Welding and shape correcting integrated welding electrode and welding method thereof

Abstract

The invention provides a welding and shape correcting integrated welding electrode and a welding method, and belongs to the technical field of welding. The welding and shape correcting integrated welding electrode comprises an electrode stem, a shaft shoulder, a spring, a bakelite pressing head and an electrode tip; certain upsetting force is applied to the part through the shaft shoulder, the spring and the bakelite pressing head in the welding and pre-pressing process, and therefore the assembly clearance of the part before welding is effectively eliminated. During welding, resistance heat generated when current passes through the workpieces is used for melting the contact surface between the two workpieces, at the moment, the bakelite pressing heads around the electrode tips continuously apply certain upsetting force to the surfaces of the workpieces, and therefore welding deformation is eliminated, and the quality of a weld joint is improved. The electrode tip is pressed on the surface of the workpiece at a certain pressure value, the electrode tip is continuously kept in a pressed state on the surface of the workpiece during welding, and the problem that the indentation size of a part is out of tolerance due to welding deformation is solved.

Description

Technical Field

[0001] The invention belongs to the technical field of welding, and relates to a welding electrode integrated with welding and shaping and a welding method thereof. Background Art

[0002] Filter resistance welding is a welding method that uses the resistance heat generated when current passes through the filter material. Filter resistance welding uses the resistance heat effect generated when current passes through the filter material to heat the contact surface of the filter material to a molten or plastic state, thereby achieving welding. This welding method mainly depends on parameters such as the resistance between the workpiece contacts, the current passed, and the power-on time. The basic principle of resistance welding (Resistance Welding) is to press the workpiece to be welded between two electrodes and apply current. When the current flows through the contact surface of the workpiece and the adjacent area, a resistance heat effect will be generated, heating the workpiece to a molten or plastic state, thereby forming a metal bond. This process mainly depends on three factors: the resistance between the workpiece contacts, the current passed, and the power-on time.

[0003] During resistance welding of filter screen and resistance welding of plate-filter screen-plate, due to the existence of mesh in the filter screen, the metal mesh wire melts or plastically deforms during welding and is reshaped under the action of electrode pressure. The original mesh part is filled with melted or deformed metal, resulting in thinning of the part to be welded. However, in traditional electrode welding, affected by welding pressure, welding current and assembly status of parts, different degrees of thinning occur at the weld point. When the thinning is serious, warping and deformation will occur near the weld point, as well as problems such as excessive indentation on the surface of the part. Currently, cold proofing is used to proofread the warping and excessive indentation problems. In severe cases, argon arc welding may be used for repair welding, but the qualified rate is low and the rework cycle is long. Summary of the invention

[0004] In view of the problems existing in the prior art, the present invention provides a welding electrode and a welding method integrating welding and shaping, which solves the problem of excessive indentation size of parts due to welding deformation and improves welding quality.

[0005] The present invention is achieved through the following technical solutions: A welding electrode integrated with welding and shaping, comprising: Electrode rod, shoulder, spring, bakelite indenter and electrode head; The electrode head is mounted on one end of the electrode rod; the shoulder is mounted on the other end of the electrode rod; The bakelite pressure head is installed at the connection between the electrode head and the electrode rod, and the spring sleeve is arranged on the electrode rod 1 and is arranged between the shaft shoulder and the bakelite pressure head.

[0006] Preferably, the end of the electrode rod close to the shaft shoulder is provided with a thread.

[0007] Preferably, the electrode rod and the shaft shoulder are assembled and connected by means of a thread and a nut.

[0008] Preferably, the installation height of the bakelite pressure head is the same as the outer ring of the electrode head.

[0009] Preferably, the bakelite pressure head and the electrode head are in contact with each other by sliding.

[0010] Preferably, the bakelite pressure head is made of insulating material.

