Welding methods

Abstract

This invention relates to the field of welding technology, and more particularly to a welding method. The method provided by this invention addresses the issue that, when welding a wire harness with a length of 500mm or less, the first end of the wire harness is subject to slight vibration during welding of the second end and the second terminal. This reduces the tension between the first terminal and the wire harness at the first end. By adjusting the welding parameters, the tensile force at the second end is reduced, and the vibration generated during welding is also decreased, thereby reducing the destructive impact on the weld at the first end and balancing the tensile force at both ends. Furthermore, clamping the first end of the wire harness with the first terminal during welding further reduces the vibration generated at the second end by the clamping mechanism, significantly reducing the propagation of vibration to the first end and thus minimizing its impact.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and more particularly to a welding method. Background Technology

[0002] In ultrasonic welding, terminals need to be welded to both ends of the wire harness in sequence; first weld one end of the wire harness to the terminal, then rotate the wire harness 180 degrees to weld the other end of the wire harness to the new terminal.

[0003] Within the same wire harness, vibration is transmitted to the other end through the harness. Differences in harness length can cause varying degrees of damage to the solder joint at the first end during welding at the second end, resulting in a decrease in tensile strength at the first end. When the connection strength between the wire harness and the two terminals differs significantly, the failure rate at the first end is too high during tensile testing; that is, the first end is more likely to break before the second end. When the failure rate at the same end reaches 70% or higher, the test fails.

[0004] Therefore, a welding method is urgently needed to solve the above-mentioned technical problems. Summary of the Invention

[0005] The purpose of this invention is to propose a welding method that welds wire harnesses and terminals according to different lengths of wire harnesses, ensuring that the difference in tensile strength between the wire harness and the terminals welded to both ends of the wire harness is small, and that the failure rate at each end is nearly equal during the overall tensile strength test, thus passing the test.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] A welding method is provided for welding terminals to both ends of a wire harness, comprising the following steps:

[0008] Obtain the length of the wire harness;

[0009] If the wire harness length is less than or equal to 500mm, fix the wire harness to the terminal, weld the first end of the wire harness to the first terminal, flip the wire harness with the first terminal welded to the first end, fix the wire harness to the second terminal, and adjust the welding parameters of the welding machine to weld the second end of the wire harness to the second terminal. The welding parameters include at least the energy and power of the welding machine.

[0010] As a preferred technical solution for the above welding method, the power is set to be greater than or equal to 500 mm when the wire harness length is... Energy is ;

[0011] When the wire harness length is less than 500mm, the welding power for the first terminal is PA, the energy is EA, and the welding power for the second terminal is... Energy is ,in , .

[0012] As a preferred technical solution of the above welding method, the length of the wire harness is measured by an ultrasonic detection sensor.

[0013] As a preferred technical solution of the above welding method, during welding, the vibration direction of the welding head of the welding machine is set at an angle to the axis of the wire harness.

[0014] As a preferred technical solution of the above welding method, during welding, the angle between the vibration direction of the welding head of the welding machine and the axis of the wire harness is... .

[0015] As a preferred technical solution of the above welding method, the welding machine is equipped with an industrial camera. During welding, the industrial camera is used to obtain terminal information, and welding parameters are switched based on the obtained terminal information. The welding parameters include welding power and welding energy.

[0016] As a preferred embodiment of the above welding method, the wire harness and the terminal to be welded are fixed by a welding fixture, which includes:

[0017] A positioning and fixing mechanism is used to position and fix the terminal;

[0018] A wire harness fixing mechanism, at least for fixing a wire harness, wherein the wire harness fixing mechanism is disposed on one side of the positioning fixing mechanism.

[0019] As a preferred technical solution of the above welding method, the wire harness fixing mechanism includes a first driving structure and a fixing member, wherein the first driving structure is connected to the fixing member to drive the fixing member to fix the wire harness.

[0020] As a preferred technical solution of the above welding method, the fixing member includes two opposing grippers, and the first driving structure is fixedly connected to the two grippers respectively to drive the two grippers to open and close.

[0021] As a preferred technical solution of the above welding method, the gripper is provided with a receiving groove.

