Device for improving welding quality of electrical contact and using method thereof

Abstract

The device for improving the welding quality of the electrical contact comprises a rack, a driving part, a welding part and a fixing part are arranged on the rack, the welding part comprises a connecting frame which is arranged on the rack in a sliding mode and is in linkage with the driving part, and two first connecting blocks which are arranged at intervals are arranged in the connecting frame; an electromagnet connected through a flexible connecting part is arranged between the first connecting blocks, the electromagnet is electrically connected with a welding power source, the flexible connecting part is connected with a flexible pressing rod arranged in the connecting frame in a sliding mode, and the flexible connecting part is used for adjusting the gap between the electromagnet and the connecting frame in the vertical direction. And the stroke of up-and-down vibration of the flexible pressing rod is further adjusted.

Description

Technical Field

[0001] The invention relates to a device for improving the welding quality of electric contacts and a use method thereof, belonging to the field of welding devices. Background Art

[0002] The contact element is the most critical electrical contact component in low-voltage electrical appliances. The main performance and service life of electrical switches depend to a large extent on the welding quality of the contact assembly. In addition to the quality of raw materials, the welding process and method play a very important role in the quality of welded contact assemblies. Therefore, solving the welding quality of contact assemblies is the first problem to be solved.

[0003] In the professional field of induction brazing of electrical contact components, especially in high current contactor products in the field of wind power and energy storage, there are some key technical points that need special attention. Among them, the large contact area is one of the prominent features of this type of product, and due to the particularity of its working environment and performance requirements, it has high standards and strict requirements for electrical life and temperature rise.

[0004] Among many influencing factors, welding area (soldering rate) is always a crucial factor, which plays a decisive role in electrical life and temperature rise. In the implementation of traditional brazing process, an unfavorable situation often occurs, that is, a large number of closed spaces are easily formed. The existence of this closed space makes it impossible for the gas in the solder to be completely discharged smoothly. The gas trapped in the welding part will seriously affect the quality and effect of welding, resulting in a reduction in welding area. The reduction of welding area will directly have a negative impact on the performance of the product, reduce the conductivity of the electrical contact assembly, shorten the electrical life, and may also cause abnormal temperature rise due to problems such as uneven heat conduction, thereby affecting the stable operation and reliability of the entire high-current contactor product in wind power or energy storage systems. Summary of the invention

[0005] The purpose of the present invention is to overcome the shortcomings and deficiencies of the prior art and to provide a device for improving the welding quality of electric contacts and a method of using the device.

[0006] A device for improving the welding quality of electric contacts comprises a frame, on which a driving component, a welding component and a fixing component are provided, the welding component comprises a connecting frame slidably arranged on the frame and linked to the driving component, two first connecting blocks arranged at intervals are provided in the connecting frame, an electromagnet connected by a flexible connecting part is provided between the first connecting blocks, the electromagnet is electrically connected to a welding power supply, the flexible connecting part is connected to a flexible pressure rod slidably arranged in the connecting frame, and the flexible connecting part is used to adjust the gap between the electromagnet and the connecting frame in the vertical direction, thereby adjusting the up and down vibration stroke of the flexible pressure rod. After the electromagnet is connected to alternating current, it is attracted / released with the frame to generate vibration with a frequency of 50Hz / second. The ceramic rod with spring buffer connected to the electromagnet is in contact with the workpiece to be welded, and the workpiece is knocked at a frequency of 50Hz / second to remove the gas on the brazing surface, which can greatly increase the welding area of ​​the welding surface. It can be applied to the induction brazing of various standard or special-shaped contact bridges, contacts and other accessories of different materials. Similarly, this method can also use micro motors and pneumatic components instead of electromagnets as power sources to achieve the same effect.

[0007] Preferably, the flexible connection part is provided with an adjustment hole for adapting to the gap adjustment variable, and the adjustment hole can make the flexible connection part change accordingly according to the gap change, thereby improving the use effect and service life of the flexible connection part.

[0008] Preferably, a first guide rail is provided on the inner walls on both sides of the connecting frame, a first sliding block is slidably provided on the first guide rail, and a fixed plate is slidably connected between the first sliding blocks, a fixed part is fixed on the fixed plate, the flexible pressure rod is fixed in the fixed part, an electric contact assembly for welding is provided at the bottom of the flexible pressure rod, and a welding induction coil is provided above the electric contact and surrounds the outside of the flexible pressure rod and is electrically connected to the welding power supply.

