A welding method

Abstract

The present application relates to the technical field of welding, in particular to a welding method. The welding method provided by the present application comprises the following steps: placing a terminal in a welding area of a welding machine; clamping the terminal along the side walls arranged oppositely on both sides in the extending direction of a cable, and exposing the surface of the terminal facing the cable; and placing the cable on the surface of the terminal and welding the cable and the terminal. Since the terminal is clamped along the side walls arranged oppositely on both sides in the extending direction of the cable, the surface of the terminal facing the cable is completely exposed. Since the surface of the terminal facing the cable is not blocked, the cable can be completely welded with the surface of the terminal facing the cable, so that full welding is achieved. In this way, the welding area can be ensured without increasing the size of the terminal, the terminal material is saved, and the manufacturing cost is reduced.

Description

Technical Field

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

[0002] When welding terminals to cables, a fixing area needs to be left at both ends of the terminal. This fixing 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 amount of 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 this invention is to provide a welding method that can save terminal materials and reduce manufacturing costs.

[0005] To achieve this objective, the present invention adopts the following technical solution:

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

[0007] S10. Place the terminal in the welding area of ​​the welding machine;

[0008] S20, The sidewalls of the terminal, which are arranged opposite each other on both sides along the cable extension direction, are clamped, and the surface of the terminal facing the cable is exposed.

[0009] S30. Place the cable on the terminal surface and solder the cable to the terminal.

[0010] As a preferred technical solution of the above welding method, the terminal is clamped by a push block, 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 by the vertical side wall of the push block in the horizontal direction, 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 disposed on both sides of the terminal, the thickness of the terminal is <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 ranges from 0.03mm to 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 of the above welding method, the distance between the two oppositely arranged push blocks toward the side wall of the terminal is 15mm-19mm, and the distance between the two oppositely arranged push blocks toward the side wall 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 pusher block facing the terminal is ≥HRC65 or higher.

[0015] As a preferred embodiment of the above welding method, the pusher block has a chamfered edge facing the terminal.

[0016] As a preferred technical solution of the above welding method, the welding machine has a welding head, the welding head has welding teeth, wherein the tooth depth D = k1 × (0.21 × ln(SQ) - 0.08) mm, SQ is the cable diameter, k1 is a proportional coefficient, wherein 0.8 ≤ k1 ≤ 1.2, the distance between adjacent welding teeth is h, wherein 1.2 mm ≤ h ≤ 1.4 mm, the included angle between teeth = 60°, the tail side of the welding machine is provided with a chamfer, the cross-sectional edge of the chamfer has a transition angle and an edge angle, wherein the diameter of the transition angle is R1, the value range of R1 is 3 mm - 6 mm, the diameter of the edge angle is R2, the value range of R2 is 0.5 mm - 2 mm, and the distance 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 = k2 × (5.67 × ln(SQ) - 6.4) mm, where k2 is a proportionality coefficient, and 0.8 ≤ k2 ≤ 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 this invention involves placing a terminal in the welding area of ​​a welding machine; then clamping the terminal against the opposing sidewalls on both sides along the cable's extension direction, exposing the surface of the terminal facing the cable; finally, placing the cable on the terminal surface and welding the cable to the terminal. Because the terminal is clamped by the opposing sidewalls along the cable's extension direction, the surface of the terminal facing the cable is fully exposed. Since the surface of the terminal facing the cable is unobstructed, the cable can be completely welded to the surface of the terminal facing the cable, achieving full welding. This ensures the welding area without increasing the terminal size, saving terminal material and reducing manufacturing costs. Attached Figure Description

[0021] 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.

[0022] Figure 1 A flowchart of a welding method provided in an embodiment of the present invention;

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

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

[0025] Figure 4 This is a schematic diagram of the second structure of the clamping device provided in an embodiment of the present invention.

[0026] In the picture:

[0027] 1. Limiting frame; 2. Drive structure; 21. First wedge block; 22. Second wedge block; 23. Drive component; 3. Push plate; 100. Cable; 200. Terminal; 300. Welding head. Detailed Implementation

[0028] 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.

[0029] 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.

[0030] 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.

[0031] 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.

[0032] Figure 1 A flowchart of the welding method provided in the embodiments of the present invention is shown below. Figure 1 As shown, the welding method includes the following steps:

[0033] S10. Place the terminal in the welding area of ​​the welding machine;

[0034] S20, The sidewalls of the terminal, which are arranged opposite each other on both sides along the cable extension direction, are clamped, and the surface of the terminal facing the cable is exposed.