[0011] A welding method based on a welding electrode integrating welding and shaping, comprising: Place the part to be welded on the workpiece surface just below the electrode tip; Press the electrode tip onto the part to be welded on the workpiece surface, and keep the electrode tip pressed against the workpiece surface during welding; The workpiece melts under the action of the electric current and forms a weld nugget, which is then kept in a clamped state for a preset time before being removed from the workpiece surface.

[0012] Preferably, the workpiece is mounted on a workbench of a resistance welding device.

[0013] Preferably, the portion of the part to be welded is at 90° to the axis of the electrode head.

[0014] Preferably, the preset time is 5-10 seconds.

[0015] Compared with the prior art, the present invention has the following beneficial technical effects: The present invention provides a welding electrode that integrates welding and shaping, comprising an electrode rod, a shoulder, a spring, a bakelite pressure head and an electrode head; the electrode head is installed at one end of the electrode rod; the shoulder is installed at the other end of the electrode rod; the bakelite pressure head is installed at the connection between the electrode head and the electrode rod, and the spring is sleeved on the electrode rod and arranged between the shoulder and the bakelite pressure head. The pressure of resistance welding mainly comes from the electrode, while the traditional resistance welding electrode is in point contact with the welded part, and the force-bearing area is very small. During welding, it is easier to deform the metal wire. The welding and shaping integrated welding electrode of the present invention applies a certain upsetting force to the part through the shoulder, spring and bakelite pressure head during the welding pre-tightening process, thereby effectively eliminating the assembly gap of the part before welding; during welding, the contact surface between the two workpieces is melted by the resistance heat generated when the current passes through the workpiece. At this time, the bakelite pressure head around the electrode head continues to apply a certain upsetting force to the workpiece surface, thereby eliminating welding deformation and improving the quality of the weld joint. In addition, the present invention also provides a welding method, pressing the electrode head on the workpiece surface with a certain pressure value, and continuing to keep the electrode head pressed on the workpiece surface during welding, thereby solving the problem of excessive size of the part indentation caused by welding deformation.

[0016] Furthermore, the welding electrode integrated with welding and shaping of the present invention is processed with a circle of thread on the outer ring of the traditional electrode, and the installation position of the bakelite pressure head is limited by adjusting the nut and the shaft shoulder; Furthermore, the present invention adds a circle of bakelite pressure heads to the outer ring of the traditional electrode. The electrode pressure head can firstly increase the pressure area to avoid deformation of the metal wire during welding; secondly, it can serve as a fixing and clamping device for the parts to be welded before welding.

[0017] Furthermore, the present invention provides a spring to compensate for the height difference caused by the wear of the electrode tip during continuous welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 Schematic diagram of the installation of the workpiece and the electrode head; Figure 2 is a schematic diagram of resistance welding electrodes; Figure 3 It is a schematic diagram of the structure of filter parts; In the figure: electrode rod 1, thread 2, nut 3, shaft shoulder 4, spring 5, bakelite pressure head 6, electrode head 7. DETAILED DESCRIPTION

[0019] The present invention is further described in detail below in conjunction with specific embodiments, which are intended to explain the present invention rather than to limit it.

[0020] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0021] Since the application object is a filter, and the filter structure is a mesh part made of metal wire, the filter wire will melt and solidify during welding. Resistance welding is a pressure welding. When the filter wire melts and solidifies, it will be affected by the resistance welding pressure and will produce local deformation (local deformation is due to the deformation of the wire under pressure after the filter wire melts). Local deformation causes the metal at the welding point to become thinner, and eventually the indentation is too deep. The pressure of resistance welding mainly comes from the electrode, and the traditional resistance welding electrode is in point contact with the welded part, and the force area is very small. It is easier to deform the metal wire during welding; The present invention provides a welding electrode with integrated welding and shaping in view of the above problems. The electrode is formed by adding a circle of bakelite pressure head on the outer ring of the traditional electrode. The electrode pressure head can firstly increase the pressure area to avoid the metal wire from being deformed during welding; secondly, it can serve as a fixing and clamping device for the parts to be welded before welding. Specifically, it includes: Electrode rod 1, shaft shoulder 4, spring 5, bakelite pressure head 6 and electrode head 7; The electrode head 7 is mounted at one end of the electrode rod 1; the shoulder 4 is mounted at the other end of the electrode rod 1; The bakelite pressure head 6 is installed at the connection between the electrode head 7 and the electrode rod 1 , and the spring 5 is sleeved on the electrode rod 1 and arranged between the shaft shoulder 4 and the bakelite pressure head 6 .

