Welding tool and welding method

Abstract

The invention discloses a welding tool and a welding method. The welding tool is characterized by comprising a fixing base, a double-wire positioning and pressing mechanism, an electric brush disc positioning and rotation preventing mechanism and a welding position switching mechanism; the welding position switching mechanism comprises a sliding table, a horizontal guide rod and a first air cylinder. The double-wire positioning and pressing mechanism and the electric brush disc positioning and anti-rotation mechanism are arranged on the sliding table; the double-wire positioning and pressing mechanism comprises a first positioning block, a rotating pressing plate, an electromagnet and a rotating seat; the electric brush disc positioning anti-rotation mechanism comprises a second positioning block, two anti-rotation blocks and a positioning column; the second positioning block is provided with a sinking groove used for placing an electric brush disc. The positioning column is fixedly arranged at the center in the sinking groove and used for being matched with a center hole of an electric brush disc, and the two anti-rotation blocks are matched with two dovetail grooves of the electric brush disc respectively and used for limiting forward and reverse rotation of the electric brush disc respectively; the displacement amount of the sliding table is equal to the parallel distance between the two straight grooves. The device can be used for positioning, clamping and welding production of electric wire and electric brush disc welding, and has the advantages of rapidness, accuracy, safety, stability, reliability and the like.

Description

Technical Field

[0001] The invention relates to the technical field of motor brush plate welding, and in particular to a welding tool and a welding method. Background Art

[0002] Motors are the cornerstone of modern technology. They convert electrical energy into power through electromagnetic induction and are widely used in home appliances, industrial production, and new energy vehicles. In the future, motors will be more intelligent, efficient, and environmentally friendly, promoting the development of the electric era. The brush plate is one of the core components of the motor.

[0003] See also Figure 1-2 It is a brush plate, and during production, two parallel wires N-1 (one black and one red) are required to be welded and fixed at the two connecting pieces N-23 of the brush plate N-2. The brush plate N-2 has a center hole N-21 in the center, and three dovetail grooves N-22 are arranged along the circumference of the edge. The original method of welding the above-mentioned brush plate is to place the brush plate directly on the workbench, then hold a wire and keep its terminal in contact with one of the connecting pieces of the brush plate and align it and place it directly under the welding head of the welding machine, then start the welding machine and drive the welding head downward to achieve welding of the terminal of one wire and one connecting piece of the brush plate, then reset the welding head of the welding machine upward, clamp the brush plate (anti-scalding) with a clamp and drag the displacement so that the other connecting piece of the brush plate is located directly under the welding head of the welding machine, then hold another wire and keep its terminal in contact with another connecting piece of the brush plate and align it, then start the welding machine and drive the welding head downward again to achieve welding of the terminal of another wire and another connecting piece of the brush plate, then reset the welding head of the welding machine upward, and then complete the welding of the two wires and the brush plate. However, the above-mentioned existing welding production process has the following deficiencies and is analyzed as follows: (1) The existing brush plate needs to hold the wire during welding, and the operator needs to operate at close range, which is not safe. At the same time, the hand will shake, resulting in poor contact between the terminal of the wire and the connecting piece of the brush plate during welding, which is prone to relative displacement and misalignment, affecting the welding accuracy; (2) In the existing method, one wire is welded first, then the brush plate is clamped and moved to change position, and then the other wire is welded. It is difficult to align the two wires manually, and it is difficult to make the two wires parallel. The operator's workload is greatly increased, the welding efficiency is low, and the welding accuracy is difficult to control. At the same time, the operation is relatively complicated, which increases the difficulty of production. The welding method is simple, the reliability is not high, the operator's skills are high, and it is not safe enough, resulting in a low pass rate and poor production consistency. (3) The existing brush plate is not restrained on the workbench during welding, so it is easy to run and rotate, which will also affect the welding quality; (4) In the prior art, since the two wires are of different colors, and the welding positions of the wires of each color are fixed and cannot be interchanged, there is a problem that it is impossible to prevent errors.

[0004] At present, no prior art or document has been found for clamping and positioning the two wires on the brush plate for welding. Under this background, the welding tool and welding method of the present invention have been designed and developed. Summary of the invention

[0005] The present invention aims to provide a welding tool to solve the problem that when welding two wires, the contact state between the terminal of the motor brush plate and the connecting piece of the brush plate is hand-held control, which is prone to poor contact and displacement, and requires manual movement and repositioning in the middle, resulting in complex and unsafe operation, low production efficiency and poor welding quality.

[0006] To achieve the above-mentioned purpose, the present invention adopts the following technical scheme: a welding tool, characterized in that: it includes a fixed seat, a double-wire positioning and clamping mechanism, a brush plate positioning and anti-rotation mechanism and a welding position switching mechanism; the welding position switching mechanism includes a slide, a horizontal guide rod and a first cylinder; the slide can be slidably matched with the fixed seat through the horizontal guide rod, the output end of the first cylinder is connected to the slide and can drive the slide to move horizontally; the double-wire positioning and clamping mechanism and the brush plate positioning and anti-rotation mechanism are arranged on the slide; the double-wire positioning and clamping mechanism includes a first positioning block, a rotating pressure plate, an electromagnet and a rotating seat, the first positioning block is provided with two straight grooves for respectively placing two wires in a positioning position, the rotating The seat is fixedly arranged on one side of the first positioning block, one end of the rotating pressure plate is hinged with the rotating seat, and the electromagnet is arranged on the first positioning block; when the electromagnet is energized to generate magnetic force, the rotating pressure plate rotates and presses the wires in the two straight grooves under the suction force of the electromagnet; the brush disc positioning and anti-rotation mechanism includes a second positioning block, two anti-rotation blocks and a positioning column; the second positioning block is provided with a sink groove for accommodating the brush disc; the positioning column is fixedly arranged at the center of the sink groove and is used to cooperate with the center hole of the brush disc, and the two anti-rotation blocks are respectively matched with the two dovetail grooves of the brush disc and are used to limit the forward and reverse rotation of the brush disc respectively; wherein, the displacement of the slide is equal to the parallel distance between the two straight grooves.