[0009] Furthermore, a mounting hole is provided on the fixed part, a threaded adjustment sleeve is provided on the flexible pressure rod, a spring is provided on the outer sleeve of the flexible pressure rod, one end of the spring abuts against the bottom of the fixed part, and the other end abuts against the adjustment sleeve. The tightness of the spring is controlled by adjusting the position of the adjustment sleeve on the flexible pressure rod. A spring buffer needs to be installed on the flexible pressure rod to avoid hard contact with the welding tooling during welding vibration, which reduces the effect of using this method.

[0010] Furthermore, the material of the flexible pressure rod is a non-metallic material, such as ceramics, to avoid being heated by an induced magnetic field during welding.

[0011] Preferably, a second connecting block in a T-shape is connected to the bottom of the flexible connecting part, and the end of the second connecting block extends to one side of the fixed plate and is fixedly connected to it, which is used to adjust the position of the fixed plate through the flexible connecting part, and then adjust the stroke of the flexible pressure rod. The adjustable stroke is 0.05mm~0.2mm.

[0012] Preferably, the fixing component includes a workpiece carrier arranged under the welding component for fixing the workpiece, the workpiece carrier includes a base, a plurality of support rods are provided on the base, the top of the support rods is used to support the workpiece, the support rods are fixed-length structures or adjustable-length structures, the workpiece carrier is designed to be fixed or movable up and down, and the machine is adjusted to a suitable position for welding according to the position of the welding induction coil. The contact bridge of the electric contact assembly or the required welding workpiece needs to have a positioning protrusion, and the magnetic field force is used to position the contact or the required welding workpiece during the welding process.

[0013] Preferably, second guide rails are provided on both sides of the frame, second sliding blocks are slidably provided on the second guide rails, and the connecting frame is fixedly connected to the second sliding blocks.

[0014] Preferably, the driving component includes a downward pressure cylinder fixed on the frame, the downward pressure cylinder is telescopically connected with a connecting shaft, the other end of the connecting shaft is connected to the connecting frame, and the downward pressure cylinder is provided with an adjusting screw for adjusting the movement stroke of the connecting shaft.

[0015] A method for using a device for improving the welding quality of electric contacts, using the device for improving the welding quality of electric contacts to perform welding, comprising the following steps:

[0016] (1) Placing the required welding workpiece and solder on a workpiece carrier, wherein the welding workpiece or contact point is provided with a positioning protrusion for cooperating with the welding induction coil;

[0017] (2) Start the downward pressure cylinder, which drives the connecting frame to move downward to the set position;

[0018] (3) starting the external power supply to energize the electromagnet to vibrate;

[0019] (4) When the solder melts, the electromagnet stops energizing and vibrating, and the welding power source continues to be energized, and the magnetic field force of the welding induction coil is used to position and correct the contacts in the electrical contact assembly so that they are butted and positioned with the positioning protrusions on the welding workpiece or the contact point;

[0020] (5) The welding power supply is turned off, and the downward pressure cylinder is reset to complete the welding;

[0021] (6) Repeat steps (1) to (5) to achieve automated welding.

[0022] The high-frequency induction brazing process has high processing efficiency and stable quality. It can be applied to the welding needs of various standard or special-shaped contact bridges, contacts and other accessories of different materials. It can also be applied to products with induction brazing of two or more materials. Especially for brazing products with large-size contacts, the advantages of this welding method can be better reflected.

[0023] The beneficial effects of the present invention are as follows: after the electromagnet is connected to alternating current, it is attracted / released with the frame to generate vibration with a frequency of 50 Hz / second, and a ceramic rod with a spring buffer connected to the electromagnet is brought into contact with the workpiece to be welded, and the workpiece is knocked at a frequency of 50 Hz / second to remove the gas on the brazing surface, which can greatly increase the welding area of ​​the welding surface. It can be applied to the welding needs of induction brazing of various standard or special-shaped contact bridges, contacts and other accessories of different materials. Similarly, this method can also use micro motors and pneumatic components instead of electromagnets as power sources to achieve the same effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, without paying creative labor, other drawings obtained based on these drawings still belong to the scope of the present invention.