[0022] Electrode rod 1: Electrode rod 1 is the main part of the electrode, used to transfer current and heat to realize the welding process.

[0023] Shoulder 4: Shoulder 4 is a key component of the electrode, which is used to limit the position during welding, and the bakelite pressure plays a supporting role; Spring 5: Spring 5 plays a role of buffering and pre-tightening in the electrode, which helps to maintain the stability of the electrode and improve the welding effect.

[0024] Bakelite pressure head 6: Bakelite pressure head is used for the insulating part of the electrode to prevent current leakage and short circuit, ensure the safety of the welding process, and effectively compact the welded materials during the welding process to ensure the welding quality.

[0025] Electrode head 7: Electrode head 7 is the working part of the electrode, which directly contacts the material to be welded to realize the welding function.

[0026] In one of the preferred implementations, a thread 2 is provided at the end of the electrode rod 1 close to the shaft shoulder 4 .

[0027] In one of the preferred implementations, the electrode rod 1 and the shaft shoulder 4 are assembled and connected by means of the cooperation of the thread 2 and the nut 3 .

[0028] In one of the preferred embodiments, the installation height of the bakelite pressure head 6 is the same as the outer ring of the electrode head 7. When the bakelite pressure head and the outer ring of the electrode head are at the same height, the two can form a tight fit when in contact, thereby reducing contact resistance and improving the reliability of electrical connection. The tight fit also helps prevent the intrusion of external factors such as dust and moisture, thereby maintaining a good state of electrical connection.

[0029] In one preferred embodiment, the bakelite pressure head 6 and the electrode head 7 are in contact with each other by sliding. The sliding contact mode can ensure that a stable electrical connection can be established between the bakelite pressure head and the electrode head when needed. This connection mode allows the electrical connection to be achieved by transmitting current through sliding contact under certain conditions (such as when a certain pressure or current is applied).

[0030] In one preferred embodiment, the material of the bakelite pressure head 6 is an insulating material. As an insulating material, the bakelite pressure head mainly compacts the welded material during welding to ensure welding quality, prevent current leakage or short circuit, and protect equipment and personnel safety. The sliding contact method can prevent current from passing through by maintaining a certain gap or sliding friction when electrical connection is not required, thereby meeting the insulation requirements. Generally, insulating bakelite, also known as bakelite, is used, which is a plastic product made by pressing phenolic compression powder with wood powder as filler.

[0031] Insulating bakelite has excellent insulation properties and is a commonly used insulating material in the electrical and electronic industries. It can maintain stable performance at high temperatures and is not easy to deform or melt. Insulating bakelite has high mechanical strength and can withstand certain pressure and impact. Insulating bakelite is easy to process into parts of various shapes and sizes to meet different application requirements.

[0032] The present invention processes a circle of thread 2 on the outer ring of the traditional electrode, firstly installs the nut 3 and the shoulder 4, the purpose of which is to limit the installation position of the bakelite pressure head 6, and then installs the spring 5 and the bakelite pressure head 6. The installation height of the bakelite pressure head 6 is the same as the outer ring of the electrode head 7 (by adjusting the nut 3 and the shoulder 4). The bakelite pressure head 6 and the electrode head 7 should be tightly matched and contacted in a sliding manner. The spring 5 is used to compensate for the height difference caused by the wear of the electrode head 7 during continuous welding.

