Thermoplastic composite material ultrasonic intelligent welding equipment and welding method

Abstract

The invention discloses thermoplastic composite material ultrasonic intelligent welding equipment and a welding method, and belongs to the technical field of thermoplastic composite material ultrasonic welding equipment.The thermoplastic composite material ultrasonic intelligent welding equipment comprises a base and a supporting frame arranged on the base, and a first servo motor is installed at the upper end of the supporting frame; the output end of the first servo motor is connected with a movable frame through a first transmission lead screw. Various parameters in the welding process are monitored in real time and adjusted in time, welding defects caused by process fluctuation, material non-uniformity and the like can be effectively avoided, the consistency and stability of welding quality are improved, the nylon bearing head is arranged, wear resistance and certain flexibility are achieved, and the welding quality is improved. The welding part can achieve certain flexible contact during welding, meanwhile, a large abrasion position can be transferred to the contact face of a protruding head and a nylon bearing head, a second servo motor drives two second transmission lead screws to enable an adjusting plate to descend synchronously, the nylon bearing head can move downwards, and the size difference caused by abrasion is compensated.

Description

Technical Field

[0001] The invention relates to welding equipment, in particular to ultrasonic intelligent welding equipment and a welding method for thermoplastic composite materials, and belongs to the technical field of ultrasonic welding equipment for thermoplastic composite materials. Background Art

[0002] With the widespread application of thermoplastic composite materials in the automotive, aviation, electronics and medical industries, how to effectively and reliably connect these materials has become an important technical challenge in the manufacturing process. Ultrasonic welding, as a technology that does not require external filling materials and uses high-frequency vibration energy to locally heat the material and achieve connection, has become an important means of welding thermoplastic composite materials due to its high efficiency, precision and environmental protection. Its main advantages include fast welding speed, no need for preheating, no pollution and high strength of welded joints, etc. It is especially suitable for thin-walled structures and welding occasions with high precision requirements.

[0003] Existing ultrasonic welding equipment and ultrasonic welding systems rely on preset welding parameters (such as power, frequency, welding time, etc.) for operation. Most of these parameters are set through experience or previous experimental data, and lack real-time feedback and adjustment of the welding process. The ultrasonic welding end needs to apply a certain pressure when the welding material contacts, and long-term use will cause wear. When welding thin composite materials, it is impossible to effectively pressurize the welding, resulting in insufficient welding reliability. Subsequent destructive testing of the finished product after welding is required to make a judgment, resulting in a waste of resources, and prone to defective products. In addition, the welding parameters need to be adjusted manually and repeatedly, affecting batch processing. Summary of the invention

[0004] The main purpose of the present invention is to solve the problems that wear and tear cannot be effectively welded, the welding effect is affected, and real-time monitoring and adjustment cannot be effectively carried out, and to provide a thermoplastic composite material ultrasonic intelligent welding equipment.

[0005] The purpose of the present invention can be achieved by adopting the following technical solutions:

[0006] A thermoplastic composite ultrasonic intelligent welding device comprises a base and a support frame arranged on the base, a first servo motor is installed on the upper end of the support frame, an output end of the first servo motor is connected to a movable frame through a first transmission screw rod, limiting sliders are arranged on the outer walls of both sides of the movable frame, an assembly frame is installed on the upper end of the limiting slider, a fixed plate is installed on the upper end of the movable frame, a second servo motor is arranged above the fixed plate, the output end of the second servo motor is connected to a second transmission screw rod through a synchronous belt, an adjustment plate is arranged below the fixed plate, a pressure-bearing member is arranged below the adjustment plate, a top plate is arranged below the pressure-bearing member, a driving part is connected to the lower end of the top plate, and a welding part is installed at the lower end of the driving part.

[0007] Preferably, a welding table is provided below the movable frame, a welding plate is installed in the middle of the welding table, a first pressure sensor is provided below the welding plate, and an ultrasonic detection module is provided on one side of the first pressure sensor.

[0008] Preferably, the pressure-bearing member comprises a high-elastic rubber plate and a nylon bearing head arranged in the middle of the high-elastic rubber plate, and an upper locking plate and a lower locking plate are respectively arranged above and below the high-elastic rubber plate.

[0009] Preferably, a second pressure sensor is installed on the lower end surface of the adjustment plate, two second transmission screws are provided, and the upper ends are connected by a synchronous belt and a synchronous pulley, and the two ends of the adjustment plate are respectively threadedly connected to the two second transmission screws.

[0010] Preferably, the nylon bearing head is slidably connected to the high-elasticity rubber plate, and a hole for the nylon bearing head to pass through is formed on the lower locking plate.

