Welding method

Abstract

The invention relates to the technical field of welding, in particular to a welding method. According to the welding method provided by the invention, the terminal is placed in the welding area of the welding machine; then the terminal is clamped along side walls which are oppositely arranged on two sides of the extension direction of the cable, and the surface, facing the cable, of the terminal is exposed; and finally, placing the cable on the surface of the terminal and welding the cable with the terminal. The terminal is clamped from the side walls which are oppositely arranged on the two sides along the extension direction of the cable, so that the surface, facing the cable, of the terminal is completely exposed, the surface, facing the cable, of the terminal is not shielded, the cable can be completely welded with the surface, facing the cable, of the terminal, the purpose of full welding is achieved, and the service life of the terminal is prolonged. Therefore, on the premise of not increasing the size of the terminal, the welding area is ensured, the terminal material is saved, and the manufacturing cost is reduced.

Description

Technical Field

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

[0002] When welding the terminal to the cable, a fixed area needs to be left at both ends of the terminal. The fixed area is used to clamp the terminal (the purpose of clamping the terminal is to fix the terminal, prevent the terminal from moving, and ensure the stability of ultrasonic welding). Such a setting will increase the material required for the terminal, resulting in material waste.

[0003] Therefore, a welding method is urgently needed to solve the above-mentioned technical problems. Summary of the invention

[0004] The purpose of the present invention is to provide a welding method which can save terminal materials and reduce manufacturing costs.

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

[0006] A welding method is provided, comprising the following steps:

[0007] S10, placing the terminal in the welding area of ​​the welding machine;

[0008] S20, the terminal is clamped by side walls opposite to each other on both sides of the cable extension direction, and the terminal is exposed on the surface facing the cable;

[0009] S30, placing the cable on the terminal surface and welding the cable to the terminal.

[0010] As a preferred technical solution for the above-mentioned welding method, the terminal is clamped by a push block, and the side wall of the push block facing the terminal is a vertical side wall. When the thickness of the terminal is ≥3mm, the two sides of the terminal are clamped horizontally by the vertical side walls of the push block, wherein the clamping force is <1000N.

[0011] As a preferred technical solution of the above welding method, the terminal is clamped by a push block, the push block is arranged on both sides of the terminal, the thickness of the terminal is less than 3mm, and after the terminal is placed in the welding area, the gap between the push block and the terminal is adjusted so that the gap value range is 0.03mm-0.08mm.

[0012] As a preferred technical solution of the above welding method, the height of the push block clamping area ranges from 6mm to 12mm.

[0013] As a preferred technical solution for the above welding method, the distance between the two relatively arranged push blocks and the side walls of the terminal is 15mm-19mm, and the distance between the two relatively arranged push blocks and the side walls of the terminal is the width of the push block clamping area.

[0014] As a preferred technical solution of the above welding method, the hardness of the side wall of the push block facing the terminal is ≥HRC65.

[0015] As a preferred technical solution of the above welding method, the edge of the push block facing the terminal has a chamfer.

[0016] As a preferred technical solution of the above welding method, the welding machine has a welding head, and the welding head has welding teeth, wherein the tooth depth D of the welding teeth is k 1 ×(0.21×ln(SQ)-0.08)mm, SQ is the cable diameter, k 1 is the proportionality coefficient, where 0.8≤k 1 ≤1.2, the distance between adjacent welding teeth is h, wherein 1.2mm≤h≤1.4mm, the angle between teeth = 60°, a chamfer is provided on the tail side of the welding machine, and the cross-sectional edge of the chamfer has a transition angle and an edge angle, wherein the diameter of the transition angle is R1, and the value range of R1 is 3mm-6mm, the diameter of the edge angle is R2, and the value range of R2 is 0.5mm-2mm, and the margin between the outermost welding tooth and the edge of the welding head is L, L = (0.6-0.8) × R1.

[0017] As a preferred technical solution of the above welding method, the welding head width W=k 2 ×(5.67×ln(SQ)-6.4)mm,k 2 is the proportionality coefficient, where 0.8≤k 2 ≤1.2.

[0018] As a preferred technical solution of the above welding method, the welding power of the welding machine is 3.5kW-6kW, and the amplitude of the welding machine is ≤30um.