[0025] Figure 1 This is a structural diagram of a specific embodiment of the present invention (fully closed state);

[0026] Figure 2 It is a side view of a specific embodiment of the present invention (fully opened state);

[0027] In the figure, 1, frame; 11, second guide rail; 12, second sliding block; 2, driving component; 21, downward pressure cylinder; 22, connecting shaft; 23, adjusting screw; 3, welding component; 31, connecting frame; 311, first guide rail; 312, first sliding block; 32, first connecting block; 33, flexible connecting part; 331, second connecting block; 332, adjusting hole; 34, electromagnet; 35, flexible pressure rod; 351, adjusting sleeve; 352, spring; 36, fixing plate; 37, fixing part; 371, mounting hole; 38, electric contact assembly; 39, welding induction coil; 4, fixing component; 41, base; 42, support rod. DETAILED DESCRIPTION

[0028] In order to make the objectives, technical solutions and advantages of the present invention more clear, the present invention will be further described in detail below with reference to the accompanying drawings.

[0029] It should be noted that all expressions using "first" and "second" in the embodiments of the present invention are for distinguishing two non-identical entities with the same name or non-identical parameters. It can be seen that "first" and "second" are only for the convenience of expression and should not be understood as limitations on the embodiments of the present invention. The subsequent embodiments will not explain this one by one.

[0030] The directions and positions mentioned in the present invention, such as "upper", "lower", "front", "back", "left", "right", "inside", "outside", "top", "bottom", "side", etc., are only for reference to the directions or positions of the drawings. Therefore, the directions and positions used are for explaining and understanding the present invention, but not for limiting the scope of protection of the present invention.

[0031] like Figure 1-2 As shown, an embodiment of a device for improving the welding quality of electric contacts of the present invention, a device for improving the welding quality of electric contacts, includes a frame, the frame is provided with a driving component, a welding component and a fixing component, the welding component includes a connecting frame slidably arranged on the frame and linked with the driving component, two first connecting blocks arranged at intervals are arranged in the connecting frame, an electromagnet connected by a flexible connecting part is arranged between the first connecting blocks, the electromagnet is electrically connected to a welding power supply, the flexible connecting part is connected to a flexible pressure rod slidably arranged in the connecting frame, and the flexible connecting part is used to adjust the gap between the electromagnet and the connecting frame in the vertical direction, thereby adjusting the up and down vibration stroke of the flexible pressure rod. After the electromagnet is connected to alternating current, it is attracted / released with the frame to generate vibration with a frequency of 50Hz / second. The ceramic rod with spring buffer connected to the electromagnet is in contact with the workpiece to be welded, and the workpiece is knocked at a frequency of 50Hz / second to remove the gas on the brazing surface, which can greatly increase the welding area of ​​the welding surface. It can be applied to the induction brazing of various standard or special-shaped contact bridges, contacts and other accessories of different materials. Similarly, this method can also use micro motors and pneumatic components instead of electromagnets as power sources to achieve the same effect.

[0032] Through the design of the flexible connection part, the gap between the electromagnet and the connecting frame can be adjusted, so as to accurately control the up and down vibration stroke of the flexible pressure rod. This feature allows the welding pressure to be flexibly adjusted according to different welding requirements to ensure that the appropriate force is maintained during the welding process. Due to the uniformity and adjustability of the welding pressure, the welding quality is significantly improved, the unevenness of the welding point and welding defects are reduced, and the connection reliability of the electrical contact is improved. Through the optimized design of the flexible pressure rod, it can be ensured that the vibration effect applied during the welding process is better, which helps to improve the fusion degree of the welding and improve the welding quality.

[0033] The flexible connection part is provided with an adjustment hole for adapting to the gap adjustment variable. The adjustment hole can make the flexible connection part change accordingly according to the gap change, thereby improving the use effect and service life of the flexible connection part.

[0034] A first guide rail is provided on the inner walls on both sides of the connecting frame, a first sliding block is slidably provided on the first guide rail, and a fixed plate is slidably connected between the first sliding blocks, a fixed part is fixed on the fixed plate, the flexible pressure rod is fixed in the fixed part, an electric contact assembly for welding is provided at the bottom of the flexible pressure rod, and a welding induction coil is provided above the electric contact and surrounds the outside of the flexible pressure rod and is electrically connected to the welding power supply.