[0007] When the above-mentioned welding tooling is used to assist in welding the brush disc and the two wires, the brush disc can be first placed in the sink groove and positioned by the positioning column cooperating with the center hole of the brush disc; the two anti-rotation blocks cooperate with the two dovetail grooves of the brush disc to respectively limit the forward and reverse rotation of the brush disc, thereby completing the center positioning of the brush disc and limiting the forward and reverse rotation of the brush disc by the brush disc positioning and anti-rotation mechanism; then, when the electromagnet is powered off, first lift the rotating pressure plate; then, put the two wires into the two straight grooves of the first positioning block and then push the two wires toward the brush disc until the terminals of the two wires are respectively flush with the two connecting pieces of the brush disc; then, put down the rotating pressure plate and energize the electromagnet to generate magnetic force, and the rotating pressure plate rotates and presses the brush disc located at the two straight grooves of the first positioning block under the suction force of the electromagnet. The wires in the two straight grooves are positioned and clamped by the double-wire positioning and clamping mechanism. At the same time, the terminals of the two wires are flush with the two connecting pieces of the brush disk and maintain a tight contact. Then the welding head of the welding machine can be started to complete a welding between the terminal of a wire located directly below it and a connecting piece of the brush disk. Then the first cylinder of the welding position switching mechanism is started to work and drive the slide to move horizontally. Since the displacement of the slide is equal to the parallel distance between the two straight grooves, the terminal of the other wire and the other connecting piece of the brush disk are just below the welding head of the welding machine, realizing automatic position change. Then the welding head of the welding machine is started to complete the second welding between the terminal of the other wire located directly below it and the other connecting piece of the brush disk. This technical solution has the following characteristics and is analyzed as follows: First, during welding, the brush plate is in the sink and positioned by the center of the positioning column, and is restricted by two anti-rotation blocks so that the brush plate cannot rotate forward or backward. Therefore, the brush plate is accurately positioned during welding, will not rotate forward or backward, is stably supported, and is not easily deformed by heat. This solves the existing technical problem that the brush plate is not restrained on the workbench during welding, is prone to running and rotating, and affects the welding quality. Second, since the two wires are positioned and constrained in two straight grooves during welding, they can be guaranteed to be parallel to each other and the direction and spacing are always consistent. At the same time, after the rotating pressure plate is pressed, the terminals of the two wires can be flush with the two connecting pieces of the brush disk and maintain a tight contact, ensuring the welding quality and preventing lateral and axial displacement. Since it is pressed by an electromagnet, manual control is not required, and the welding machine is controlled remotely; therefore, the positions of the two wires are accurate during welding, without displacement and dislocation, and they are kept flush and stably contacted and pressed at the welding point, which can be operated remotely and the welding is safer; furthermore, it can solve the existing technical problems that the operator needs to hold the wires in hand during welding, which is not safe enough and the hands will shake, resulting in poor pressing contact between the terminals of the wires and the connecting pieces of the brush disk during welding, and relative displacement and dislocation are prone to occur, affecting the welding accuracy; Third, after the welding of one wire on the welding tool and a connecting piece of the brush disk is completed, the welding position is automatically switched by starting the welding position switching mechanism, and then the welding machine can realize the second welding of another wire on the welding tool and another connecting piece of the brush disk when the welding head is in the original position. Therefore, there is no need for manual operation in the middle, the two positions can be accurate, the operation is simple, the welding efficiency is fast, the operator requirements are low, the production is safer, and the qualified rate and product consistency can be improved; furthermore, it can solve the existing problems of welding one wire first, then clamping the brush disk and moving it for replacement, and then welding another wire, which is difficult to align manually, the two wires are difficult to be parallel, the operator's workload is greatly increased, the welding efficiency is low, and the welding accuracy is difficult to control. At the same time, the operation is relatively complicated, which increases the difficulty of production; the welding method is simple, the reliability is not high, the operator's skills are high, it is not safe enough, resulting in a low qualified rate and poor production consistency.

[0008] To sum up, the above technical scheme can solve at least the above three technical problems at the same time, especially how to manually control the terminals of the wires and the connecting piece of the brush disk when welding two wires of the motor brush disk, which is prone to poor contact, displacement and misalignment, requires manual movement and repositioning in the middle, has complex and unsafe operations, low production efficiency and poor welding quality.

[0009] In summary, the above technical solution can solve at least the above three technical problems at the same time, especially solve the problem that the contact state between the terminal of the motor brush plate and the connecting piece of the brush plate is hand-held control when welding two wires, which is easy to have poor contact, easy to be displaced, and needs to be manually moved and replaced in the middle, resulting in complex and unsafe operation, low production efficiency, and poor welding quality.

[0010] Furthermore, the anti-rotation block is fixedly arranged on the second positioning block, one end of the anti-rotation block extends into the sink groove to form a protrusion, the edge width of the protrusion is smaller than the width of the outer end of the dovetail groove opening of the brush plate; the protrusion is provided with an angle tip that matches the inner angle on one side of the dovetail groove of the brush plate; the two anti-rotation blocks are symmetrically distributed. Since the angle tip of the protrusion of the anti-rotation block matches the inner angle on one side of the dovetail groove of the brush plate, the brush plate is only limited to rotate in one direction, and at the same time, the edge width of the protrusion is smaller than the outer end width of the dovetail groove opening of the brush plate, so that the protrusion can easily enter the dovetail groove when clamping, and can also easily go out when loosening, which can avoid the problem of jamming, and also ensure that only one-way anti-rotation can be achieved. Since the two anti-rotation blocks are symmetrically distributed, when the angle tips of the two anti-rotation blocks respectively match the inner angles on one side of the two dovetail grooves of the brush plate, the limited rotation directions are exactly opposite, so that bidirectional anti-rotation restriction can be achieved.