[0011] Preferably, a boss is provided on the upper portion of the top plate, and the boss is adapted to the hole opened in the middle portion of the lower locking plate.

[0012] Preferably, a plurality of guide rods are provided at the upper end of the movable frame, and a cavity for sliding of the adjustment plate is provided on the inner side of the limit sliding block.

[0013] Preferably, an infrared temperature probe with an adjustable angle is installed on the lower outer wall of the movable frame, and a computer interactive device is installed on the base.

[0014] A welding method of a thermoplastic composite material ultrasonic intelligent welding device comprises the following steps:

[0015] Step 1: Pre-preparation adjustment, adjust the equipment according to the welding requirements, and conduct experimental welding. The temperature and pressure state data of the welding area are recorded by the infrared temperature probe, the first pressure sensor and the second pressure sensor as the reference value, and the ultrasonic detection module is used to detect and analyze whether there are pores, cracks, etc.;

[0016] Step 2: Automatically optimize the welding process, analyze the real-time monitoring data through computer interactive equipment, and make timely adjustments and feedback when the pressure and temperature data fluctuate;

[0017] Step 3: Automatically adjust the pressure and temperature. Adjust the pressure and temperature according to the different data of the first and second pressure sensors. When the temperature is too high, the duration of welding should be reduced and the interval time of welding should be increased.

[0018] Step 4: Data storage: The data of each welding process is recorded in a timely manner and stored through computer interactive equipment to facilitate subsequent data tracing.

[0019] Preferably, the step 3 also includes the following steps:

[0020] Step A: Wear adjustment: the position of the adjustment plate can be adjusted by the second servo motor, and the pressure bearing member can be pressed downward by the adjustment plate to enable the nylon bearing head to move downward to compensate for the wear size;

[0021] Step B: Operator intervention: If the data still does not meet the standard after the automatic adjustment is completed, a warning will be issued and the welding operation will be stopped, allowing the operator to manually adjust the operation.

[0022] The beneficial technical effects of the present invention are as follows: 1. Improving welding quality: By real-time monitoring of various parameters in the welding process and timely adjusting the welding process, welding defects caused by process fluctuations, material inhomogeneity, etc. can be effectively avoided, and the consistency and stability of welding quality can be improved.

[0023] 2. Real-time defect detection and feedback: Through the first pressure sensor, the second pressure sensor and the infrared temperature probe in conjunction with the ultrasonic detection module, welding defects can be discovered and corrected immediately during the welding process, avoiding the situation in which defects are not discovered in time in traditional methods, thereby greatly improving the product qualification rate.

[0024] 3. Automation and intelligence: Data recorded by computer interactive equipment can automatically adjust welding parameters according to real-time data, reduce manual intervention, improve production efficiency and reduce human errors. At the same time, machine learning and data analysis technology can automatically optimize the welding process to adapt to the welding needs of different materials and workpieces.

[0025] 4. Improve production efficiency and reduce costs: Through real-time monitoring and intelligent adjustment of the welding process, the welding defect rate can be effectively reduced, waste and rework can be reduced, and production efficiency can be improved. At the same time, automated control reduces dependence on operators, reduces labor intensity and human errors.

[0026] 5. Wear detection and automatic compensation: A nylon bearing head is provided with wear resistance and certain flexibility, so that the welding part can have a certain flexible contact during welding, and at the same time, the larger wear position can be transferred to the contact surface between the convex head and the nylon bearing head. When the nylon bearing head is subjected to multiple extrusion wear, the second servo motor drives the two second transmission screws to synchronously descend the adjustment plate so that the nylon bearing head can move downward to compensate for the size difference caused by wear.

[0027] Comprehensive data traceability and quality management: All data in the welding process can be recorded and stored, ensuring the integrity of quality traceability. Data analysis can be used to optimize the production process, identify potential problems and make improvements, and improve overall production quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the overall structure of a preferred embodiment of the ultrasonic intelligent welding equipment and welding method for thermoplastic composite materials according to the present invention;

[0029] Figure 2 It is a side view of the overall structure of a preferred embodiment of the ultrasonic intelligent welding equipment and welding method for thermoplastic composite materials according to the present invention;

[0030] Figure 3 It is a schematic diagram of a movable frame structure according to a preferred embodiment of the ultrasonic intelligent welding equipment and welding method for thermoplastic composite materials of the present invention;

[0031] Figure 4 It is a schematic diagram of the exploded structure of the movable frame and the driving part according to a preferred embodiment of the ultrasonic intelligent welding equipment and welding method for thermoplastic composite materials of the present invention;