[0022] As a preferred technical solution of the above welding method, when the clamps hold the wire harness, the two clamps are staggered; or, the side of the clamps facing the wire harness is provided with a plurality of slots at intervals, the slots divide the clamps to form a plurality of insert teeth, and the oppositely arranged insert teeth cooperate with the slots to adjust the distance between the two clamps.

[0023] As a preferred technical solution of the above welding method, it further includes a top material assembly, which is arranged opposite to the wire harness fixing mechanism along the length direction of the wire harness.

[0024] As a preferred technical solution of the above welding method, the welding fixture further includes a top-loading assembly, which is arranged opposite to the wire harness fixing mechanism along the length direction of the wire harness.

[0025] As a preferred technical solution of the above welding method, the positioning and fixing mechanism includes:

[0026] A pusher assembly includes a pusher, a first adjusting member, and a second driving structure. The pusher and the second driving structure are connected through the first adjusting member. The pusher is used to press the terminal to be welded.

[0027] The push plate assembly includes a push plate, a second adjusting member, and a third driving structure. The push plate and the third driving structure are connected through the second adjusting member. The push plate is used to clamp the terminal to be welded.

[0028] As a preferred technical solution of the above welding method, the first adjusting member includes a first wedge block and a second wedge block. The first wedge block has a first inclined working surface, the second wedge block is connected to the push block, the second wedge block has a second inclined working surface, the first inclined working surface and the second inclined working surface are in contact, and the second driving structure is fixedly connected to the first wedge block to drive the first wedge block to squeeze or release the second wedge block.

[0029] The second adjusting component includes a third wedge block and a fourth wedge block. The third wedge block has a third inclined working surface. The fourth wedge block is connected to the push plate and has a fourth inclined working surface. The third inclined working surface is in contact with the fourth inclined working surface. The third driving structure is fixedly connected to the third wedge block to drive the third wedge block to squeeze or release the fourth wedge block.

[0030] The present invention has at least the following beneficial effects:

[0031] The method provided by this invention addresses the issue that, when welding a wire harness with a length less than 500mm, the first end of the wire harness is subject to slight vibration during welding of the second end and the second terminal. This reduces the tension between the first terminal and the wire harness at the first end. Adjusting the welding parameters reduces both the tension at the second end and the vibration generated during welding, thereby minimizing damage to the weld at the first end and balancing the tension values ​​at both ends. Furthermore, clamping the first end of the wire harness with the first terminal during welding reduces the vibration generated during welding of the second end, significantly decreasing the propagation of vibration to the first end and thus minimizing its impact. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the content of the embodiments of the present invention and these drawings without creative effort.

[0033] Figure 1 A flowchart of a welding method provided in an embodiment of the present invention;

[0034] Figure 2 A top view of the welding fixture provided in an embodiment of the present invention;

[0035] Figure 3 This is a schematic diagram showing the positional relationship between the wire harness fixing mechanism and the top material assembly provided in an embodiment of the present invention;

[0036] Figure 4 This is a schematic diagram of the wire harness fixing mechanism provided in an embodiment of the present invention;

[0037] Figure 5 A first-view structural schematic diagram of the welding fixture provided in an embodiment of the present invention (without cover plate);

[0038] Figure 6 This is a schematic diagram of the positioning and fixing mechanism provided in an embodiment of the present invention.

[0039] In the picture:

[0040] 1. Wire harness fixing mechanism; 11. First drive structure; 12. Gripper; 121. Receiving groove; 122. Slot; 123. Insertion tooth; 2. Push block assembly; 21. Push plate; 22. First adjusting component; 221. First wedge block; 222. Second wedge block; 223. First elastic component; 23. Second drive structure; 3. Push plate assembly; 31. Push block; 32. Second adjusting component; 321. Third wedge block; 322. Fourth wedge block; 323. Second elastic component; 33. Third drive structure; 4. Limiting frame; 5. Cover plate; 6. Top material assembly; 7. Terminal positioning block; 8. Frame;

[0041] 100, wire harness; 200, first terminal. Detailed Implementation

[0042] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0043] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0044] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0045] In the description of this embodiment, the terms "upper," "lower," "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0046] This invention provides a welding method that welds wire harnesses and terminals according to different lengths of wire harnesses, ensuring that the difference in tensile strength between the wire harness and the terminals welded to both ends of the wire harness is small, and that the failure rate at each end is nearly equal during the overall tensile strength test, thus passing the test.