[0035] The design of the first guide rail provides a stable guide for the first sliding block, effectively reducing the lateral displacement during the up and down vibration process, ensuring accurate positioning during welding, and improving the welding quality. Since the first sliding block can slide on the first guide rail, the height of the fixed plate can be adjusted. Under different welding requirements, users can flexibly adjust the distance between the flexible pressure rod and the workpiece to optimize the welding effect.

[0036] The fixing part is provided with a mounting hole, the flexible pressure rod is provided with a threaded adjustment sleeve, the flexible pressure rod outer sleeve is provided with a spring, one end of the spring is in contact with the bottom of the fixing part, and the other end is in contact with the adjustment sleeve. The spring controls the tightness of the spring by adjusting the position of the adjustment sleeve on the flexible pressure rod. The flexible pressure rod needs to be installed with a spring buffer to avoid hard contact with the welding tooling during welding vibration, which reduces the effect of this method. The tightness of the spring can be easily adjusted through the adjustment sleeve, so that the operator can quickly adjust the scene according to different materials and welding conditions, improving the adaptability of the equipment.

[0037] The material of the flexible pressure rod is non-metallic material, such as ceramics, so as to avoid being heated by an induced magnetic field during welding.

[0038] A second T-shaped connecting block is connected to the bottom of the flexible connecting part, and the end of the second connecting block extends to one side of the fixed plate and is fixedly connected to it, which is used to adjust the position of the fixed plate through the flexible connecting part, and then adjust the stroke of the flexible pressure rod. The adjustable stroke is 0.05mm~0.2mm.

[0039] The fixing component includes a workpiece carrier arranged under the welding component for fixing the workpiece, the workpiece carrier includes a base, a plurality of support rods are arranged on the base, the top of the support rods is used to support the workpiece, the support rods are of fixed length structure or adjustable length structure, the workpiece carrier is designed to be fixed or movable up and down, and the machine is adjusted to a suitable position for welding according to the position of the welding induction coil. The contact bridge of the electric contact assembly or the required welding workpiece needs to have a positioning protrusion, and the magnetic field force is used to position the contact or the required welding workpiece during the welding process.

[0040] The present invention also provides a method for using the device for improving the welding quality of electric contacts, and using the device for improving the welding quality of electric contacts to perform welding comprises the following steps:

[0041] (1) Placing the required welding workpiece and solder on a workpiece carrier, wherein the welding workpiece or contact point is provided with a positioning protrusion for cooperating with the welding induction coil;

[0042] (2) Start the downward pressure cylinder, which drives the connecting frame to move downward to the set position;

[0043] (3) starting the external power supply to energize the electromagnet to vibrate;

[0044] (4) When the solder melts, the electromagnet stops energizing and vibrating, and the welding power source continues to be energized, and the magnetic field force of the welding induction coil is used to position and correct the contacts in the electrical contact assembly so that they are butted and positioned with the positioning protrusions on the welding workpiece or the contact point;

[0045] (5) The welding power supply is turned off, and the downward pressure cylinder is reset to complete the welding;

[0046] (6) Repeat steps (1) to (5) to achieve automated welding.

[0047] The steps of this method of use are clear and simplified, and the operator can easily understand and execute them, which reduces the dependence on operating skills and improves the operability of the welding operation. By connecting multiple steps in series, the welding process is automated, which improves production efficiency, reduces labor costs and potential human errors, and adapts to the needs of modern industrial production. The electromagnet control in steps (3) and (4) synchronizes the melting process with the positioning correction through precise power-on and stop, ensuring that the solder is welded in the best condition and further improving the quality of welding. The use of flexible pressure rods made of non-metallic materials such as ceramics avoids material deformation or performance degradation caused by induced magnetic field heating, ensuring stability during the welding process. The reset design of the downward pressure cylinder ensures that the component can automatically return to the initial position after welding is completed, preparing for the next round of welding, further optimizing the operation process. Through the system steps and control mechanism, the probability of failure is reduced, the overall reliability of the welding process is improved, and high-quality guarantees are provided for production.

[0048] The above disclosure is only the preferred embodiment of the present invention, which certainly cannot be used to limit the scope of the present invention. Therefore, equivalent changes made according to the claims of the present invention are still within the scope of the present invention.

