This invention belongs to the technical field of welding equipment, and particularly relates to a welding device for the conductive layer of composite busbars. This invention provides a welding device for the conductive layer of composite busbars, which, by setting columns, lifting cylinders, hinges, perforated plate units, movable pressure block units, openings, and U-shaped frame units on a base plate, enables: 1. The movable pressure block unit to have an adjustable position for pressing and fixing the conductive layer, adapting to the size of the conductive layer while avoiding the terminals; 2. The movable pressure block unit, after being removed from the perforated plate unit, can fully and appropriately lift the conductive layer at the openings and U-shaped frame units, ensuring smooth welding of the downwardly bent terminals.

Description

Technical Field

[0001] This invention belongs to the field of welding equipment technology, and particularly relates to a welding device for preparing conductive layers of composite busbars. Background Technology

[0002] Composite busbars refer to multi-layered composite busbars whose main function is to distribute power. Their advantages include safety and reliability, compact structure, low impedance, and low inductance.

[0003] The composite busbar mainly consists of a conductive layer, an insulating layer, and terminals. The conductive layer is typically made of various types of copper sheets, while the insulating layer is usually an epoxy resin film or a polyester film. Insulating layers are provided between adjacent conductive layers. The main function of the aforementioned welding equipment is to weld and fix the terminals onto the conductive layers.

[0004] On the other hand, the conductive layer can be rectangular, irregular, or even non-planar bent. Similarly, the shape of the terminals is also variable; various types of terminals, such as those that protrude laterally, curve upwards, or bend downwards, may exist on the same conductive layer. This places high demands on the practicality of the aforementioned welding equipment.

[0005] For example, Chinese utility model patent with authorization announcement number CN219005027U and authorization announcement date of May 12, 2023 discloses an automatic welding device for a composite busbar conductive layer. Its structure includes a placement plate, a first bracket, a left support plate, a second bracket, a support block, a slide rod, a right support plate, a fixing plate, an automatic welding head, an electric push rod, an equipment box, a slide plate, a square rod, a first fixing block, a first slide groove, a first slider, a soft pad, a threaded rod, a second fixing block, and a second slider.

[0006] The automatic welding device in this utility model patent has the following general structural principle and advantages: When the electric push rod is raised, one end of the right support plate remains fixed in one position, while the other end rises until the right support plate is tilted. The busbar can then be placed on the upper surface of the fixed plate that is fixed to the right support plate. The threaded rod is operated to fix the busbar by the first slider, and then the automatic welding head performs welding. With the cooperation of the above structures, when welding a busbar with an angle, the electric push rod can be operated to adjust the angle for fixing, which improves work efficiency and the flexibility of changing the angle of welding.

[0007] However, in actual use, this automatic welding device still has at least two shortcomings, which are also the technical problems that this invention aims to solve:

[0008] First, the positions of its two clamping structures are fixed, and they can only clamp the two sides of the bent conductive layer that are parallel to the bent edge. When the above-mentioned side positions need to be welded with terminals, the clamping structure itself will interfere with the welding operation, or the distance between the above-mentioned two sides is relatively small and cannot be clamped at the same time, which is very troublesome.

[0009] Secondly, its two clamping structures can only press and adhere the bent conductive layer separately and completely to its two fixed plates. If it is necessary to weld horizontally protruding and upward-curving terminals, the automatic welding device is suitable. However, if it is necessary to weld downward-bent terminals, the above clamping method is not applicable.

[0010] Therefore, in summary, there is an urgent need for a new type of welding equipment with a more flexible, versatile, and practical clamping method to weld various types of terminals that are laterally protruding, upwardly curved, or downwardly bent on the conductive layer, thereby producing more practical composite busbar products with various bent shapes. Summary of the Invention

[0011] This invention provides a conductive layer welding device for preparing composite busbars. By configuring a base plate with columns, a lifting cylinder, a hinge, a perforated plate unit, a movable pressure block unit, an opening, and a U-shaped frame unit, the following features are achieved: 1. The movable pressure block unit provides adjustable pressure to fix the conductive layer, adapting to the size of the conductive layer while avoiding the terminals; 2. The movable pressure block unit, removed from the perforated plate unit, can fully and appropriately lift the conductive layer at the opening and the U-shaped frame unit, ensuring smooth welding of the downwardly bent terminals.