[0011] Furthermore, two color recognition sensors and a light shielding baffle are provided on the slide; the light shielding baffle is located between the two wires; the two color recognition sensors are respectively located on both sides of the light shielding baffle and are used to respectively sense the color signals of the wires in the two straight slots. Since the color signals of the wires in the two straight slots are respectively sensed by the two color recognition sensors during clamping, error prevention can be performed before welding. If the color position of the wire is incorrectly placed, an alarm or error prompt can be issued before the welding machine is started, thereby avoiding the problem of wrong welding of wires (wrong color) or missing welding (such as one wire is missing). Therefore, the existing problem of being unable to prevent errors due to the two wires being of different colors and the welding positions of the wires of each color being fixed and unable to be exchanged can be solved.

[0012] Furthermore, the rotating pressure plate is made of iron or is provided with iron parts.

[0013] Furthermore, the other end of the rotating pressure plate is provided with a U-shaped bayonet for the limiting plate to be inserted into; the limiting plate limits the swing of the rotating pressure plate. The rotating pressure plate can maintain a stable state when pressing the two wires, and the fit is tighter. When the two wires are welded, the welding head will press them and generate traction. When the two wires are pulled along the center line direction of the wires, they can always remain pressed tightly and will not loosen.

[0014] Furthermore, it also includes an ejection mechanism; the ejection mechanism includes a second cylinder and a top ring; a ring groove that can accommodate the top ring is provided at the center of the bottom surface of the sink; the output end of the second cylinder is connected to the top ring and is used to drive the top ring to move up and down. Since the brush plate is welded in the sink, after welding, the second cylinder of the ejection mechanism is started to work and the brush plate in the sink is ejected upward, and then the product can be easily taken away. Since the temperature of the brush plate is high after welding, it is easy to deform, affecting the shape and dimensional accuracy. However, by using the second cylinder to drive the top ring to eject the brush plate upward, the brush plate will not be deformed, the circumferential force is uniform, and it can also avoid being burned, which is very safe and efficient.

[0015] Furthermore, the output end of the second cylinder is fixedly connected to the middle of the cross, and the four free ends of the cross are fixedly connected to the top ring through vertical rods. The second cylinder drives the top ring to move up and down through the four vertical rods on the cross, and the movement is smooth and the four-way reliable support ensures that the top ring is stably raised and lowered without tilting, so that the brush plate is kept horizontal and ejected without deformation.

[0016] Furthermore, a proximity switch for sensing whether the brush plate is in place is provided in the sink.

[0017] The present invention also discloses a welding method, which is characterized by comprising the following steps: S100, firstly put the brush plate into the sink, and position it by the positioning column and the center hole of the brush plate; two anti-rotation blocks cooperate with the two dovetail grooves of the brush plate to limit the forward and reverse rotation of the brush plate respectively, and then obtain the brush plate in place signal through the proximity switch and send it to the controller; S200, when the electromagnet is powered off, first lift the rotating pressure plate; then put the two wires into the two straight grooves of the first positioning block respectively, and then push the two wires toward the brush plate until the terminals of the two wires are flush with the two connecting pieces of the brush plate respectively; then put down the rotating pressure plate and energize the electromagnet to generate magnetic force, the rotating pressure plate rotates and presses the wires in the two straight grooves under the suction force of the electromagnet, and then obtains the color signals of the wires in the two straight grooves respectively through the two color recognition sensors and sends them to the controller; S300, first confirm that the brush plate is in place and the colors of the two wires are correct, then start the following automatic working mode: S301, first drive the welding head of the welding machine downward to a position, and then weld a terminal of one of the wires to a connecting piece of the brush plate until the welding is completed; S302, driving the welding head of the welding machine upward to a certain position; S303, starting the first cylinder of the welding position switching mechanism to work and drive the slide table to move horizontally into position; S304, first drive the welding head of the welding machine downward to a position, and then weld the terminal of another wire to another connecting piece of the brush plate until the welding is completed; S400, firstly turning off the power of the electromagnet, and then rotating and lifting the rotating pressing plate; S500, first start the second cylinder of the ejection mechanism to work and eject the brush plate in the sink upwards, and then take out the product.

[0018] First, the tooling of the present invention ensures that the brush disc is accurately positioned during welding, does not rotate forward or backward, is stably supported, and is not deformed by heat because the brush disc is in the sink during welding and is positioned by the center of the positioning column and is restricted by two anti-rotation blocks. Second, the tooling of the present invention can ensure that the two wires are parallel to each other and the direction and spacing are always consistent because the two wires are positioned and constrained in two straight grooves during welding. At the same time, after the rotating pressing plate is pressed, the terminals of the two wires can be flush with the two connecting pieces of the brush plate and maintain a tight contact, thereby ensuring the welding quality and preventing lateral and axial displacement. Since it is pressed by an electromagnet, manual control is not required, and the welding machine can be controlled remotely; Thirdly, the tooling of the present invention realizes automatic switching of welding positions by starting the welding position switching mechanism after welding one wire on the welding tooling and one connecting piece of the brush plate. Then, the welding machine can realize the second welding of another wire on the welding tooling and another connecting piece of the brush plate with the welding head in the original position. Therefore, manual operation is not required in the middle, the two positions can be accurately welded, the operation is simple, the welding efficiency is high, the operator requirements are low, the production is safer, and the qualified rate and product consistency can be improved; Fourthly, the tooling of the present invention can solve the problem of poor contact, displacement and misalignment when the motor brush plate is welded with two wires, and the combination of complex and unsafe operation, low production efficiency and poor welding quality caused by hand-held control of the terminals of the wires and the connecting piece of the brush plate; Fifth, the method of the present invention uses the brush plate positioning and anti-rotation mechanism to position and anti-rotate the brush plate and the double-wire positioning and clamping mechanism to position and clamp the two wires. The two are combined to keep the brush plate and the two wires in a relative position reference. At the same time, the welding quality is not affected by the problems of misalignment, poor contact, deflection, etc., and the generation of welding defects is avoided. Sixth, the method of the present invention is to set the brush plate positioning anti-rotation mechanism and the double-line positioning and clamping mechanism on the slide at the same time, and the slide can be automatically horizontally guided and displaced by the first cylinder of the welding position switching mechanism, thereby realizing the automatic switching of the welding position, and the displacement of the slide is equal to the parallel distance between the two straight grooves, so that the welding head of the welding machine can realize the double-position welding work in situ, and there is no need to operate the welding machine for horizontal displacement. The whole process does not require workers to operate to avoid burns and inaccurate displacement, and also reduces the labor burden; Seventh, the method of the present invention can realize that the welding machine can start the automatic mode when welding two wire terminals and two connecting pieces of the brush plate at two locations through the cooperation of the welding tool and the welding machine, and can perform fully automatic double-location precise welding, which can greatly reduce manual intervention, improve production efficiency, and have good consistency in product welding quality. In addition, the clamping state of the brush plate and the brush plate and the two wires on the slide table remains unchanged throughout the welding process, which also reduces the influence of deformation and looseness. Eighth, the method of the present invention can ensure the welding quality and accuracy and avoid the problem of missing or wrong wires after welding by confirming whether the brush plate is in place and whether the colors of the two wires are correct before starting the automatic working mode; Ninth, the method of the present invention is far away from the high temperature of welding during welding, and the production is safer. Since it is non-manual holding, clamping and positioning control, it can reduce human interference and greatly reduce the number of manual operators. The skill requirements are extremely low and the operation is very simple. Welding automation can be realized with good reliability, which can greatly improve the product qualification rate and consistency. Therefore, the present invention can be used for positioning, clamping and welding production of electric wires and brush discs, and at the same time meet the advantages of fast, accurate, safe, stable and reliable.