[0047] The welding method is used to weld terminals to both ends of the wire harness. The terminal located at the first end of the wire harness is designated as the first terminal 2, and the terminal located at the second end of the wire harness is designated as the second terminal.

[0048] like Figure 1 and Figure 2 As shown, the method includes the following steps:

[0049] S101, Obtain a wire harness length of 100;

[0050] S102. If the length of the wire harness 100 is less than 500mm, fix the first end of the wire harness 100 to the first terminal 200, weld the first end of the wire harness 100 to the first terminal 200, flip the wire harness 100 with the first terminal 200 welded to the first end, fix the wire harness 100 to the second terminal, and adjust the welding parameters of the welding machine to weld the second end of the wire harness 100 to the second terminal. The welding parameters include at least the energy and power of the welding machine.

[0051] The method provided by this invention addresses the issue that, when the length of the wire harness 100 is less than 500mm, the first end of the wire harness 100 is subject to slight vibration during welding of its second end and second terminal. This reduces the tension between the first terminal 200 and the wire harness 100. Adjusting the welding parameters reduces both the tension at the second end and the vibration generated during welding, thereby minimizing damage to the weld at the first end and balancing the tension values ​​at both ends. Furthermore, clamping the first end of the wire harness 100 with the first terminal 200 during welding reduces the vibration generated during welding of the second end, significantly decreasing the propagation of vibration to the first end and thus minimizing its impact.

[0052] In short-distance welding, using the same parameters for two welds will result in a significantly higher tensile force on the second end compared to the first. USCAR38 requires that a failure rate of 70% or higher on the same end of a short sample indicates that the welded sample is "process sensitive" and is considered a failure. However, by adjusting the welding parameters at the second end, the tensile force values ​​at both ends can be balanced, greatly reducing the failure rate on the same side.

[0053] The power is set when the wire harness length is greater than or equal to 500mm. Energy is When the wire harness length is less than 500mm, the welding power for the first terminal 200 is: Energy is The welding power for the second terminal is Energy is ,in , This setup reduces the tension at the second end to 75-85% of the optimal weld strength, while the tension at the first end is affected by vibration during welding at the second end, further reducing weld strength. The tension values ​​at both ends are brought closer together by adjusting the value of X. Slightly increasing the equipment power at the second end serves two purposes: firstly, it allows the reduced energy to be transferred to the workpiece in a shorter time, increasing weld strength; secondly, it reduces welding time and minimizes the impact of vibration transmission.

[0054] For example, 300mm thick 70mm square copper wire is welded to both ends with 3mm thick T2 copper terminals. The first end is welded using a power of 4500W and an energy of 14000J. The second end is welded using a power of 5000W and an energy of 13000J. The tensile force at both the first and second ends of wire harness 100 is close to 7000N.

[0055] In some embodiments, the length of the wire harness 100 is measured by an ultrasonic detection sensor. Before welding, the length of the wire harness 100 is detected by an ultrasonic detection sensor. If the measured length of the wire harness 100 is ≥500mm, it is considered normal long-distance welding. When welding terminals at both ends of a normal long-distance wire harness, the parameters remain unchanged, and welding is performed according to the normal procedure.

[0056] In some embodiments, during welding, the vibration direction of the welding head of the welding machine is set at an angle to the axial direction of the wire harness 100. Without changing the material placement direction and position, the equipment can be compatible with different vibration directions. By adjusting the position of the equipment, if the vibration direction of the welding head forms an angle α with the axial direction of the wire harness 100, the vibration transmission along the axial direction of the wire harness 100 can be reduced. It can even be made perpendicular to each other. In this case, the vibration will not be transmitted along the axial direction of the wire harness 100 and will not affect the welding strength of the second end of the wire harness 100.

[0057] Specifically, by adjusting the transducer direction, the vibration transmission is reduced by creating an angle between the welding head vibration direction and the axis of the wire harness 100.

[0058] For example, the angle α between the welding head vibration direction of the welding machine and the wire harness axis is ≤90°.