[0012] The technical solution adopted by the present invention to solve the above problems is: a conductive layer welding device for preparing composite busbars, the structure of which includes a base plate, a column, a lifting cylinder, and a hinge, and further includes two perforated plate units disposed on the hinge and respectively connected to the column and the lifting cylinder, several movable pressure block units disposed on the perforated plate units for pressing down and fixing the conductive layer, an opening disposed on the perforated plate units, and a U-shaped frame unit disposed on the lower surface of the perforated plate units for lifting the conductive layer at the opening by installing the removed movable pressure block units.

[0013] A further preferred technical solution is that the perforated plate unit includes a rectangular plate that connects to the hinge and is used to fix the column or press down the lifting cylinder, and screw holes that are arranged on the rectangular plate at uniform intervals in a linear arrangement and are used to install the movable pressure block unit.

[0014] A further preferred technical solution is that the movable pressure block unit includes a screw rod disposed on the screw hole, a pressure block, an elongated hole disposed on the pressure block and used to pass through the screw rod, and a fastening nut disposed on the screw rod and used to press down the pressure block.

[0015] A further preferred technical solution is that the movable pressure block unit also includes a gripping ring disposed on the screw.

[0016] A further preferred technical solution is that the U-shaped frame unit includes a vertical plate disposed on the lower surface of the rectangular plate, a horizontal plate disposed on the vertical plate, and a support screw hole disposed on the horizontal plate for mounting the screw.

[0017] A further preferred technical solution is that the shape of the opening and the cross-sectional shape of the pressing block are both rectangular, and the length and width of the opening are 2-4 mm larger than the length and width of the cross-section of the pressing block.

[0018] A further preferred technical solution is that the cylinder shaft of the lifting cylinder is also provided with a height fine-tuning frame unit for lifting the rectangular plate by installing the removed movable pressure block unit.

[0019] A further preferred technical solution is that the height fine-tuning frame unit includes a mounting plate, a mounting screw hole disposed on the mounting plate for connecting the cylinder shaft, a vertical rod disposed at one end of the mounting plate for inserting the removed pressure block, and a circular hole disposed at the other end of the mounting plate for supporting the pressure block by installing the removed screw.

[0020] A further preferred technical solution is that the circular hole is a screw hole or a smooth hole.

[0021] A further preferred technical solution is that the indentation distance of the gripping ring on the end face of the screw is ≥2cm. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of the present invention.

[0023] Figure 2 This is a schematic diagram of one shape of a conductive layer in the prior art.

[0024] Figure 3 This is a schematic diagram illustrating how the present invention is used.

[0025] Figure 4 This is a schematic diagram of the structure of the fixed perforated plate unit in this invention.

[0026] Figure 5This is a schematic diagram of the rotating perforated plate unit in this invention.

[0027] Figure 6 This is a schematic diagram of the structure of the movable pressure block unit in this invention.

[0028] Figure 7 This is a schematic diagram illustrating the usage of the U-shaped frame unit in this invention.

[0029] Figure 8 This is a schematic diagram illustrating the usage of the height fine-tuning frame unit in this invention.

[0030] Figure 9 This is a schematic diagram illustrating one application of the pressure block in this invention.

[0031] Figure 10 This is a schematic diagram illustrating one usage method of the height fine-tuning frame unit in this invention.

[0032] The meanings of the markings in the diagram are as follows:

[0033] Conductive layer a, terminal b, indentation distance L;

[0034] 11. Base plate; 12. Column; 13. Lifting cylinder; 14. Hinge; 15. Welding arm base;

[0035] Perforated plate unit 1, movable pressure block unit 2, opening 3, U-shaped frame unit 4, height fine-adjustment frame unit 5;

[0036] Rectangular plate 101, screw hole 102;

[0037] Screw 201, pressure block 202, oblong hole 203, fastening nut 204, gripping ring 205;

[0038] Vertical plate 401, horizontal plate 402, screw holes for support 403;

[0039] Mounting plate 501, mounting screw hole 502, vertical rod 503, round hole 504. Detailed Implementation

[0040] The following description is only a preferred embodiment of the present invention and is not intended to limit the scope of the present invention.