[0019] Other advantages, objectives and features of the present invention will be embodied in part through the following description, and in part will be understood by those skilled in the art through study and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1-2 A schematic structural diagram of a brush plate with two parallel electric wires welded and fixed on its two connecting pieces.

[0021] Figure 3 A schematic structural diagram of a welding tool in the present invention.

[0022] Figure 4 yes Figure 3 Enlarged view of point A in the middle.

[0023] Figure 5 A schematic diagram of the structure of a welding tool in the present invention when it is partially cut open.

[0024] Figure 6 yes Figure 5 Enlarged view of point B in the middle.

[0025] Figure 7 It is a structural diagram of the ejection mechanism.

[0026] Figure 8 A working state diagram of a welding tool in the present invention when a brush plate and two electric wires are installed but the rotating pressing plate is not rotated and pressed.

[0027] Fig. 9 yes Figure 8 Enlarged view of center C.

[0028] Fig.10 A working state diagram (top view) of a welding tool in the present invention when a brush plate and two electric wires are installed and a rotating pressing plate is rotated and pressed.

[0029] Fig.11 yes Fig.10 Enlarged view of point D in the middle.

[0030] Fig.12A working state diagram (stereoscopic diagram) of a welding tool in the present invention when a welding machine is welding a welding point (a terminal of a right electric wire and a connecting piece on the right side of a brush plate).

[0031] Fig.13 A working state diagram (top view) of a welding tool in the present invention when the first cylinder of the welding position switching mechanism is started to work and drives the slide table to move horizontally to the right position (i.e., move W2 to the right).

[0032] Fig.14 A working state diagram (stereoscopic diagram) of a welding tool in the present invention when a welding machine is welding welding point 2 (a terminal of a left electric wire and a connecting piece on the left side of a brush plate). DETAILED DESCRIPTION

[0033] In order to make the technical means, creative features, objectives and functions of the present invention clearer and easier to understand, the present invention is further described below in conjunction with the accompanying drawings and specific embodiments: Example

[0034] like Figure 1-14 As shown, this embodiment discloses a welding tool, which includes a fixing seat 1, a double-wire positioning and clamping mechanism 2, a brush plate positioning and anti-rotation mechanism 3 and a welding position switching mechanism 4.

[0035] See also Figure 3-6 , wherein the welding position switching mechanism 4 includes a slide 4-1, a horizontal guide rod 4-2 and a first cylinder 4-3; the slide 4-1 is slidably matched with the fixed seat 1 through the horizontal guide rod 4-2, and the output end of the first cylinder 4-3 is connected to the slide 4-1 and can drive the slide 4-1 to move horizontally.

[0036] In this embodiment, the horizontal guide rods 4-2 have two and are fixed on the fixed seat 1 in parallel and at intervals, and a guide hole for sliding cooperation with the horizontal guide rods 4-2 is opened at the bottom of the slide 4-1; the first cylinder 4-3 is horizontally fixedly installed on the fixed seat 1, and the output end of the first cylinder 4-3 is fixedly connected to the slide 4-1.

[0037] Specifically, the displacement stroke of the first cylinder 4-3 is W2. When the output end of the first cylinder 4-3 moves in a telescopic manner, the displacement of the slide 4-1 is W2, and the displacement is consistent in both left and right reciprocating movements.

[0038] See also Figure 3-6 Specifically, the double-wire positioning and clamping mechanism 2 and the brush plate positioning and anti-rotation mechanism 3 are arranged on the slide 4 - 1 and distributed front and back.

[0039] See also Figure 3-6, wherein the double-wire positioning and clamping mechanism 2 comprises a first positioning block 2-1, a rotating pressure plate 2-2, an electromagnet 2-3 and a rotating seat 2-4, wherein the first positioning block 2-1 is fixed on the slide 4-1, and the upper surface of the first positioning block 2-1 is provided with two straight grooves 2-11 for respectively placing and positioning two wires N-1, wherein the two straight grooves 2-11 are parallelly distributed on the left and right sides, wherein the rotating seat 2-4 is fixedly arranged on one side of the first positioning block 2-1 (the left side in this embodiment), and one end of the rotating pressure plate 2-2 (the left side in this embodiment) is hinged to the rotating seat 2-4, and the electromagnet 2-3 is arranged on the first positioning block 2-1; in this embodiment, the electromagnet 2-3 is embedded in the upper surface of the first positioning block 2-1 and has two electromagnets spaced apart on the left and right sides. When the electromagnet 2-3 is energized to generate magnetic force, the rotating pressure plate 2-2 rotates and clamps the wire N-1 located in the two straight grooves 2-11 under the suction of the electromagnet 2-3.