[0059] In some embodiments, the welding machine is equipped with an industrial camera that works in conjunction with an ultrasonic detection sensor. During welding, the industrial camera obtains terminal information at the end of the wire harness 100 furthest from the welding position. Based on the obtained terminal information, welding parameters are switched. These welding parameters include welding power and welding energy. For example, the industrial camera (CCD) detects the end of the wire harness 100 furthest from the welding position. If this end has a terminal and the detected wire harness length is less than 500mm, the welding parameters are adjusted. For instance, the adjusted welding parameters include power... and energy If this end has no terminal, the welding parameters are set parameters, including power. and energy ,in , .

[0060] This invention uses a welding fixture to fix a wire harness 100 to a terminal to be welded during welding. The welding fixture includes a positioning and fixing mechanism and a wire harness fixing mechanism 1. The positioning and fixing mechanism is used to position and fix the terminal to be welded, which can be a first terminal 200 or a second terminal. The wire harness fixing mechanism 1 is used to fix the wire harness 100 at least on one side of the positioning and fixing mechanism. The positioning and fixing mechanism can fix the position of the terminal to be welded during welding of the wire harness 100, reducing the vibration impact transmitted to the already welded first end during welding.

[0061] In short-distance welding, the second-end welding affects the first-end welding, resulting in insufficient tensile force at the first end. The shorter the wire harness 100, the more obvious the destructive effect on the first end. By using a wire harness and terminal clamping device, the influence of the second-end welding on the first-end welding is significantly reduced, so as to achieve a near-equal tensile force at both ends of the wire harness.

[0062] like Figure 3 As shown, the welding fixture also includes a frame 8, and the positioning and fixing mechanism and the wire harness fixing mechanism 1 are both fixedly mounted on the frame 8 and supported by the frame 8.

[0063] In some embodiments, continue to refer to Figure 3 The wire harness fixing mechanism 1 includes a first drive structure 11 and a fixing member. The first drive structure 11 is connected to the fixing member to drive the fixing member to fix the wire harness 100. The fixing member can fix the wire harness 100 and reduce the vibration impact transmitted to the soldered first end.

[0064] The first drive structure 11 is determined based on the selection of the fixing member. The first drive structure 11 can be a rod cylinder, a rodless cylinder, or a motor. For example, when the first drive structure 11 is a motor, the wire harness fixing mechanism 1 also includes a transmission structure, which can be a lead screw and nut. The fixing member is connected to the second drive structure 23 through the lead screw and nut to achieve linear movement. When the first drive structure 11 is a rod cylinder, there are two first drive structures 11. The two first drive structures 11 are arranged opposite each other on both sides of the wire harness 100. The first drive structure 11 is arranged one-to-one with the fixing member, so that the connection between the first drive structure 11 and the fixing member can achieve the clamping of the wire harness 100 by the two fixing members. When the first drive structure 11 is a rodless cylinder, the two fixing members are connected to the first drive structure 11. The first drive structure 11 drives the two fixing members to move towards each other, thereby clamping the wire harness 100. The first drive structure 11 also drives the two fixing members to move away from each other, thereby releasing the wire harness 100.

[0065] In some embodiments, such as Figure 4As shown, the fixing component includes two opposing clamps 12. The first driving structure 11 is fixedly connected to the two clamps 12 to drive the two clamps 12 to open and close. The clamps 12 can clamp the wire harness 100 from both sides to prevent the wire harness 100 from swinging randomly during the welding process.

[0066] To prevent the grippers 12 from damaging the wire harness 100, in some embodiments the grippers 12 are provided with receiving grooves 121. The shape of the receiving grooves 121 can be V-shaped, with each of the two grippers 12 arranged opposite to each other having a receiving groove 121, and the receiving grooves 121 on different grippers 12 are also arranged opposite to each other. This ensures that a space can be formed to accommodate the wire harness 100 after the two grippers 12 are closed, avoiding excessive damage to the wire harness 100 by the grippers 12.

[0067] In some embodiments, the grippers 12 have a plurality of slots 122 spaced apart on the side facing the wire harness 100. The slots 122 divide the grippers 12 into a plurality of teeth 123. The grippers 12 are inserted into each other through the slots 122, and the teeth 123 cooperate with the slots 122 to adjust the distance between the two grippers 12. The cooperation of the teeth 123 with the slots 122 can prevent the grippers 12 from moving relative to each other along the axis of the wire harness 100, so as to ensure that the wire harness 100 can be firmly fixed.