[0033] A welding method based on a welding electrode integrating welding and shaping, comprising: Place the part to be welded on the workpiece surface just below the electrode tip 7; Press the electrode head 7 onto the part to be welded on the surface of the workpiece, and keep the electrode head 7 pressed against the surface of the workpiece during welding; The workpiece melts under the action of the electric current and forms a weld nugget, which is then kept in a clamped state for a preset time before being removed from the workpiece surface.

[0034] Preferably, the workpiece is mounted on a workbench of a resistance welding device.

[0035] Preferably, the portion of the part to be welded is at 90° to the axis of the electrode head 7 .

[0036] Preferably, the preset time is 5-10 seconds.

[0037] After the weld nugget is formed, continuing to maintain the clamping state can make the weld area denser and help eliminate welding defects such as pores and cracks, thereby improving the welding quality. In the clamping state, the molten nugget can dissipate heat faster and solidify to form a strong weld joint. If the clamping force is withdrawn too early, the molten nugget may produce defects such as shrinkage holes and cracks due to poor heat dissipation or external forces. The clamping state can also help stabilize the weld joint and prevent deformation or stress concentration caused by thermal expansion and contraction during welding.

[0038] The traditional method of eliminating the excessively deep indentation of the filter screen is: after resistance welding, the welds with excessively deep indentations are calibrated, and the resistance welds that cannot be eliminated by calibrating are eliminated by repair welding. The present invention provides a welding method based on a welding electrode that integrates welding and calibrating, in which the electrode head is pressed against the workpiece surface at a certain pressure value, and the electrode head is kept pressed against the workpiece surface during welding, thereby solving the problem of excessive indentation size of parts caused by welding deformation.

[0039] Embodiment 1, the purpose of the present invention is achieved through the following steps: (1) Install the parts on the workbench of the resistance welding equipment, and place the part to be welded directly under the electrode tip 7 and at 90° to the axis of the electrode tip 7, such as Figure 1 As shown: (2) Select the appropriate welding-shaping integrated electrode according to the part size Welding-calibration integrated electrode, its structure is as follows Figure 2 As shown: it includes an electrode rod 1, a shaft shoulder 4, a spring 5, a bakelite pressure head 6, and an electrode head 7.

[0040] (3) Without power, press the electrode tip 7 against the workpiece surface with a certain pressure value and keep it for about 5 seconds.

[0041] (4) Turn on the current switch and start welding. Keep the electrode tip 7 pressed against the workpiece surface during welding.

[0042] (5) The workpiece melts under the action of the current and forms a weld nugget. At this time, the electrode head 7 should not be removed, but should continue to maintain the clamping state for about 5 seconds before withdrawing from the part surface.

[0043] (6) The electrode tip 7 is removed from the workpiece surface, completing the welding.

[0044] Embodiment 2: The conventional method for eliminating deep indentations of a filter screen is as follows: after resistance welding, the welds with deep indentations are calibrated, and the resistance welds that cannot be eliminated by calibrating are eliminated by repair welding.

[0045] (1) Install the parts on the workbench of the resistance welding equipment, and place the part to be welded directly under the electrode tip 7 and at 90° to the axis of the electrode tip 7, such as Figure 1 As shown: (2) Select the appropriate welding-shaping integrated electrode according to the part size Welding-calibration integrated electrode, its structure is as follows Figure 2 As shown: it includes an electrode rod 1, a shaft shoulder 4, a spring 5, a bakelite pressure head 6, and an electrode head 7.

[0046] (3) Disconnect the current and press the electrode tip 7 against the workpiece surface with a certain pressure value for about 10 seconds.

[0047] (4) Turn on the current switch and start welding. Keep the electrode tip 7 pressed against the workpiece surface during welding.

[0048] (5) The workpiece melts under the action of the current and forms a weld nugget. At this time, the electrode head 7 should not be removed, but should continue to maintain the clamping state for about 10 seconds before withdrawing from the surface of the part.

[0049] Embodiment 3, the conventional method for eliminating the excessively deep indentation of the filter screen is: after resistance welding, the welds with excessively deep indentations are calibrated, and the resistance welds that cannot be eliminated by the calibration method are eliminated by repair welding.