[0040] Furthermore, the rotating pressure plate 2-2 is made of iron or is provided with iron parts.

[0041] See also Figure 3-6 , wherein the brush plate positioning and anti-rotation mechanism 3 comprises a second positioning block 3-1, two anti-rotation blocks 3-2 and a positioning column 3-3; the second positioning block 3-1 is fixed on the slide 4-1, and a sink 3-11 for accommodating the brush plate N-2 is provided on the second positioning block 3-1; the positioning column 3-3 is fixedly arranged at the center of the inner bottom surface of the sink 3-11 and is used to cooperate with the center hole N-21 of the brush plate N-2. , See also Figure 3-6, wherein the two anti-rotation blocks 3-2 respectively cooperate with the two dovetail grooves N-22 of the brush plate N-2 and are used to limit the forward and reverse rotation of the brush plate N-2 respectively; specifically, the anti-rotation block 3-2 is fixedly set on the second positioning block 3-1, and one end of the anti-rotation block 3-2 extends into the recessed groove 3-11 to form a protrusion 3-21, and the edge width K of the protrusion 3-21 is smaller than the width M of the outer end of the opening of the dovetail groove N-22 of the brush plate N-2; the protrusion 3-21 is provided with an angle tip 3-22 that matches the inner side angle N-221 of the dovetail groove N-22 of the brush plate N-2; the two anti-rotation blocks 3-2 are symmetrically distributed. Since the corner tip 3-22 of the protrusion 3-21 of the anti-rotation block 3-2 cooperates with the inner corner N-221 on one side of the dovetail groove N-22 of the brush disc N-2, the brush disc N-2 is only restricted to one-way rotation. At the same time, the edge width K of the protrusion 3-21 is smaller than the width M of the outer end of the dovetail groove N-22 of the brush disc N-2, so that the protrusion 3-21 can easily enter the dovetail groove N-22 during clamping and can also easily come out during release, thereby avoiding the problem of jamming and ensuring one-way anti-rotation. Since the two anti-rotation blocks 3-2 are symmetrically distributed, when the corner tips 3-22 of the two anti-rotation blocks 3-2 respectively cooperate with the inner corners N-221 on one side of the two dovetail grooves N-22 of the brush disc N-2, the restricted rotation directions are exactly opposite, so that two-way anti-rotation restriction can be achieved.

[0042] See also Figure 12-14 , wherein the displacement W1 of the slide 4 - 1 is equal to the parallel distance W2 between the two straight grooves 2 - 11 .

[0043] When the welding tool of this embodiment assists in welding the brush plate and two wires, the brush plate N-2 can be placed in the sink 3-11 first, and the positioning column 3-3 is matched with the center hole N-21 of the brush plate N-2 to position it (see Figure 8-9 ); The two anti-rotation blocks 3-2 cooperate with the two dovetail grooves N-22 of the brush plate N-2 to limit the forward and reverse rotation of the brush plate N-2 respectively, so that the brush plate positioning and anti-rotation mechanism 3 can position the center of the brush plate N-2 and limit the forward and reverse rotation of the brush plate N-2 (see Figure 8-9 ); Then, when the electromagnet 2-3 is powered off, first lift the rotating pressure plate 2-2; then put the two wires N-1 into the two straight grooves 2-11 of the first positioning block 2-1 and then push the two wires N-1 toward the brush plate N-2 until the terminals of the two wires N-1 are flush with the two connecting pieces N-22 of the brush plate N-2; then put down the rotating pressure plate 2-2 and energize the electromagnet 2-3 to generate magnetic force. The rotating pressure plate 2-2 rotates and presses the wires N-1 located in the two straight grooves 2-11 under the suction force of the electromagnet 2-3. In this way, the positioning and pressing of the two wires N-1 by the double-wire positioning and pressing mechanism 2 is completed. At the same time, the terminals of the two wires N-1 are flush with the two connecting pieces N-22 of the brush plate N-2 and maintain a tight contact (see Figure 10-11 ); Then the welding head of the welding machine can be started to weld the terminal of a wire N-1 located directly below it and a connecting piece N-22 of the brush plate N-2 (see Fig.12 ); and then start the first cylinder 4-3 of the welding position switching mechanism 4 to work and drive the slide 4-1 to move horizontally. Since the displacement W1 of the slide 4-1 is equal to the parallel distance W2 between the two straight grooves 2-11 (see Fig.13 ), so that at this time, the terminal of the other wire N-1 and the other connecting piece N-22 of the brush plate N-2 are just below the welding head of the welding machine, realizing automatic position change, and then the welding head of the welding machine is started to complete the second welding of the terminal of the other wire N-1 and the other connecting piece N-22 of the brush plate N-2 located just below it (see Fig.14 ).

[0044] The tooling of this embodiment has the following characteristics: First, during welding, the brush disc is in the sink groove 3-11 and is positioned at the center of the positioning column 3-3. At the same time, the two anti-rotation blocks 3-2 respectively limit the brush disc N-2 and prevent it from rotating forward and backward. Therefore, the brush disc is accurately positioned during welding, does not rotate forward and backward, is stably supported, and does not deform due to heat. This solves the existing technical problem that the brush disc is not restrained on the workbench during welding, is prone to running and rotating, and also affects the welding quality (i.e., one of the problems raised in the background technology).

[0045] Secondly, since the two wires N-1 are positioned and constrained in the two straight grooves 2-11 respectively during welding, they can be ensured to be parallel to each other and the direction and spacing are always consistent. At the same time, after being pressed by the rotating pressure plate 2-2, the terminals of the two wires N-1 can be flush with the two connecting pieces N-22 of the brush disk N-2 respectively and maintain a pressed contact, ensuring the welding quality and preventing lateral and axial displacement. Since it is pressed by an electromagnet, it does not require manual control and the welding machine can be controlled remotely. Therefore, the two wires N-1 are accurately positioned during welding, will not be displaced or misaligned, and will maintain a flush and stable contact and pressure at the welding point. It can be operated remotely, and welding is safer. Furthermore, it can solve the existing problem that the operator needs to hold the wires in hand during welding, and the operator needs to operate at close range, which is not safe enough, and the hands will shake, resulting in the terminals of the wires and the brush disk (i.e., one of the problems raised in the background technology).