[0068] In other embodiments, when the grippers 12 hold the wire harness 100, the two grippers 12 are staggered. The staggered arrangement of the two grippers 12 can increase the travel of the grippers 12, thus making the grippers 12 suitable for wire harnesses 100 of a wider diameter.

[0069] During welding, the terminals to be welded may vibrate and the position of the wire harness 100 may change, affecting the welding effect. Therefore, in some embodiments, the fixture also includes a top-loading assembly 6, which is arranged opposite to the wire harness fixing mechanism 1 along the length of the wire harness 100. The wire harness fixing mechanism 1 clamps the wire harness 100, while the top-loading assembly 6 presses the terminals to be welded against it, and the positioning and fixing mechanism clamps the terminals to be welded from the side.

[0070] like Figure 5 and Figure 6As shown, the positioning and fixing mechanism includes a push block assembly 2 and a push plate assembly 3. The push block assembly 2 includes a push plate 21, a first adjusting member 22, and a second driving structure 23. The push plate 21 and the second driving structure 23 are connected through the first adjusting member 22. The push plate 21 is used to clamp the tail of the terminal to be welded, thereby clamping both sides of the terminal to be welded. During the welding process, the vibration frequency of the terminal to be welded is changed due to the clamping of the push plate 21, thus preventing the terminal to be welded from cracking in the welding area to the clamping area. The push plate assembly 3 includes a push block 31, a second adjusting member 32, and a third driving structure 33. The push block 31 and the third driving structure are connected through the second adjusting member 32. The push block 31 is used to clamp the edge of the terminal to be welded.

[0071] The second drive structure 23 and the third drive structure 33 are arranged opposite each other, which saves space compared to the second drive structure 23 and the third drive structure 33 being arranged side by side.

[0072] In some embodiments, the first adjusting member 22 includes a first wedge block 221 having a first inclined working surface, a push plate 21 connected to a second wedge block 222 having a second inclined working surface, the first inclined working surface and the second inclined working surface being in contact, and a second driving structure 23 fixedly connected to the first wedge block 221 to drive the first wedge block 221 to press or release the push plate 21. When the second driving structure 23 pushes the first wedge block 221 forward, since the first wedge block 221 has a first inclined working surface and the second wedge block 222 has a second inclined working surface, the first inclined working surface will press against the second inclined working surface. Under the pressure of the first wedge block 221, the second wedge block 222 connected to the push plate 21 moves towards the terminal to be welded, and thus has a tendency to clamp towards the edge of the terminal to be welded.

[0073] In some embodiments, the second adjusting member 32 includes a third wedge block 321 having a third inclined working surface. A fourth wedge block 322 is connected to the push block 31, and the fourth wedge block 322 has a fourth inclined working surface. The third inclined working surface and the fourth inclined working surface are in contact. A third driving structure 33 is fixedly connected to the third wedge block 321 to drive the third wedge block 321 to squeeze or release the fourth wedge block 322 connected to the push block 31. Driven by the third driving structure 33, the third wedge block 321 moves forward along the axial direction of the third driving structure 33. Since the third inclined working surface and the fourth inclined working surface are in contact with each other, when the third inclined working surface moves relative to the fourth inclined working surface, it forces the fourth wedge block 322 with the fourth inclined working surface to move. In turn, the fourth wedge block 322 drives the push block 31 to move, thereby clamping the terminal from both sides of the terminal.

[0074] When the first wedge block 221 extends back under the drive of the second drive structure 23, the pushing force on the push plate 21 also disappears accordingly. In order to keep the push plate 21 in contact with the first wedge block 221 for the next clamping of the terminal, in some embodiments, the positioning and fixing mechanism also includes a limiting frame 4, and the first adjusting member 22 includes a first elastic member 223. One end of the first elastic member 223 extends into the second wedge block 222, and the other end abuts against the limiting frame 4. In this way, when the push plate 21 is squeezed, the first elastic member 223 is compressed. After the pushing force on the push plate 21 disappears, the first elastic member 223 will push the push plate 21 towards the first wedge block 221 under its own restoring force, thereby keeping the first wedge block 221 in contact with the push plate 21 for the next clamping of the terminal to be welded.