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

[0036] S30. Place the cable on the terminal surface and solder the cable to the terminal.

[0037] The welding method provided by the present invention allows the terminal to be fully exposed on the surface of the terminal facing the cable because the terminal is clamped by the side walls arranged opposite to each other on both sides along the extension direction of the cable. Since the surface of the terminal facing the cable is unobstructed, the cable can be fully welded to the surface of the terminal facing the cable, achieving the purpose of full welding. This can ensure the welding area without increasing the size of the terminal, save terminal material, and reduce manufacturing costs.

[0038] In some embodiments, the terminal is clamped by a push block, the sidewall of the push block facing the terminal being a vertical sidewall. When the thickness of the terminal is greater than or equal to 3mm, the two sides of the terminal are clamped horizontally by the vertical sidewall of the push block, thereby clamping both sides of the terminal. The clamping force applied to the terminal by the push block is <1000N. This arrangement can avoid damage to the clamped area of ​​the terminal sidewall due to excessive clamping force.

[0039] In some embodiments, the terminal is clamped by push blocks positioned on both sides of the terminal. The terminal thickness is less than 3mm. After the terminal is placed in the welding area, the gap between the push blocks and the terminal is adjusted to a range of 0.03mm-0.08mm. Optionally, the gap can be 0.03mm, 0.04mm, 0.05mm, 0.06mm, 0.07mm, or 0.08mm, and is not specifically limited in this embodiment. If the gap is less than 0.03mm, the terminal may be subjected to high-frequency vibration during welding, causing it to impact the push blocks and damaging the drive structure connected to the push blocks. Conversely, an excessively large gap may cause the terminal to misalign, increasing the welding failure rate. Setting the gap range to 0.03mm-0.08mm avoids impacts to the push blocks and prevents damage to the drive structure.

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

[0041] In some embodiments, the distance between the two opposing push blocks and their sidewalls facing the terminal is 15mm-19mm. Specifically, the distance between the two opposing push blocks and their sidewalls facing the terminal is 15mm, 16mm, 17mm, 18mm, or 19mm, and is not specifically limited in this embodiment. It should be noted that the distance between the two opposing push blocks and their sidewalls facing the terminal is the width of the push block clamping area. If the sidewalls of the two opposing push blocks facing the terminal are too narrow, the cable will leak from the welding head and the sides of the push blocks, resulting in a loss of welding strength. If they are too wide, it will limit the size requirements of the terminal welding area. This arrangement can prevent cable leakage and does not impose size requirements on the terminal welding area.

[0042] In some embodiments, the hardness of the sidewall of the push block facing the terminal is ≥HRC65 or higher. This setting can ensure good wear resistance of the sidewall of the push block facing the terminal and improve the service life of the push block.

[0043] Since the terminals inevitably come into contact with the push block during the handling process, and the edges of the push block can squeeze the terminals, causing damage to the terminal clamping mechanism, in some embodiments, the edge of the push block facing the terminal has a chamfer. Specifically, the chamfer is a rounded corner, which makes the push block smoother and improves the safety of the terminals.

[0044] In some embodiments, the welding machine has a welding head. Figure 2 This is a front view of the welding head 300 provided in an embodiment of the present invention, as shown below. Figure 2 As shown, the welding head 300 has welding teeth, wherein the tooth depth d = k1 × (0.21 × ln(SQ) - 0.08) mm, SQ is the cable diameter, k1 is a proportionality coefficient, where 0.8 ≤ k1 ≤ 1.2, the distance between adjacent welding teeth is h, where 1.2 mm ≤ h ≤ 1.4 mm, the included angle between teeth is 60°, and the tail side of the welding head 300 is provided with a chamfer. 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 of R1 ranges from 3 mm to 6 mm. For example, the value of R1 can be 3 mm, 4 mm, 5 mm or 6 mm, which is not specifically limited in this embodiment. Optionally, the diameter of the edge angle is R2, and the value of R2 ranges from 0.5 mm to 2 mm. For example, the value of R2 can be 0.5 mm, 1 mm, 1.5 mm or 2 mm, which is not specifically limited in this embodiment. Optionally, the distance between the outermost welding tooth and the edge of the welding head is L, where L = (0.6-0.8) × R1. In some embodiments, the welding head width W = k2 × (5.67 × ln(SQ) - 6.4) mm, where k2 is a proportionality coefficient, and 0.8 ≤ k2 ≤ 1.2. This ensures that the welding head can weld the cable, achieving full welding of the cable.

