Ultrasonic welding method and welding device capable of preventing wire leakage

Abstract

The invention belongs to the technical field of welding, and discloses an anti-wire-running ultrasonic welding method and welding device.The anti-wire-running ultrasonic welding method comprises the steps that S1, a plurality of core wires are placed on a lower die; s2, the multiple core wires are welded into a core wire whole through a first upper welding head; s3, the whole core wire is taken out, the terminal is placed on the lower die, the whole core wire is placed on the terminal, the first upper welding head is replaced with a second upper welding head, and the width of the second upper welding head is larger than that of the first upper welding head; and S4, integrally welding the core wire to the terminal through a second upper welding head. The welding device is applied to the wire running prevention ultrasonic welding method, the wire running phenomenon can be greatly reduced, and the probability of potential safety hazards is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of welding, and in particular to an ultrasonic welding method and a welding device for preventing wire escape. Background Art

[0002] Ultrasonic welding uses high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the two surfaces of the objects rub against each other to form a fusion between the molecular layers.

[0003] The wire harness is composed of multiple core wires. When the wire harness is welded to the terminal, the above-mentioned ultrasonic welding is usually used. During welding, multiple core wires need to be welded to one terminal, and a single core wire has only 0.15-0.2 wires. During welding, the "wire running" phenomenon is prone to occur, that is, the core wire will extend outward from the gap of the ultrasonic welding equipment; if the above-mentioned wire running phenomenon occurs, manual wire trimming is required. If the wire is not trimmed or the wire trimming is not done well, the contact between the core wire and the cable shielding layer is likely to cause a short circuit, posing a safety hazard. Summary of the invention

[0004] The object of the present invention is to provide an ultrasonic welding method and a welding device for preventing wire running, which can greatly reduce the above-mentioned wire running phenomenon and reduce the probability of safety hazards.

[0005] To achieve this object, the present invention adopts the following technical solutions:

[0006] The ultrasonic welding method for preventing wire running comprises the following steps:

[0007] S1. Place multiple core wires on the lower mold;

[0008] S2, welding the plurality of core wires into a core wire as a whole by using a first upper welding head;

[0009] S3, taking out the core wire as a whole, placing the terminal on the lower mold, placing the core wire as a whole on the terminal, and replacing the first upper welding head with a second upper welding head, wherein the width of the second upper welding head is greater than the width of the first upper welding head;

[0010] S4. Weld the core wire as a whole to the terminal using a second upper welding head.

[0011] In some embodiments, the first upper welding head forms a first weld print area when welding, and the second upper welding head forms a second weld print area when welding, and the second weld print area covers the first weld print area in width.

[0012] In some embodiments, the first upper welding head forms a first welding depth when welding; the second upper welding head forms a second welding depth when welding, and the depth of the first welding depth is not greater than the depth of the second welding depth.

[0013] In some embodiments, the first upper welding head welds the plurality of core wires with a first welding energy, and the second upper welding head welds the entire core wire with a second welding energy, and the first welding energy is less than the second welding energy.

[0014] In some embodiments, the first welding energy=first welding power*first welding time; the second welding energy=second welding power*second welding time.

[0015] A welding device is also provided, which is applied to the ultrasonic welding method for preventing wire escape as described above, and the welding device comprises:

[0016] Lower mold;

[0017] A first upper welding head and a second upper welding head, wherein the width of the second upper welding head is greater than the width of the first upper welding head, and one of the first upper welding head and the second upper welding head is detachably disposed above the lower mold;

[0018] Push blocks, the two push blocks can abut against both sides of the first upper welding head or the second upper welding head in the width direction.

[0019] In some embodiments, a side of the first upper welding head facing the lower mold has a plurality of first welding teeth, and a side of the second upper welding head facing the lower mold has a plurality of second welding teeth.

[0020] In some embodiments, a plurality of the first welding tooth arrays are distributed on the first upper welding head; a plurality of the second welding tooth arrays are distributed on the second upper welding head.

[0021] Beneficial effects of the present invention:

[0022] First, a plurality of core wires are welded into a core wire as a whole by using a first upper welding head, and then the core wire as a whole is covered by using a second upper welding head with a larger width, so that the core wire as a whole can be welded to the terminal, thereby preventing a single core wire from overflowing from the edge of the welding head during one welding process; that is, if a single core wire is loose when welding a plurality of core wires into a core wire as a whole by using a first welding head, the second upper welding head with a larger width can be used to remedy and cover it, thereby minimizing the occurrence of the loose wire phenomenon and reducing the probability of safety hazards;

[0023] By using the two-way welding method of first welding with the upper welding head and then welding with the upper welding head, multiple core wires can be arranged and positioned twice; the arrangement and positioning requirements are lower than those of the traditional one-time welding method; and because the energy is transmitted from the outside to the inside and attenuated layer by layer during ultrasonic welding, the load conditions and friction behaviors of each core wire are more consistent than those of one-time welding, and the welding quality is more consistent. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a flow chart of the ultrasonic welding method for preventing wire running of the present invention;

[0025] Figure 2 It is a schematic diagram of the first upper welding head welding the core wire to form a core wire as a whole according to the present invention;

[0026] Figure 3 It is a schematic diagram of the second upper welding head welding the core wire as a whole to the terminal of the present invention.