[0046] Third, after the welding of a wire N-1 on the welding tool and a connecting piece N-22 of the brush plate N-2 is completed, the welding position is automatically switched by starting the welding position switching mechanism 4, and then the welding machine can realize the second welding of another wire N-1 on the welding tool and another connecting piece N-22 of the brush plate N-2 when the welding head is in the original position. Therefore, there is no need for manual operation in the middle, the two positions can be precise, the operation is simple, the welding efficiency is fast, the operator requirements are low, the production is safer, and the qualified rate and product consistency can be improved; furthermore, it can solve the existing problems of welding one wire first, then clamping the brush plate and moving it for replacement, and then welding another wire, which is difficult to align manually, the two wires are difficult to be parallel, the operator's workload is greatly increased, the welding efficiency is low, and the welding accuracy is difficult to control. At the same time, the operation is relatively complicated, which increases the difficulty of production; the welding method is simple, the reliability is not high, the operator's skills are high, it is not safe enough, resulting in a low qualified rate and poor production consistency (i.e., one of the problems raised in the background technology).

[0047] In summary, the above technical scheme can solve at least the above three technical problems at the same time, especially can solve the problem that when welding two wires, the contact state between the terminal of the wire and the connecting piece of the brush disc of the prior art motor brush disc is hand-held control, which is easy to have poor contact, easy to be displaced, and needs to be manually moved and replaced in the middle, resulting in complex and unsafe operation, low production efficiency and poor welding quality.

[0048] Therefore, this tool can be used for positioning and clamping of electric wires and brush disc welding, and at the same time meet the advantages of fast, accurate, safe, stable and reliable.

[0049] See also Figure 8-9Furthermore, two color recognition sensors 5-1 and a light shielding baffle 5-2 are provided on the slide 4-1; the light shielding baffle 5-2 is located between the two wires N-1; the two color recognition sensors 5-1 are respectively located on both sides of the light shielding baffle 5-2 and are used to respectively sense the color signals of the wires N-1 in the two straight slots 2-11. Since the color signals of the wires N-1 in the two straight slots 2-11 are respectively sensed by the two color recognition sensors 5-1 during clamping, error prevention can be performed before welding. If the color position of the wires is detected to be incorrect, an alarm or error prompt can be issued before the welding machine is started, thereby avoiding the problem of incorrect welding of wires of incorrect colors or leakage welding such as missing one wire. Therefore, the existing problem that the two wires are of different colors and the welding positions of the wires of each color are fixed and cannot be exchanged, which cannot prevent errors (i.e., one of the problems raised in the background technology) can be solved.

[0050] See also Figure 3-4 Furthermore, the double-wire positioning and clamping mechanism 2 also includes a limit plate 2-5; the other end of the rotating pressure plate 2-2 is provided with a U-shaped bayonet 2-21 for the limit plate 2-5 to be inserted into; in this way, when the rotating pressure plate 2-2 clamps the wires in the two straight grooves 2-11, the limit plate 2-5 limits the swing of the rotating pressure plate 2-2, so that the rotating pressure plate 2-2 can maintain a stable state when clamping the two wires N-1, and the fit is tighter. When the two wires N-1 are welded, the welding head will press and generate traction on them. When the two wires N-1 are pulled along the center line direction of the wire N-1, the two wires N-1 can always keep the pressure on the pressure plate 2-2 and will not loosen. Since there are two wires N-1, any looseness of any one of them will affect the welding quality. By limiting the swing of the rotating pressure plate 2-2 by the limit plate 2-5, it can be ensured that the rotating pressure plate 2-2 can stably clamp the two wires N-1 at the same time, which is very reliable and meets the long-term performance unchanged, reducing maintenance.

[0051] See also Figure 5-7 , further, it also includes an ejection mechanism 6; the ejection mechanism 6 includes a second cylinder 6-1 and a top ring 6-2; the center of the inner bottom surface of the sink 3-11 is provided with a ring groove 3-12 that can accommodate the top ring 6-2; the output end of the second cylinder 6-1 is connected to the top ring 6-2 and is used to drive the top ring 6-2 to move up and down. Since the brush plate N-2 is welded in the sink 3-11, after the welding is completed, the second cylinder 6-1 of the ejection mechanism 6 is started to work and the brush plate N-2 in the sink 3-11 is ejected upward, and then the product is easily taken away. Since the brush plate N-2 has a high temperature after welding, it is easy to deform, affecting the shape and dimensional accuracy. However, by using the second cylinder 6-1 to drive the top ring 6-2 to eject the brush plate N-2 upward, and using the top ring 6-2 to eject upward, the brush plate N-2 will not be deformed, the circumferential force is uniform, and it is also avoided to be hot, which is very safe and efficient.

[0052] See also Figure 5-7 Furthermore, the output end of the second cylinder 6-1 is fixedly connected to the middle of the cross 6-3, and the four free ends 6-31 of the cross 6-3 are fixedly connected to the top ring 6-2 through the vertical rods 6-4. The second cylinder 6-1 drives the top ring 6-2 to move through the four vertical rods 6-4 on the cross 6-3, and the movement is smooth and reliable in four directions, ensuring that the top ring 6-2 is stably lifted and lowered without tilting, so that the brush plate N-2 is kept horizontal and ejected without deformation.

[0053] See also Figure 5-7 Furthermore, a proximity switch 7 is provided in the sink 3-11 to sense whether the brush plate N-2 is in place. This can prevent the brush plate N-2 from being installed in place and affecting the welding quality, and can play a role in self-confidence inspection and confirmation before welding, avoid manual misjudgment, and ensure the consistency of welding quality.