[0045] In some embodiments, the welding power of the welding machine is 3.5kW-6kW. Optionally, the welding power of the welding machine can be 3.5kW, 4kW, 4.5kW, 5kW, 5.5kW, or 6kW, and no specific limitation is made in this embodiment. In some embodiments, the amplitude of the welding machine is ≤30µm. Limiting the welding machine amplitude to less than or equal to 30µm can prevent the terminals from being driven by high-frequency vibration to impact the push block during the welding process, thus reducing the probability of impact.

[0046] Figure 3 This is a first structural schematic diagram of the clamping device provided in an embodiment of the present invention. Figure 4 This is a schematic diagram of the second structure of the clamping device provided in an embodiment of the present invention, as shown below. Figure 3 and Figure 4 As 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 located outside the limiting frame 1 and is connected to the push plate 3 to drive the push plate 3 to move horizontally.

[0047] The drive structure 2 includes a drive component 23 and an adjusting component. The adjusting component is provided within the area enclosed by the limiting frame 1. For example, the drive component 23 can be a cylinder or a hydraulic cylinder. Specifically, the adjusting component 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, which has a second inclined working surface. The first inclined working surface and the second inclined working surface are in contact. The drive component 23 is fixedly connected to the first wedge block 21 to drive the first wedge block 21 to press against or move away from the second wedge block 22 connected to the push plate 3. Under the drive of the drive component 23, the first wedge block 21 moves forward along the axial direction of the drive component 23. Since the first inclined working surface and the second inclined working surface are in contact with each other, when the first inclined working surface moves relative to the second inclined working surface, it forces the second wedge block 22 with the second inclined working surface to move. In turn, the second wedge block 22 drives the push plate 3 to move, thereby clamping the terminal 200 from both sides.

[0048] The first wedge block 21 extends back under the drive of the drive member 23, and the pushing force on the push plate 3 also disappears accordingly. In order to keep the push plate 3 in 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 abuts against the limiting frame 1. The push plate 3 is set in the area enclosed by the limiting frame 1. In this way, when the push plate 3 is squeezed, the elastic member is compressed. After the pushing force on the push plate 3 disappears, the elastic member will push the push plate 3 towards the first wedge block 21 under its own restoring force, thereby keeping the first wedge block 21 in contact with the push plate 3, so as to facilitate the clamping of the terminal 200 next time.

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

[0050] 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, characterized in that, Includes the following steps: S10. Place the terminal in the welding area of ​​the welding machine; S20, The sidewalls of the terminal, which are arranged opposite each other on both sides along the cable extension direction, are clamped, and the surface of the terminal facing the cable is fully exposed; S30. Place the cable on the terminal surface and solder the cable to the terminal; The terminal is clamped by push blocks, which are located on both sides of the terminal. The thickness of the terminal is <3mm. After the terminal is placed in the welding area, the gap between the push blocks and the terminal is adjusted so that the gap ranges from 0.03mm to 0.08mm. The height of the push block clamping area ranges from 6mm to 12mm. The welding machine has a welding head with welding teeth, wherein the tooth depth D = k1 × (0.21 × ln(SQ) - 0.08) mm, SQ is the cable diameter, k1 is a proportional coefficient, where 0.8 ≤ k1 ≤ 1.2, the distance between adjacent welding teeth is h, where 1.2 mm ≤ h ≤ 1.4 mm, the included angle between teeth is 60°, the tail side of the welding machine is provided with a chamfer, the cross-sectional edge of the chamfer has a transition angle and an edge angle, wherein the diameter of the transition angle is R1, the value range of R1 is 3 mm - 6 mm, the diameter of the edge angle is R2, the value range of R2 is 0.5 mm - 2 mm, the distance between the outermost welding tooth and the edge of the welding head is L, L = (0.6 - 0.8) × R1; The welding head width W = k2 × (5.67 × ln(SQ) - 6.4) mm, where k2 is a proportionality coefficient, and 0.8 ≤ k2 ≤ 1.

2.

2. The welding method according to claim 1, characterized in that, The distance between the two opposing push blocks and the sidewalls of the terminal is 15mm-19mm, and the distance between the two opposing push blocks and the sidewalls of the terminal is the width of the push block clamping area.

3. The welding method according to claim 1, characterized in that, The hardness of the sidewall of the pusher block facing the terminal is ≥HRC65.

4. The welding method according to claim 1, characterized in that, The push block has a chamfered edge facing the terminal.

5. 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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