[0041] As attached Figure 1-10As shown, a conductive layer welding device for preparing composite busbars includes a base plate 11, a column 12, a lifting cylinder 13, and a hinge 14. It also includes two perforated plate units 1 disposed on the hinge 14 and connected to the column 12 and the lifting cylinder 13 respectively, several movable pressure block units 2 disposed on the perforated plate units 1 and used to press down and fix the conductive layer a, an opening 3 disposed on the perforated plate units 1, and a U-shaped frame unit 4 disposed on the lower surface of the perforated plate units 1 and used to lift the conductive layer a at the opening 3 by installing the removed movable pressure block units 2.

[0042] In this embodiment, the column 12, the lifting cylinder 13, and the welding arm base 15 are screwed onto the base plate 11. There are two perforated plate units 1, one of which is fixed to the column 12, and the other is simply pressed against the lifting cylinder 13. Finally, the two perforated plate units 1 are hinged together by 2-3 hinges 14, such as common hinges.

[0043] At this point, the conductive layer welding equipment can stably support conductive layer a after one bend. Generally, the bend angle ranges from 100-150°; please refer to the appendix for details. Figure 2 .

[0044] The number of movable pressure block units 2 is 3-10. When the welding equipment is in use, 1-4 movable pressure block units 2 are pressed on one side plate of conductive layer a. When a downwardly bent terminal b needs to be welded on conductive layer a, one of the movable pressure block units 2 needs to be removed from the perforated plate unit 1 and then installed on the opening 3 and U-shaped frame unit 4. Finally, its upward protrusion at the opening 3 is adjusted to ensure that one side plate of conductive layer a provides sufficient space below for the downwardly bent terminal b. For details, please refer to the appendix. Figure 3 .

[0045] On the other hand, there is only one opening 3 and one U-shaped frame unit 4, both of which are mounted on the horizontally fixed and immovable perforated plate unit 1. Therefore, this welding equipment is not suitable when both sides of the conductive layer a require the installation of downwardly bent terminals b.

[0046] However, in general, for composite busbars, in order to make the wiring method more reasonable and to separate the subsequent wiring as much as possible, the multiple terminals b are usually separated horizontally and staggered vertically. Therefore, the above-mentioned inapplicable situation rarely occurs.

[0047] The perforated plate unit 1 includes a rectangular plate 101 that connects to the hinge 14 and is used to fix the column 12 or press down the lifting cylinder 13, and screw holes 102 that are arranged on the rectangular plate 101 at uniform intervals in a linear arrangement and are used to install the movable pressure block unit 2.

[0048] In this embodiment, the perforated plate unit 1 is made of stainless steel or plastic, and the opening 3 is opened to avoid the screw hole 102, so as to avoid the appearance of an incomplete screw hole 102.

[0049] The hinge 14 is screwed onto the side of the rectangular plate 101, avoiding the screw holes 102, so that the movable pressure block unit 2 can be installed on all the screw holes 102 as needed.

[0050] The movable pressure block unit 2 includes a screw 201 disposed on the screw hole 102, a pressure block 202, an elongated hole 203 disposed on the pressure block 202 and used to pass through the screw 201, and a fastening nut 204 disposed on the screw 201 and used to press down the pressure block 202.

[0051] In this embodiment, the movable pressing block unit 2 is made of plastic, and the length and width of the pressing block 202 are slightly smaller than the length and width of the opening 3, so that when the removed pressing block 202 pushes up the single side plate of the conductive layer a at the opening 3 as needed, the former is not easy to shift laterally in the latter.

[0052] The primary function of the movable pressure block unit 2 is to fully and appropriately press down the conductive layer a, and its secondary function is to lift the conductive layer a as needed. The former requires selecting one of the numerous screw holes 102 before triggering its activation. The general usage method is as follows:

[0053] First, the lifting cylinder 13 first rotates the rotatable rectangular plate 101 to a suitable angle, that is, the two rectangular plates 101 respectively attach to the two single-side plates of the conductive layer a;

[0054] Second, select a fully exposed screw hole 102 near the side of the conductive layer a, and screw the screw 201 onto it. The standard for screwing it in place is that the lower end of the screw 201 is exposed and visible.