[0019] The present invention has at least the following beneficial effects:

[0020] The welding method provided by the present invention is as follows: the terminal is placed in the welding area of ​​the welding machine; then the side walls of the terminal are clamped on both sides of the cable extension direction, and the surface of the terminal facing the cable is exposed; finally, the cable is placed on the terminal surface and the cable and the terminal are welded. Since the terminal is clamped from the side walls on both sides of the cable extension direction, the surface of the terminal facing the cable can be completely exposed. Since the surface of the terminal facing the cable is unobstructed, the cable can be completely welded with the surface of the terminal facing the cable, achieving the purpose of full welding. In this way, the welding area can be guaranteed without increasing the size of the terminal, saving terminal materials and reducing manufacturing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments of the present invention. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the contents of the embodiments of the present invention and these drawings without paying any creative work.

[0022] Figure 1 A flow chart of a welding method provided by an embodiment of the present invention;

[0023] Figure 2 A front view of a welding head provided by an embodiment of the present invention;

[0024] Figure 3 A first structural schematic diagram of a clamping device provided in an embodiment of the present invention;

[0025] Figure 4 A second structural schematic diagram of the clamping device provided in an embodiment of the present invention.

[0026] In the figure:

[0027] 1. Limiting frame; 2. Driving structure; 21. First wedge block; 22. Second wedge block; 23. Driving member; 3. Push plate; 100. Cable; 200. Terminal; 300. Welding head. DETAILED DESCRIPTION

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

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

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

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

[0032] Figure 1 A flow chart of a welding method provided by an embodiment of the present invention, such as Figure 1 As shown, the welding method comprises the following steps:

[0033] S10, placing the terminal in the welding area of ​​the welding machine;

[0034] S20, the terminal is clamped by side walls opposite to each other on both sides of the cable extension direction, and the terminal is exposed on the surface facing the cable;

[0035] Specifically, the welding area of ​​the welding machine has a clamping device, which has a driving structure and a push plate. The driving structure is connected to the push plate to drive the push plate to move horizontally, so that both sides of the terminal can be clamped and fixed.

[0036] S30, placing the cable on the terminal surface and welding the cable to the terminal.

[0037] According to the welding method provided by the present invention, since the terminal is clamped by side walls arranged opposite to each other on both sides along the extension direction of the cable, the surface of the terminal facing the cable can be completely exposed. Since the surface of the terminal facing the cable is not blocked, the cable can be completely welded to the surface of the terminal facing the cable, thereby achieving full welding. In this way, the welding area can be guaranteed without increasing the size of the terminal, thus saving terminal materials and reducing manufacturing costs.

[0038] In some embodiments, the terminal is clamped by a push block, and the side wall of the push block facing the terminal is a vertical side wall. When the thickness of the terminal is greater than or equal to 3 mm, the two sides of the terminal are clamped by the vertical side walls of the push block in the horizontal direction, thereby clamping the two sides of the terminal. The clamping force applied by the push block to the terminal is less than 1000N. Such a setting can avoid damage to the clamped area of ​​the terminal side wall caused by excessive clamping force.

[0039] In some other embodiments, the terminal is clamped by a push block, and the push blocks are arranged on both sides of the terminal. The thickness of the terminal is less than 3mm. After the terminal is placed in the welding area, the gap between the push block and the terminal is adjusted so that the gap ranges from 0.03mm to 0.08mm. Optionally, the gap can be 0.03mm, 0.04mm, 0.05mm, 0.06mm, 0.07mm or 0.08mm, which is not specifically limited in this embodiment. If the gap is less than 0.03, the gap is too small, which will cause the terminal to be driven by high-frequency vibration to hit the push block during welding, causing the push block to be hit and causing damage to the drive structure connected to the push block. If the gap is too large, the terminal position will deviate, resulting in an increase in the welding failure rate. Setting the gap range to 0.03mm-0.08mm can prevent the push block from being hit and the drive structure from being damaged.

[0040] In some embodiments, the height of the push block clamping area ranges from 6 mm to 12 mm. Specifically, the height of the push block clamping area is 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm or 12 mm, which is not specifically limited in this embodiment. This arrangement ensures that the surface of the terminal facing the cable is completely exposed, so that the welding head will not contact the push block during welding, ensuring that the push block will not be damaged.