[0075] The third wedge block 321 extends back under the drive of the third drive structure 33, and the pushing force on the push block 31 also disappears accordingly. In order to keep the push block 31 in contact with the third wedge block 321, in some embodiments, the second adjusting member 32 also includes a second elastic member 323. One end of the second elastic member 323 extends into the fourth wedge block 322, and the other end abuts against the limiting frame 4. The push block 31 and the push plate 21 are both set in the area enclosed by the limiting frame 4. In this way, when the push block 31 is squeezed, the second elastic member 323 is compressed. After the pushing force on the push block 31 disappears, the second elastic member 323 will push the push block 31 towards the third wedge block 321 under its own restoring force, thereby keeping the third wedge block 321 in contact with the push block 31, so as to facilitate the clamping of the terminal to be welded next time.

[0076] The welding fixture also includes a terminal positioning block 7, which is fixed to the frame 8 and located between two positioning and fixing mechanisms. The terminal positioning block 7 is used to support and position the terminal to be welded. The ejector assembly 6 is located on one side of the terminal positioning block 7 to limit the position of the terminal and prevent large positional displacement due to terminal vibration. The terminal positioning block 7 is mounted on the frame 8 and can move relative to the frame 8 along the axial direction of the wire harness 100. The movement of the terminal positioning block 7 relative to the frame 8 can be achieved by a slide rail slider.

[0077] This embodiment also includes a controller, which is communicatively connected to the first drive structure 11, the second drive structure 23, and the third drive structure 33 to send commands to them so that they work in coordination. For example, the second drive structure 23 and the third drive structure 33 are both rod cylinders.

[0078] Furthermore, the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of the present invention, the scope of which is determined by the scope of the appended claims.

Claims

1. A welding method, wherein terminals are welded to both ends of a wire harness (100) by ultrasonic welding, characterized in that, Includes the following steps: Obtain the length of the wire harness (100); If the length of the wire harness (100) is less than 500mm, fix the first end of the wire harness (100) to the first terminal (200), weld the first end of the wire harness (100) to the first terminal (200), flip the wire harness (100) with the first terminal (200) welded to its first end, fix the wire harness (100) to the second terminal, adjust the welding parameters of the welding machine to weld the second end of the wire harness (100) to the second terminal, the welding parameters include at least the energy and power of the welding machine, and set the power when the length of the wire harness (100) is greater than or equal to 500mm. Energy is , When the length of the wire harness (100) is less than 500mm, the welding power of the first terminal (200) is: Energy is The welding power for the second terminal is Energy is ,in , L is the length of the wire harness. During welding, the angle between the direction of vibration of the welding head of the welding machine and the axial direction of the wire harness (100) is... During the welding process, the first end of the wire harness with the first terminal is clamped, and the vibration generated when the second end of the wire harness is welded is reduced by the clamping mechanism.

2. The welding method according to claim 1, characterized in that, The length of the wire harness (100) was measured by an ultrasonic detection sensor.

3. The welding method according to claim 1, characterized in that, The welding machine is equipped with an industrial camera. During welding, it obtains terminal information of the end of the wire harness (100) away from the welding position and switches welding parameters based on the obtained terminal information. The welding parameters include welding power and welding energy.

4. The welding method according to any one of claims 1-3, characterized in that, The wire harness (100) is fixed to the terminal to be welded by a welding fixture, which includes: A positioning and fixing mechanism is used to position and fix the terminal; A wire harness fixing mechanism (1) is provided for fixing at least one side of the positioning fixing mechanism.

5. The welding method according to claim 4, characterized in that, The wire harness fixing mechanism (1) includes a first driving structure (11) and a fixing member. The first driving structure (11) is connected to the fixing member to drive the fixing member to fix the wire harness (100).

6. The welding method according to claim 5, characterized in that, The fixing member includes two opposing grippers (12), and the first driving structure (11) is fixedly connected to the two grippers (12) respectively to drive the two grippers (12) to open and close.

7. The welding method according to claim 6, characterized in that, The gripper (12) is provided with a receiving groove (121).

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