[0055] Third, rotate and slide the pressure block 202 on the screw 201 to make the pressure block 202's pressing position and pressing area on the conductive layer a sufficient and appropriate, and then place the pressure block 202 on the conductive layer a;

[0056] Fourth, rotate the fastening nut 204 downwards so that the pressure block 202 itself does not move, and fully and appropriately press the conductive layer a. During this process, the pressure block 202 can be held and fixed by hand.

[0057] At this point, the entire installation method is complete. After all the terminals b are soldered, the disassembly method of the movable pressure block unit 2 is generally the same as the installation method described above. Moreover, during disassembly, even if the pressure block 202 rotates and loosens along with the fastening nut 204, there is little problem and it is difficult to scratch the conductive layer a.

[0058] On the other hand, the word "active" in the active pressing unit 2 mainly includes the following two meanings:

[0059] First, since there are many screw holes 102, the movable pressure block unit 2 can select one of them for installation. Even if the conductive layer a is irregularly shaped, the movable pressure block unit 2 can fully press and fix it. This pressing method is flexible, adjustable, practical and efficient.

[0060] Secondly, the pressure block 202 has an elongated hole 203, so it can slide and rotate on the screw 201. This makes the selection of the screw hole 102 very flexible and not unique. Even if a relatively unsuitable screw hole that is far from the side of the conductive layer a is selected, the pressure block 202 can still press the side of the conductive layer a sufficiently and appropriately. This is also flexible and efficient.

[0061] The width of the oblong hole 203 is slightly larger than the diameter of the screw 201, the length of the pressure block 202 is 3-5cm, and the length of the oblong hole 203 is 70-80% of its length.

[0062] The movable pressure block unit 2 also includes a gripping ring 205 disposed on the screw 201.

[0063] In this embodiment, the gripping ring 205 is sleeved or clamped onto the screw 201, or cast onto the latter. Its first function is to make the rotation of the screw 201 relatively comfortable when it rotates to connect to the screw hole 102. Otherwise, the operator's fingers would need to grip the threaded part with great force, which is very inefficient and uncomfortable.

[0064] The U-shaped frame unit 4 includes a vertical plate 401 disposed on the lower surface of the rectangular plate 101, a horizontal plate 402 disposed on the vertical plate 401, and a support screw hole 403 disposed on the horizontal plate 402 for mounting the screw 201.

[0065] In this embodiment, the vertical plate 401 also needs to avoid the screw 201 when selecting the installation position.

[0066] In addition, the support screw hole 403 is located at the middle position of the horizontal plate 402, which is also aligned with the middle position of the opening 3, so that the fastening nut 204 supports the middle of the pressure block 202 as much as possible, avoiding the harmful phenomenon of the pressure block 202 tilting itself when supporting the pressure block 202.

[0067] The general method of using the movable pressure block unit 2 on the U-shaped frame unit 4 is as follows:

[0068] First, the idle movable pressure block unit 2 is generally screwed onto the screw hole 102 near the side. It is first removed from the screw hole 102, and the screw 201 and the fastening nut 204 are separated.

[0069] Second, the screw 201 passes through the support screw hole 403 from bottom to top, and the fastening nut 204 is reconnected to the screw 201. Then the pressure block 202 is placed on the opening 3, and the lower end of the former naturally falls on the fastening nut 204.

[0070] Third, rotate the screw 201 on the support screw hole 403, and / or rotate the fastening nut 204 on the screw 201, so that the pressure block 202 rises and falls as needed until it fully and properly lifts the conductive layer a, so that the conductive layer a on this side has been raised, leaving enough space for the downward protruding terminal b.

[0071] Fourth, when there are enough movable pressure block units 2 on the rectangular plate 101, the movable pressure block unit 2 does not even need to be removed from the U-shaped frame unit 4. It is only necessary to lower the pressure block 202 until its upper surface does not protrude. When the number of movable pressure block units 2 is relatively small, the movable pressure block unit 2 can be reused on the rectangular plate 101 by first unscrewing the fastening nut 204 and then unscrewing the screw 201.