[0027] In the figure: 1. first upper welding head; 2. lower mold; 3. core wire; 4. core wire as a whole; 5. second upper welding head; 6. terminal; 7. push block. DETAILED DESCRIPTION

[0028] The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for ease of description, only parts related to the present invention, rather than all structures, are shown in the accompanying drawings.

[0029] In the description of the present invention, unless otherwise clearly specified and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0030] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0031] In the description of this embodiment, the terms "upper", "lower", "right", etc., directions or positional relationships are based on the directions or positional relationships shown in the drawings, and are only for the convenience of description and simplification of operation, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used to distinguish in the description and have no special meaning.

[0032] like Figures 1 to 3 As shown, the present invention provides an ultrasonic welding method for preventing wire escape, which comprises the following steps:

[0033] S1, placing a wire harness containing a plurality of core wires 3 on a lower mold 2;

[0034] S2, welding a plurality of core wires 3 into a core wire body 4 by a first upper welding head 1;

[0035] S3, take out the core wire 4, place the terminal 6 on the lower mold 2, place the core wire 4 on the terminal 6, and replace the first upper welding head 1 with the second upper welding head 5, the width of the second upper welding head 5 is greater than the width of the first upper welding head 1;

[0036] S4 . Weld the core wire 4 to the terminal 6 through the second upper welding head 5 .

[0037] Through the above steps, multiple core wires 3 are first welded into a core wire entity 4 by the first upper welding head 1, and then the above core wire entity 4 is covered by the second upper welding head 5 with a larger width, so that the core wire entity 4 can be welded to the terminal 6, thereby preventing the single core wire 3 from overflowing from the edge of the welding head during one welding process; that is, if a single core wire 3 is loose when welding multiple core wires 3 to form the core wire entity 4 by the first upper welding head 1, it can be remedied and covered by the second upper welding head 5 with a larger width, thereby minimizing the occurrence of the loose wire phenomenon and reducing the probability of safety hazards.

[0038] In addition, by using the two-way welding method of first welding with the first upper welding head 1 and then welding with the second upper welding head 5, multiple core wires 3 can be arranged and positioned twice during welding; the arrangement and positioning requirements are lower than those of the traditional one-time welding method; and because energy is transmitted from the outside to the inside and attenuated layer by layer during ultrasonic welding, the load conditions and friction behaviors of each core wire 3 are more consistent in welding quality than those of one-time welding.

[0039] It should be noted that the width of the first upper welding head 1 and the width of the second upper welding head 5 are Figure 2 The width of the welding head is in the X direction. In other words, the width of the welding head is perpendicular to the direction of the core wire.

[0040] In some embodiments, the first upper welding head 1 forms a first weld mark area on the core wire 4 after welding the core wire 3, and the second upper welding head 5 forms a second weld mark area on the core wire 4 after welding the core wire 4 to the terminal 6, and the second weld mark area covers the first weld mark area in width. That is to say, when the core wire 4 is welded to the terminal 6, it is only necessary to ensure that the welding coverage is achieved in the width direction to avoid welding omissions in the width direction, so that the welding wire can be welded to the terminal 6 as a whole.

[0041] In some embodiments, the first upper welding head 1 forms a first welding depth when welding the core wire 3, and the second upper welding head 5 forms a second welding depth when welding. It should be noted here that the welding depth referred to in the current embodiment is the welding depth, that is, the depth of the first upper welding head 1 pressing the core wire 3 is the first welding depth, and the depth of the second upper welding head 5 pressing the core wire as a whole 4 is the second welding depth. In the current embodiment, the depth of the first welding depth is not greater than the depth of the second welding depth, so that when the second welding print area covers the first welding print area in width, it can ensure that the core wire as a whole 4 is in smooth contact with the terminal 6, avoiding the phenomenon of loose welding.

[0042] In some embodiments, in order to ensure that the core wire 4 is welded to the terminal 6 more smoothly, the first upper welding head 1 welds the multiple core wires 3 with the first welding energy, and the second upper welding head 5 welds the core wire 4 with the second welding energy, wherein the first welding energy is less than the second welding energy, so that the welding of the core wire 4 to the terminal 6 is more stable than welding multiple core wires 3, avoiding the occurrence of cold welding phenomena such as loose welding. Further, the first welding energy = the first welding power * the first welding time; the second welding energy = the second welding power * the second welding time. It should be noted that the specific welding power and the time required for welding need to be set according to different core wires 3 and terminals 6, and are not specifically limited.