[0054] Embodiment 2: Based on the welding tool described in the first embodiment, this embodiment discloses a welding method, which includes the following steps: S100, first put the brush plate N-2 into the sink 3-11, and position it by the positioning column 3-3 cooperating with the center hole N-21 of the brush plate N-2; the two anti-rotation blocks 3-2 cooperate with the two dovetail grooves N-22 of the brush plate N-2 to limit the forward and reverse rotation of the brush plate N-2 respectively, and then obtain the in-position signal of the brush plate N-2 through the proximity switch 7 and send it to the controller, so as to complete the clamping of the brush plate N-2 on the brush plate positioning and anti-rotation mechanism 3 (see Figure 8-9 ); S200, when the electromagnet 2-3 is powered off, first lift the rotating pressure plate 2-2; then put the two wires N-1 into the two straight grooves 2-11 of the first positioning block 2-1 respectively, and then push the two wires N-1 toward the brush plate N-2 until the terminals of the two wires N-1 are flush with the two connecting pieces N-22 of the brush plate N-2; then put down the rotating pressure plate 2-2 and energize the electromagnet 2-3 to generate magnetic force, and the rotating pressure plate 2-2 rotates and presses the wires N-1 in the two straight grooves 2-11 under the suction force of the electromagnet 2-3, and then obtains the color signals of the wires N-1 in the two straight grooves 2-11 through the two color recognition sensors 5 and sends them to the controller, so as to complete the clamping of the two wires N-1 on the double-wire positioning and clamping mechanism 2 (see Figure 10-11 ); S300, first confirm that the brush plate N-2 is in place and the colors of the two wires N-1 are correct, and then start the following automatic working mode: S301, first drive the welding head of the welding machine down to the position, and then weld the terminal of one of the wires N-1 (i.e. the one on the right) and the connecting piece N-23 of the brush plate N-2 (i.e. the one on the right), until the welding is completed, that is, the welding position is completed (i.e. the one on the right), which can be seen in Fig.12 ; S302, driving the welding head of the welding machine upward to a certain position; S303, start the first cylinder 4-3 of the welding position switching mechanism 4 to work and drive the slide 4-1 to move horizontally to the right position (i.e., move rightward by W1 to the right position); thus, the welding position switching is realized while the welding head remains in the original position. Fig.13 ; S304, first drive the welding head of the welding machine down to the position, and then weld the terminal of another wire N-1 (i.e., the one on the left) and the other connecting piece N-23 of the brush plate N-2 (i.e., the one on the left) until the welding is completed (i.e., the second welding is completed, which is the other group on the left), see Fig.14 ; S400, firstly cut off the power of the electromagnet 2-3, and then rotate and lift the rotating pressing plate 2-2; S500, first start the second cylinder 6-1 of the ejection mechanism 6 to work and eject the brush plate N-2 in the sink 3-11 upwards, and then take away the product.

[0055] In addition, in the above step S300, the judgment and confirmation are made through the in-place signal of the proximity switch 7 and the color signal of the wire N-1 in the two straight slots 2-11 received by the controller; when it is detected that the brush plate N-2 is not in place, a prompt or warning will be given to re-clamp the brush plate; when it is detected that the color signal of the wire N-1 in the two straight slots 2-11 is incorrect, a prompt or warning will be given to re-clamp the wire N-1, that is, if something is incorrect, reminders and warnings can be given by means of lights or text displays).

[0056] The method of the present invention has the following characteristics: First, the method of the present invention uses the brush plate positioning and anti-rotation mechanism 3 to position and anti-rotate the brush plate and the double-wire positioning and clamping mechanism 2 to position and clamp the two wires N-1. The two are combined to keep the brush plate and the two wires N-1 in a relative position reference. At the same time, the welding quality is not affected by the problems of misalignment, poor contact, deflection, etc., and the generation of welding defects is avoided. Second, the method of the present invention is to simultaneously set the brush plate positioning anti-rotation mechanism 3 and the double-line positioning and clamping mechanism 2 on the slide 4-1, and the slide 4-1 can be automatically horizontally guided and displaced by the first cylinder 4-3 of the welding position switching mechanism 4, thereby realizing the automatic switching of the welding position, and the displacement W1 of the slide 4-1 is equal to the parallel distance W2 between the two straight grooves 2-11, so that the welding head of the welding machine can realize the double-position welding work in situ, without the need to operate the welding machine for horizontal displacement, and the whole process does not require the operation of workers to avoid burns and inaccurate displacement, and also reduces the labor burden; Third, the method of the present invention can realize that the welding tool and the welding machine work together to realize that the welding machine can turn on the automatic mode when welding the two terminals of the two wires N-1 and the two connecting pieces of the brush plate N-2 at two places, and can perform fully automatic double-place precise welding, which can greatly reduce manual intervention, improve production efficiency, and have good consistency in product welding quality. In addition, during the entire welding process, the clamping state of the brush plate, the brush plate and the two wires N-1 on the slide 4-1 remains unchanged at all times, which also reduces the effects of deformation and looseness.

[0057] Fourthly, the method of the present invention can ensure the welding quality accuracy and avoid the problem of missing wires or wrong wires after welding by confirming whether the brush plate N-2 is in place and whether the colors of the two wires N-1 are correct before starting the automatic working mode.

[0058] Fifth, the method of the present invention is far away from the high temperature of welding during welding, and the production is safer. Since it is non-manual holding, clamping and positioning control, it can reduce human interference and greatly reduce the number of manual operators. The skill requirements are extremely low and the operation is very simple. It can realize welding automation and has good reliability, which can greatly improve the product qualification rate and consistency.

[0059] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution of the present invention, which should be included in the scope of the claims of the present invention.