[0041] In some embodiments, the distance between the two push blocks arranged opposite to each other and facing the side wall of the terminal is 15mm-19mm. Specifically, the distance between the two push blocks arranged opposite to each other and facing the side wall of the terminal is 15mm, 16mm, 17mm, 18mm or 19mm, which is not specifically limited in the present embodiment. It should be noted that the distance between the two push blocks arranged opposite to each other and facing the side wall of the terminal is the width of the clamping area of ​​the push blocks. If the side walls of the two push blocks arranged opposite to each other and facing the terminal are too narrow, the cable will leak from the welding head and the side of the push blocks, resulting in loss of welding strength. If the side walls are too wide, the size requirements of the terminal welding area will be limited. Such a setting can prevent the cable from leaking and will not have any size requirements for the terminal welding area.

[0042] In some embodiments, the hardness of the side wall of the push block facing the terminal is ≥HRC65. Such a configuration can ensure that the side wall of the push block facing the terminal has good wear resistance and improve the service life of the push block.

[0043] Since the terminal will inevitably touch the push block during the process of taking and placing, and the edge of the push block will squeeze the terminal and cause the terminal clamping damage, in some embodiments, the edge of the push block facing the terminal has a chamfer. The chamfer is specifically a rounded corner, which can make the push block smoother and improve the safety of the terminal.

[0044] In some embodiments, the welder has a welding head, Figure 2 A front view of a welding head 300 provided in an embodiment of the present invention is shown in FIG. Figure 2 As shown, the welding head 300 has welding teeth, wherein the tooth depth of the welding teeth is d=k 1 ×(0.21×ln(SQ)-0.08)mm, SQ is the cable diameter, k 1 is the proportionality coefficient, where 0.8≤k 1 ≤1.2, the distance between adjacent welding teeth is h, wherein 1.2mm≤h≤1.4mm, the angle between teeth = 60°, the tail side of the welding head 300 is provided with a chamfer, and the cross-sectional edge of the chamfer has a transition angle and an edge angle, wherein the diameter of the transition angle is R1, and the value range of R1 is 3mm-6mm. For example, the value of R1 can be 3mm, 4mm, 5mm or 6mm, which is not specifically limited in this embodiment. Optionally, the diameter of the edge angle is R2, and the value range of R2 is 0.5mm-2mm. For example, the value of R2 can be 0.5mm, 1mm, 1.5mm or 2mm, which is not specifically limited in this embodiment. Optionally, the margin between the outermost welding tooth and the edge of the welding head is L, L = (0.6-0.8) × R1. In some embodiments, the welding head width W = k 2 ×(5.67×ln(SQ)-6.4)mm,k 2 is the proportionality coefficient, where 0.8≤k 2 ≤1.2. This ensures that the welding head can weld the cable and achieve full welding of the cable.

[0045] In some embodiments, the welding power of the welder is 3.5kW-6kW. Optionally, the welding power of the welder may be 3.5kW, 4kW, 4.5kW, 5kW, 5.5kW or 6kW, which is not specifically limited in this embodiment. In some embodiments, the amplitude of the welder is ≤30um. The amplitude of the welder is limited to be less than or equal to 30um, so that the terminal can be prevented from being driven by high-frequency vibration to hit the push block during the welding process, thereby reducing the probability of collision.

[0046] Figure 3 A first structural schematic diagram of a clamping device provided in an embodiment of the present invention, Figure 4 A second structural schematic diagram of the clamping device provided in an embodiment of the present invention is shown in FIG. Figure 3 and Figure 4As shown, in some embodiments, the clamping device has a limiting frame 1, a driving structure 2 and a push plate 3, wherein the driving structure 2 is partially located outside the limiting frame 1, and the driving structure 2 is connected to the push plate 3 to drive the push plate 3 to move horizontally.

[0047] The driving structure 2 includes a driving member 23 and an adjusting member. The adjusting member is arranged in the area surrounded by the limiting frame 1. For example, the driving member 23 can be a cylinder or an oil cylinder. Specifically, the adjusting member includes a first wedge block 21 and a second wedge block 22. The first wedge block 21 has a first inclined working surface. The push plate 3 is connected to the second wedge block 22. The second wedge block 22 has a second inclined working surface. The first inclined working surface fits with the second inclined working surface. The driving member 23 is fixedly connected to the first wedge block 21 to drive the first wedge block 21 to squeeze or move away from the second wedge block 22 connected to the push plate 3. Under the drive of the driving member 23, the first wedge block 21 moves forward along the axial direction of the driving member 23. Since the first inclined working surface and the second inclined working surface fit with each other, when the first inclined working surface moves relative to the second inclined working surface, it will force the second wedge block 22 with the second inclined working surface to move, and then the second wedge block 22 drives the push plate 3 to move, so as to clamp the terminal 200 from both sides of the terminal 200.