[0043] like Figure 2 and Figure 3 As shown, the present invention also provides a welding device, which is used in the above-mentioned ultrasonic welding method for preventing wire running, and the welding device includes a lower mold 2, a first upper welding head 1, a second upper welding head 5 and a push block 7; the width of the second upper welding head 5 is greater than the width of the first upper welding head 1, and the first upper welding head 1 and the second upper welding head 5 are selectively detachably arranged above the lower mold 2, and the push block 7 can abut on both sides of the first upper welding head 1 or the second upper welding head 5 in the width direction; when the push block 7 abuts, the side of the push block 7 facing the lower mold 2 protrudes out of the side of the first upper welding head 1 or the second upper welding head 5 facing the lower mold 2.

[0044] Through the above structure, the first upper welding head 1 and the second upper welding head 5 can be selected to be placed between the two push blocks 7, and then the multiple core wires 3 are placed between the two push blocks 7 for restriction. The first upper welding head 1 is pressed onto the multiple core wires 3 to form a first welding mark area, and similarly, a plurality of second upper welding heads 5 are pressed onto the core wire as a whole 4 to form a second welding mark area.

[0045] It should be noted that the detachable manner of the first upper welding head 1 and the second upper welding head 5 is not specifically limited. It should also be noted that the lower mold 2 can be a welding head or a bottom felt.

[0046] In some embodiments, the first upper welding head 1 has a plurality of first welding teeth on one side facing the lower mold 2, and the second upper welding head 5 has a plurality of second welding teeth on one side facing the lower mold 2. The first welding teeth are pressed to the core wire 3 to form a first welding depth; and the second welding teeth are pressed to the core wire as a whole 4 to form a second welding depth. Further, a plurality of first welding teeth arrays are distributed on the first upper welding head 1; and a plurality of second welding teeth arrays are distributed on the second upper welding head 5, so that the welding area is uniform and neat.

[0047] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, various obvious changes, readjustments and substitutions can be made without departing from the protection scope of the present invention. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. The ultrasonic welding method for preventing wire from running away is characterized by: The steps include: S1, placing a plurality of core wires (3) on the lower mold (2); S2, welding the plurality of core wires (3) into a core wire whole (4) by using a first upper welding head (1); S3, taking out the core wire as a whole (4), placing the terminal (6) on the lower mold (2), placing the core wire as a whole (4) on the terminal (6), and replacing the first upper welding head (1) with a second upper welding head (5), wherein the width of the second upper welding head (5) is greater than the width of the first upper welding head (1); S4. Welding the core wire as a whole (4) to the terminal (6) through a second upper welding head (5).

2. The ultrasonic welding method for preventing wire running according to claim 1, characterized in that: The first upper welding head (1) forms a first weld print area when welding, and the second upper welding head (5) forms a second weld print area when welding, and the second weld print area covers the first weld print area in width.

3. The ultrasonic welding method for preventing wire running according to claim 1, characterized in that: The first upper welding head (1) forms a first welding depth when welding; the second upper welding head (5) forms a second welding depth when welding, and the depth of the first welding depth is not greater than the depth of the second welding depth.

4. The ultrasonic welding method for preventing wire running according to claim 1, characterized in that: The first upper welding head (1) welds the plurality of core wires (3) with a first welding energy, and the second upper welding head (5) welds the entire core wire (4) with a second welding energy, wherein the first welding energy is less than the second welding energy.

5. The ultrasonic welding method for preventing wire running according to claim 4, characterized in that: The first welding energy=first welding power*first welding time; the second welding energy=second welding power*second welding time.

6. A welding device, used in the ultrasonic welding method for preventing wire from running away as claimed in any one of claims 1 to 5, characterized in that: The welding device comprises: Lower mold (2); A first upper welding head (1) and a second upper welding head (5), wherein the width of the second upper welding head (5) is greater than the width of the first upper welding head (1), and one of the first upper welding head (1) and the second upper welding head (5) is detachably arranged above the lower mold (2); Push blocks (7), the two push blocks (7) being capable of abutting against both sides of the first upper welding head (1) or the second upper welding head (5) in the width direction.

7. The welding device according to claim 6, characterized in that: The first upper welding head (1) has a plurality of first welding teeth on the side facing the lower mold (2), and the second upper welding head (5) has a plurality of second welding teeth on the side facing the lower mold (2).

8. The welding device according to claim 7, characterized in that: A plurality of the first welding tooth arrays are distributed on the first upper welding head (1); and a plurality of the second welding tooth arrays are distributed on the second upper welding head (5).

Images