[0050] (1) Install the parts on the workbench of the resistance welding equipment, and place the part to be welded directly under the electrode tip 7 and at 90° to the axis of the electrode tip 7, such as Figure 1 As shown: (2) Select the appropriate welding-shaping integrated electrode according to the part size Welding-calibration integrated electrode, its structure is as follows Figure 2 As shown: it includes an electrode rod 1, a shaft shoulder 4, a spring 5, a bakelite pressure head 6, and an electrode head 7.

[0051] (3) Disconnect the current and press the electrode tip 7 against the workpiece surface with a certain pressure value for about 7 seconds.

[0052] (4) Turn on the current switch and start welding. Keep the electrode tip 7 pressed against the workpiece surface during welding.

[0053] (5) The workpiece melts under the action of the current and forms a weld nugget. At this time, the electrode head 7 should not be removed, but should continue to maintain the clamping state for about 7 seconds before withdrawing from the part surface.

[0054] The advantages of the method of the present invention are as follows: the shoulder 4, the spring 5 and the bakelite pressure head 6 apply a certain upsetting force to the parts during the welding pre-tightening process, thereby effectively eliminating the assembly gap of the parts before welding; during welding, the contact surface between the two workpieces is melted by the resistance heat generated when the current passes through the workpieces. At this time, the bakelite pressure head 6 around the electrode head 7 continuously applies a certain upsetting force to the workpiece surface, thereby eliminating welding deformation and improving the quality of the weld joint.

[0055] The spring 5 is usually installed between the bakelite pressure head and the shaft shoulder 4 to provide the necessary preload and buffering effect. The installation of the spring 5 needs to ensure that the preload is moderate, which can not only maintain the stability of the electrode, but also avoid damage caused by excessive preload.

[0056] Bakelite pressure head is a plastic product made by pressing bakelite powder or bakelite powder.

[0057] Bakelite has the characteristics of excellent quality, good insulation, strong impact resistance, first-class toughness, friction resistance, high temperature resistance, grease resistance, etc. Bakelite indenters are used in the insulating part of electrodes to prevent current leakage and short circuit.

[0058] It is wrapped around the periphery of the electrode rod 1 and the electrode head and fixed in place by bonding, fastening or other means.

[0059] The electrode head 7 is usually tightly connected to the electrode rod 1 through precision machining and matching. This connection needs to ensure that the electrode head 7 can stably transfer current and heat during the welding process and maintain good contact with the material to be welded.

[0060] During the installation and connection process, it is necessary to ensure that all parts are clean and dry to avoid the influence of impurities and moisture on the welding quality. The matching between the various parts should be accurate to ensure the stability of the electrode and the welding effect. The preload force of the spring 5 should be moderate to avoid instability or damage of the electrode caused by excessive or insufficient force. The use of the bakelite pressure head 6 should comply with safety standards to ensure the safety of the welding process.

[0061] The connection modes of the electrode head 7 and the electrode rod 1 are mainly as follows: Threaded connection, thread 2 connection is a common connection method, which requires the thread 2 parts of the electrode rod 1 and the electrode head 7 to be buckled together. This connection method has good repeatability and is firm and reliable. When using thread 2 connection, it is necessary to ensure that the thread 2 specifications of the electrode rod 1 and the electrode head 7 are the same, and the thread 2 structure should meet the standard requirements. At the same time, it is necessary to apply appropriate preload force during connection to overcome the concave and achieve full fit, but the preload force should not be too large, exceeding the yield strength of the joint, nor too small, otherwise it will not provide sufficient positive pressure and friction between the threads 2, which is easy to cause loosening.

[0062] The snap-fit ​​connection is a method of snapping the electrode rod 1 and the electrode head 7 together using a snap ring. This connection method requires that corresponding snap rings be installed on the electrode rod 1 and the electrode head 7, respectively, and the connection can be completed by docking the snap rings. Compared with the threaded connection 2, the snap-fit ​​connection can more quickly disassemble and replace the electrode, which is convenient for use and maintenance.