[0048] The first wedge block 21 extends back under the drive of the driving member 23, and the pushing force exerted on the push plate 3 will disappear accordingly. In order to enable the push plate 3 to maintain contact with the first wedge block 21, in some embodiments, the adjusting member also includes an elastic member, one end of the elastic member extends into the second wedge block 22, and the other end is against the limit frame 1. The push plate 3 is arranged in the area surrounded by the limit frame 1. In this way, when the push plate 3 is squeezed, the elastic member is compressed. After the pushing force exerted on the push plate 3 disappears, the elastic member will push the push plate 3 to move toward the first wedge block 21 under the action of its own restoring force, thereby keeping the first wedge block 21 and the push plate 3 in contact with each other, so as to facilitate the next clamping of the terminal 200.

[0049] During welding, the welding head 300 welds the wire harness 100 and the terminal 200 .

[0050] In addition, the above are only preferred embodiments of the present invention and the technical principles used. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and that various obvious changes, readjustments and substitutions can be made by those skilled in the art without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in more detail through the above embodiments, the present invention is not limited to the above embodiments, and may include more other equivalent embodiments without departing from the concept of the present invention, and the scope of the present invention is determined by the scope of the appended claims.

Claims

1. A welding method, characterized in that: The steps include: S10, placing the terminal in the welding area of ​​the welding machine; S20, the terminal is clamped by side walls opposite to each other on both sides of the cable extension direction, and the terminal is exposed on the surface facing the cable; S30, placing the cable on the terminal surface and welding the cable to the terminal.

2. The welding method according to claim 1, characterized in that: The terminal is clamped by a push block, and the side wall of the push block facing the terminal is a vertical side wall. When the thickness of the terminal is ≥3mm, the two sides of the terminal are clamped horizontally by the vertical side walls of the push block, wherein the clamping force is <1000N.

3. The welding method according to claim 1, characterized in that: The terminal is clamped by a push block, which is arranged on both sides of the terminal. The thickness of the terminal is less than 3mm. After the terminal is placed in the welding area, the gap between the push block and the terminal is adjusted so that the gap value range is 0.03mm-0.08mm.

4. The welding method according to claim 2 or 3, characterized in that: The height of the push block clamping area ranges from 6mm to 12mm.

5. The welding method according to claim 2 or 3, characterized in that: The distance between the two oppositely arranged push blocks and the side walls of the terminal is 15 mm to 19 mm, and the distance between the two oppositely arranged push blocks and the side walls of the terminal is the width of the clamping area of ​​the push blocks.

6. The welding method according to claim 2 or 3, characterized in that: The hardness of the side wall of the push block facing the terminal is ≥HRC65.

7. The welding method according to claim 2 or 3, characterized in that: The edge of the push block facing the terminal has a chamfer.

8. The welding method according to claim 1, characterized in that: The welding machine has a welding head, and the welding head has welding teeth, wherein the tooth depth of the welding teeth is D=k1×(0.21×ln(SQ)-0.08)mm, SQ is the cable diameter, k1 is the proportional coefficient, wherein 0.8≤k1≤1.2, the distance between adjacent welding teeth is h, wherein 1.2mm≤h≤1.4mm, the angle between teeth=60°, and a chamfer is provided on the tail side of the welding machine, and the cross-sectional edge of the chamfer has a transition angle and an edge angle, wherein the diameter of the transition angle is R1, and the value range of R1 is 3mm-6mm, the diameter of the edge angle is R2, and the value range of R2 is 0.5mm-2mm, and the margin between the outermost welding tooth and the edge of the welding head is L, L=(0.6-0.8)×R1.

9. The welding method according to claim 8, characterized in that: The welding head width W=k2×(5.67×ln(SQ)-6.4) mm, k2 is the proportionality coefficient, wherein 0.8≤k2≤1.

2.

10. The welding method according to claim 1, characterized in that: The welding power of the welding machine is 3.5kW-6kW, and the amplitude of the welding machine is ≤30um.

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