[0072] It should be noted that when the conductive layer a is lifted on the fixed, horizontal rectangular plate 101, there is no need and no way to install other movable pressure block units 2 on it. The clamping and fixing effect of the conductive layer a is entirely provided by the movable pressure block units 2 on the rotatable rectangular plate 101. Several movable pressure block units 2 can be set appropriately at this location.

[0073] At this point, the clamping and fixing strength of the conductive layer a is still sufficient to fully meet the stability requirements of the welding and installation operation of the terminal b.

[0074] The shape of the opening 3 and the cross-sectional shape of the pressing block 202 are both rectangular, and the length and width of the opening 3 are 2-4 mm larger than the length and width of the cross-section of the pressing block 202.

[0075] In this embodiment, the thickness of the rectangular plate 101 is 0.2-1.0cm, and the thickness of the pressing block 202 is 1.5-2.0cm.

[0076] The cylinder shaft of the lifting cylinder 13 is also provided with a height fine-tuning frame unit 5 for lifting the rectangular plate 101 by installing the removed movable pressure block unit 2.

[0077] In this embodiment, the active pressing unit 2 is used in three main ways, and only one of these ways can be triggered for a single active pressing unit 2:

[0078] First, screw the screw hole 102 and press down to fix the conductive layer a;

[0079] Second, the upward protrusion at the opening 3 supports and fixes one side of the relatively inclined conductive layer a, so that the downward protruding terminal b has sufficient alignment space during welding.

[0080] Third, a height fine-tuning frame unit 5 is installed to stably support the lower surface of the rotatable rectangular plate 101.

[0081] Additionally, it should be noted that:

[0082] Firstly, the rotation and lifting action of the rectangular plate 101 mainly relies on the lifting cylinder 13. The lifting and adjusting effect of the movable pressure block unit 2 on the height fine-tuning frame unit 5 is only fine-tuning, supplementary, and auxiliary.

[0083] Secondly, when the lifting cylinder 13 controls the lifting of the rectangular plate 101, the movable pressure block unit 2 may slide and rub on the lower surface of the rectangular plate 101. Therefore, the lower surface of the rotatable rectangular plate 101 can be provided with a common smooth coating as needed. Alternatively, a more direct solution is to manually lift the rectangular plate 101 before each lifting adjustment of the lifting cylinder 13, and then lower it after the cylinder stops moving. This process is repeated multiple times until the angle between the rectangular plate 101 and the fixed rectangular plate 101 matches the angle of the conductive layer a.

[0084] The height fine-tuning frame unit 5 includes a mounting plate 501, a mounting screw hole 502 disposed on the mounting plate 501 for connecting the cylinder shaft, a vertical rod 503 disposed at one end of the mounting plate 501 for inserting the removed pressure block 202, and a circular hole 504 disposed at the other end of the mounting plate 501 for supporting the pressure block 202 by installing the removed screw 201.

[0085] In this embodiment, the second function of the gripping ring 205 is reflected in the height fine-tuning frame unit 5. At this time, the screw 201 and the vertical rod 503 are inserted together into the elongated hole 203, so that the pressure block 202 is fixed laterally, while the screw 201 has a height-adjustable function in the circular hole 504, which makes the above-mentioned "height fine-tuning" effect possible.

[0086] The adjustable support height mentioned above relies on the end face of the grip ring 205, as detailed in the attached document. Figure 8 and 10 .

[0087] On the other hand, the vertical rod 503 is a round rod, and the size setting between it and the round hole 504 allows it and the screw 201 to simultaneously lock the two arc-shaped ends of the elongated hole 203, so that the pressure block 202 has a sufficiently stable lateral limiting effect on the height fine-tuning frame unit 5.

[0088] At this point, although the pressure block 202 is supported only on one side, the support strength is still sufficient. Alternatively, the vertical rod 503 can be configured as a screw with a support nut, which, together with the fastening nut 204, can more stably support the pressure block 202.

[0089] The circular hole 504 is either a screw hole or a smooth hole.

[0090] In this embodiment, when the circular hole 504 is a screw hole, the attached diagram can be referenced. Figure 8 At this point, the fastening nut 204 can be installed either on the screw 201 or the cylinder shaft, and both locations provide a reinforced screw connection.