[0049] Although the invention has been described with reference to several specific embodiments, it should be understood that the invention is not limited to the specific embodiments disclosed. The invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A device for improving the welding quality of electric contacts, characterized in that: The invention comprises a frame, on which a driving component, a welding component and a fixing component are provided, wherein the welding component comprises a connecting frame slidably arranged on the frame and linked with the driving component, wherein two first connecting blocks arranged at intervals are arranged in the connecting frame, and an electromagnet connected by a flexible connecting part is arranged between the first connecting blocks, wherein the electromagnet is electrically connected to a welding power source, and the flexible connecting part is connected to a flexible pressure rod slidably arranged in the connecting frame, and the flexible connecting part is used to adjust the gap between the electromagnet and the connecting frame in the vertical direction, thereby adjusting the up and down vibration stroke of the flexible pressure rod.

2. The device for improving the welding quality of electric contacts as claimed in claim 1, characterized in that: The flexible connection part is provided with an adjustment hole for adapting to the gap adjustment variable.

3. The device for improving the welding quality of electric contacts as claimed in claim 1, characterized in that: A first guide rail is provided on the inner walls on both sides of the connecting frame, a first sliding block is slidably provided on the first guide rail, and a fixed plate is slidably connected between the first sliding blocks, a fixed part is fixed on the fixed plate, the flexible pressure rod is fixed in the fixed part, an electric contact assembly for welding is provided at the bottom of the flexible pressure rod, and a welding induction coil is provided above the electric contact and surrounds the outside of the flexible pressure rod and is electrically connected to the welding power supply.

4. The device for improving the welding quality of electric contacts as claimed in claim 3, characterized in that: The fixing part is provided with a mounting hole, the flexible pressure rod is sleeved with a threaded adjustment sleeve, the flexible pressure rod outer sleeve is provided with a spring, one end of the spring abuts against the bottom of the fixing part, and the other end abuts against the adjustment sleeve, and the tightness of the spring is controlled by adjusting the position of the adjustment sleeve on the flexible pressure rod.

5. The device for improving the welding quality of electric contacts according to claim 1 or 3, characterized in that: The material of the flexible pressure rod is non-metallic material.

6. The device for improving the welding quality of electric contacts as claimed in claim 1, characterized in that: A second connection block in a T-shape is connected to the bottom of the flexible connection part, and the end of the second connection block extends to one side of the fixed plate and is fixedly connected thereto, so as to adjust the position of the fixed plate through the flexible connection part, thereby adjusting the stroke of the flexible pressure rod.

7. The device for improving the welding quality of electric contacts as claimed in claim 1, characterized in that: The fixing component includes a workpiece carrier arranged below the welding component for fixing the workpiece, the workpiece carrier includes a base, a plurality of support rods are arranged on the base, the top of the support rods are used to support the workpiece, and the support rods are fixed length structures or adjustable length structures.

8. The device for improving the welding quality of electric contacts as claimed in claim 1, characterized in that: Second guide rails are arranged on both sides of the frame, second sliding blocks are slidably arranged on the second guide rails, and the connecting frame is fixedly connected to the second sliding blocks.

9. The device for improving the welding quality of electric contacts as claimed in claim 1, characterized in that: The driving component comprises a downward pressure cylinder fixed on the frame, the downward pressure cylinder is telescopically connected with a connecting shaft, the other end of the connecting shaft is connected to the connecting frame, and the downward pressure cylinder is provided with an adjusting screw for adjusting the movement stroke of the connecting shaft.

10. A method for using a device for improving the welding quality of electric contacts, characterized in that: The device for improving the welding quality of electric contacts according to any one of claims 1 to 9 is used for welding, comprising the following steps: (1) Placing the required welding workpiece and solder on a workpiece carrier, wherein the welding workpiece or contact point is provided with a positioning protrusion for cooperating with the welding induction coil; (2) Start the downward pressure cylinder, which drives the connecting frame to move downward to the set position; (3) starting the external power supply to energize the electromagnet to vibrate; (4) When the solder melts, the electromagnet stops energizing and vibrating, and the welding power source continues to be energized, and the magnetic field force of the welding induction coil is used to position and correct the contacts in the electrical contact assembly so that they are butted and positioned with the positioning protrusions on the welding workpiece or the contact point; (5) The welding power supply is turned off, and the downward pressure cylinder is reset to complete the welding; (6) Repeat steps (1) to (5) to achieve automated welding.

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