[0063] The welding connection is to connect the electrode rod 1 and the electrode head 7 by welding technology. This connection method requires certain welding technology and equipment. When using welding connection, special attention should be paid to parameters such as welding temperature, current and time to ensure welding quality. Welding connection is usually stronger and more stable than threaded connection and snap-fit ​​connection, and is suitable for some occasions that require long-term use.

[0064] It should be noted that the terms "including" and "having" and any variations thereof in the specification and claims of the present invention and the above-mentioned drawings are intended to cover non-exclusive inclusions. For example, a process, method, system, product or apparatus comprising a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or apparatus.

[0065] It should be noted that when a component is referred to as being "fixed to" another component, it may be directly on the other component or there may be a central component. When a component is considered to be "connected to" another component, it may be directly connected to the other component or there may be a central component at the same time. When a component is considered to be "set on" another component, it may be directly set on the other component or there may be a central component at the same time.

[0066] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used in the specification of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0067] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Any ordinary technician in the industry can smoothly implement the present invention as shown in the drawings and described above. However, any equivalent changes, modifications and evolutions made by technicians familiar with the profession without departing from the scope of the technical solution of the present invention using the technical content disclosed above are all equivalent embodiments of the present invention. At the same time, any equivalent changes, modifications and evolutions made to the above embodiments based on the essential technology of the present invention are still within the protection scope of the technical solution of the present invention.

Claims

1. A welding electrode integrating welding and shaping, characterized in that: include, An electrode rod (1), a shaft shoulder (4), a spring (5), a bakelite pressure head (6), and an electrode head (7); The electrode head (7) is mounted on one end of the electrode rod (1); the shaft shoulder (4) is mounted on the other end of the electrode rod (1); The bakelite pressure head (6) is installed at the connection between the electrode head (7) and the electrode rod (1), and the spring (5) is sleeved on the electrode rod (1) and arranged between the shaft shoulder (4) and the bakelite pressure head (6).

2. The welding electrode integrated with welding and shaping according to claim 1, characterized in that: A thread (2) is provided at the end of the electrode rod (1) close to the shaft shoulder (4).

3. The welding electrode integrated with welding and shaping according to claim 2, characterized in that: The electrode rod (1) and the shaft shoulder (4) are assembled and connected by means of the cooperation of the thread (2) and the nut (3).

4. The welding electrode integrated with welding and shaping according to claim 1, characterized in that: The installation height of the bakelite pressure head (6) is the same as the outer ring of the electrode head (7).

5. The welding electrode integrated with welding and shaping according to claim 1, characterized in that: The bakelite pressure head (6) and the electrode head (7) are in contact with each other in a sliding manner.

6. The welding electrode integrated with welding and shaping according to claim 1, characterized in that: The bakelite pressure head (6) is made of insulating material.

7. A welding method based on a welding electrode with integrated welding and shaping, based on the welding electrode with integrated welding and shaping according to any one of claims 1 to 6, characterized in that: include The part to be welded on the surface of the workpiece is placed directly below the electrode head (7); The electrode head (7) is pressed against the part to be welded on the surface of the workpiece, and the electrode head (7) is kept pressed against the surface of the workpiece during welding; The workpiece melts under the action of the electric current and forms a weld nugget, which is then kept in a clamped state for a preset time before being removed from the workpiece surface.

8. A welding method based on welding electrodes integrating welding and shaping according to claim 7, characterized in that: The workpiece is mounted on a resistance welding equipment workbench.

9. A welding method based on welding electrodes integrating welding and shaping according to claim 7, characterized in that: The portion of the part to be welded is at 90 degrees to the axis of the electrode head (7).

10. A welding method based on welding electrodes integrated with welding and shaping according to claim 7, characterized in that: The preset time is 5 seconds.

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