[0091] When the circular hole 504 is a smooth hole, that is, without threads, then the attached diagram can be referenced. Figure 10 At this time, the fastening nut 204 can only be screwed onto the screw rod 201 and supported on the upper surface of the mounting plate 501. In this method, the threaded section of the cylinder shaft is also screwed onto the mounting screw hole 502. Although the screwing stability is relatively poor compared to the above method, it can still effectively support the rectangular plate 101.

[0092] In other words, the flexible use of the movable pressure block unit 2 on the height fine-tuning frame unit 5 removes the restrictions on the style requirements of the circular hole 504, which is very practical.

[0093] The retraction distance L of the gripping ring 205 on the end face of the screw 201 is ≥2cm.

[0094] In this embodiment, the aforementioned end face refers to the end face that is relatively closer to the gripping ring 205 among the two end faces, and the aforementioned indentation distance L ensures that when the screw 201 is on the height fine-tuning frame unit 5, the former has sufficient size for the lateral engagement limiting pressure block 202.

[0095] On the other hand, the height fine-tuning frame unit 5, when paired with a movable pressure block unit 2, upgrades the original "point-like" support pattern of the lifting cylinder 13 on the rectangular plate 101 to a "linear" pattern, resulting in better support stability. The aforementioned "linear" position refers to one of the upper length edges of the pressure block 202.

[0096] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various modifications can be made without departing from the spirit of the present invention. These are non-inventive modifications and are protected by patent law as long as they fall within the scope of the claims of the present invention.

Claims

1. A welding device for preparing a conductive layer of a composite busbar, comprising a base plate (11), a column (12), a lifting cylinder (13), and a hinge (14), characterized in that: It also includes two perforated plate units (1) disposed on the hinge (14) and respectively connected to the column (12) and the lifting cylinder (13), several movable pressure block units (2) disposed on the perforated plate units (1) and used to press down and fix the conductive layer (a), an opening (3) disposed on the perforated plate units (1), and a U-shaped frame unit (4) disposed on the lower surface of the perforated plate units (1) and used to lift the conductive layer (a) at the opening (3) by installing the removed movable pressure block units (2). The perforated plate unit (1) includes a rectangular plate (101) that connects to the hinge (14) and is used to fix the column (12) or press down the lifting cylinder (13), and screw holes (102) that are arranged on the rectangular plate (101) and are evenly spaced in a linear arrangement for installing the movable pressure block unit (2). The movable pressure block unit (2) includes a screw (201) disposed on the screw hole (102), a pressure block (202), an elongated hole (203) disposed on the pressure block (202) and used to pass through the screw (201), and a fastening nut (204) disposed on the screw (201) and used to press down the pressure block (202). The movable pressure block unit (2) also includes a gripping ring (205) disposed on the screw (201). The cylinder shaft of the lifting cylinder (13) is also provided with a height fine-tuning frame unit (5) for lifting the rectangular plate (101) by installing the movable pressure block unit (2) that has been removed. The height fine-tuning frame unit (5) includes a mounting plate (501), a mounting screw hole (502) on the mounting plate (501) for connecting the cylinder shaft, a vertical rod (503) at one end of the mounting plate (501) for inserting the removed pressure block (202), and a round hole (504) at the other end of the mounting plate (501) for supporting the pressure block (202) by installing the removed screw (201). The retraction distance of the gripping ring (205) on the end face of the screw (201) is ≥2cm.

2. The conductive layer welding equipment for preparing composite busbars according to claim 1, characterized in that: The U-shaped frame unit (4) includes a vertical plate (401) disposed on the lower surface of the rectangular plate (101), a horizontal plate (402) disposed on the vertical plate (401), and a support screw hole (403) disposed on the horizontal plate (402) for mounting the screw (201).

3. The conductive layer welding equipment for preparing composite busbars according to claim 1, characterized in that: The shape of the opening (3) and the cross-sectional shape of the pressure block (202) are both rectangular. The length and width of the opening (3) are 2-4 mm larger than the length and width of the cross-section of the pressure block (202).

4. The conductive layer welding equipment for preparing composite busbars according to claim 1, characterized in that: The circular hole (504) is either a screw hole or a smooth hole.

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