Claims

1. A welding tool, characterized in that: It comprises a fixing seat (1), a double-wire positioning and clamping mechanism (2), a brush plate positioning and anti-rotation mechanism (3) and a welding position switching mechanism (4); The welding position switching mechanism (4) comprises a slide table (4-1), a horizontal guide rod (4-2) and a first cylinder (4-3); the slide table (4-1) is slidably matched with the fixed seat (1) via the horizontal guide rod (4-2), and the output end of the first cylinder (4-3) is connected to the slide table (4-1) and can drive the slide table (4-1) to move horizontally; The double-wire positioning and clamping mechanism (2) and the brush plate positioning and anti-rotation mechanism (3) are arranged on the slide table (4-1); The double-wire positioning and clamping mechanism (2) comprises a first positioning block (2-1), a rotating pressure plate (2-2), an electromagnet (2-3) and a rotating seat (2-4); the first positioning block (2-1) is provided with two straight grooves (2-11) for respectively placing two wires (N-1) for positioning; the rotating seat (2-4) is fixedly arranged on one side of the first positioning block (2-1); one end of the rotating pressure plate (2-2) is hinged to the rotating seat (2-4); the electromagnet (2-3) is arranged on the first positioning block (2-1); when the electromagnet (2-3) is energized to generate magnetic force, the rotating pressure plate (2-2) rotates under the suction force of the electromagnet (2-3) to clamp the wires (N-1) located in the two straight grooves (2-11); The brush plate positioning and anti-rotation mechanism (3) comprises a second positioning block (3-1), two anti-rotation blocks (3-2) and a positioning column (3-3); the second positioning block (3-1) is provided with a sink (3-11) capable of accommodating the brush plate (N-2); the positioning column (3-3) is fixedly arranged at the center of the sink (3-11) and is used to cooperate with the center hole (N-21) of the brush plate (N-2); the two anti-rotation blocks (3-2) are respectively matched with two dovetail grooves (N-22) of the brush plate (N-2) and are used to respectively limit the forward and reverse rotation of the brush plate (N-2); The displacement (W1) of the slide table (4-1) is equal to the parallel distance (W2) between the two straight grooves (2-11).

2. A welding tool according to claim 1, characterized in that: The anti-rotation block (3-2) is fixedly arranged on the second positioning block (3-1); one end of the anti-rotation block (3-2) extends into the sink groove (3-11) to form a protrusion (3-21); the edge width (K) of the protrusion (3-21) is smaller than the width (M) of the outer end of the opening of the dovetail groove (N-22) of the brush plate (N-2); the protrusion (3-21) is provided with an angle tip (3-22) that matches a side inner angle (N-221) of the dovetail groove (N-22) of the brush plate (N-2); The two anti-rotation blocks (3-2) are symmetrically distributed.

3. A welding tool according to claim 1 or 2, characterized in that: Two color recognition sensors (5-1) and a light-shielding baffle (5-2) are arranged on the slide (4-1); the light-shielding baffle (5-2) is located between the two wires (N-1); the two color recognition sensors (5-1) are respectively located on both sides of the light-shielding baffle (5-2) and are used to respectively sense color signals of the wires (N-1) in the two straight slots (2-11).

4. A welding tool according to claim 1, characterized in that; The rotating pressing plate (2-2) is made of iron or is provided with iron parts.

5. A welding tool according to claim 1, characterized in that: The double-line positioning and clamping mechanism (2) also includes a limiting plate (2-5); The other end of the rotating pressure plate (2-2) is provided with a U-shaped bayonet (2-21) for exactly inserting the limiting plate (2-5); the limiting plate (2-5) limits the swinging of the rotating pressure plate (2-2).

6. A welding tool according to claim 1, characterized in that: It also includes an ejection mechanism (6); The ejection mechanism (6) comprises a second cylinder (6-1) and a top ring (6-2); a ring groove (3-12) capable of accommodating the top ring (6-2) is provided at the center of the inner bottom surface of the sink (3-11); the output end of the second cylinder (6-1) is connected to the top ring (6-2) and is used to drive the top ring (6-2) to move up and down.

7. A welding tool according to claim 7, characterized in that: The output end of the second cylinder (6-1) is fixedly connected to the middle of the cross (6-3), and the four free ends (6-31) of the cross (6-3) are all fixedly connected to the top ring (6-2) via vertical rods (6-4).

8. A welding tool according to claim 1, characterized in that: A proximity switch (7) is arranged in the sink (3-11) for sensing whether the brush plate (N-2) is in place.

9. A welding method, characterized in that: The steps include: S100, firstly put the brush plate (N-2) into the sink groove (3-11), and position it by cooperating the positioning column (3-3) with the center hole (N-21) of the brush plate (N-2); by cooperating the two anti-rotation blocks (3-2) with the two dovetail grooves (N-22) of the brush plate (N-2), respectively restricting the forward and reverse rotation of the brush plate (N-2), and then obtaining a signal of whether the brush plate (N-2) is in place through the proximity switch (7) and sending it to the controller; S200, when the electromagnet (2-3) is powered off, first lift the rotating pressure plate (2-2); then place the two wires (N-1) into the two straight slots (2-11) of the first positioning block (2-1) respectively, and then push the two wires (N-1) toward the brush plate (N-2) until the terminals of the two wires (N-1) are flush with the two connecting pieces (N-22) of the brush plate (N-2); then lower the rotating pressure plate (2-2) and energize the electromagnet (2-3) to generate magnetic force, and the rotating pressure plate (2-2) rotates and presses the wires (N-1) in the two straight slots (2-11) under the suction force of the electromagnet (2-3), and then obtains the color signals of the wires (N-1) in the two straight slots (2-11) through the two color recognition sensors (5) and sends them to the controller; S300, first confirm that the brush plate (N-2) is in place and the colors of the two wires (N-1) are correct, then start the following automatic working mode: S301, first drive the welding head of the welding machine downward to a position, and then weld the terminal of one of the electric wires (N-1) and a connecting piece (N-23) of the brush plate (N-2) until the welding is completed; S302, driving the welding head of the welding machine upward to a certain position; S303, starting the first cylinder (4-3) of the welding position switching mechanism (4) to work and drive the slide table (4-1) to move horizontally to the desired position; S304, first drive the welding head of the welding machine downward to the position, and then weld the terminal of another electric wire (N-1) and another connecting piece (N-23) of the brush plate (N-2) until the welding is completed; S400, firstly turning off the power of the electromagnet (2-3), and then rotating and lifting the rotating pressing plate (2-2); S500, first start the second cylinder (6-1) of the ejection mechanism (6) to work and eject the brush plate (N-2) in the sink (3-11) upwards, and then take away the product.

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