[0032] Figure 5 It is a schematic diagram of an explosion of a pressure-bearing component structure according to a preferred embodiment of the ultrasonic intelligent welding equipment and welding method for thermoplastic composite materials of the present invention;

[0033] Figure 6 It is a schematic diagram of the assembly frame structure of a preferred embodiment of the ultrasonic intelligent welding equipment and welding method for thermoplastic composite materials according to the present invention;

[0034] Figure 7 A schematic diagram of a welding plate structure according to a preferred embodiment of the ultrasonic intelligent welding device and welding method for thermoplastic composite materials of the present invention;

[0035] Figure 8 The figure is a schematic diagram of the structure of an adjustment plate according to a preferred embodiment of the ultrasonic intelligent welding equipment and welding method for thermoplastic composite materials of the present invention.

[0036] In the figure: 1. welding table; 2. movable frame; 3. support frame; 4. infrared temperature probe; 5. welding plate; 6. first servo motor; 7. limit slider; 8. second servo motor; 9. computer interactive device; 10. base; 11. fixed plate; 12. adjustment plate; 13. top plate; 14. pressure-bearing member; 15. driving part; 16. welding part; 17. guide rod; 18. assembly frame; 19. boss; 20. upper locking plate; 21. high elastic rubber plate; 22. lower locking plate; 23. nylon bearing head; 24. first pressure sensor; 25. ultrasonic detection module; 26. second pressure sensor. DETAILED DESCRIPTION

[0037] In order to make the technical solution of the present invention more clear and specific to those skilled in the art, the present invention is further described in detail below in conjunction with embodiments and drawings, but the implementation manner of the present invention is not limited thereto.

[0038] like Figure 1-Figure 8As shown, the thermoplastic composite ultrasonic intelligent welding equipment provided in this embodiment includes a base 10 and a support frame 3 arranged on the base 10, a first servo motor 6 is installed on the upper end of the support frame 3, and the output end of the first servo motor 6 is connected to the movable frame 2 through a first transmission screw rod, and the movable frame 2 is driven by the first servo motor 6 to move up and down, thereby driving the welding part 16 and the driving part 15 to move downward for welding stroke operation, and adjusting the stroke distance in the pre-preparation stage, and limiting sliders 7 are arranged on the outer walls of both sides of the movable frame 2, and an assembly frame 18 is installed on the upper end of the limiting slider 7, and a fixing plate 11 is installed on the upper end of the movable frame 2. A second servo motor 8 is arranged above the fixed plate 11, and the output end of the second servo motor 8 is connected to the second transmission screw through a synchronous belt. An adjusting plate 12 is arranged below the fixed plate 11, and a pressure-bearing member 14 is arranged below the adjusting plate 12. A top plate 13 is arranged below the pressure-bearing member 14, and a driving part 15 is connected to the lower end of the top plate 13. A welding part 16 is installed at the lower end of the driving part 15. Ultrasonic welding is performed by cooperating with the welding part 16 through the driving part 15. The driving part 15 and the welding part 16 are common ultrasonic generators and transducer welding heads. A welding table 1 is arranged below the movable frame 2, and a welding plate 5 is installed in the middle of the welding table 1. A first pressure sensor 24 is provided below the welding plate 5, an ultrasonic detection module 25 is provided on one side of the first pressure sensor 24, the pressure bearing member 14 includes a high elastic rubber plate 21 and a nylon bearing head 23 provided in the middle of the high elastic rubber plate 21, an upper locking plate 20 and a lower locking plate 22 are provided above and below the high elastic rubber plate 21, a second pressure sensor 26 is installed on the lower end surface of the adjustment plate 12, two second transmission screws are provided, and the upper ends are connected by a synchronous belt and a synchronous pulley, the two ends of the adjustment plate 12 are respectively threadedly connected to the two second transmission screws, and the two transmission screws are driven by the second servo motor 8 to adjust the adjustment plate 12 It can move synchronously, the nylon bearing head 23 is slidably connected with the high-elastic rubber plate 21, a hole for the nylon bearing head 23 to pass through is opened on the lower locking plate 22, a convex head 19 is arranged on the upper section of the top plate 13, the convex head 19 is used to cooperate with the nylon bearing head 23, the convex head 19 is adapted to the hole opened in the middle of the lower locking plate 22, a plurality of guide rods 17 are arranged on the upper end of the movable frame 2, a cavity for adjusting the sliding of the plate 12 is opened on the inner side of the limit slider 7, an infrared temperature probe 4 with an adjustable angle is installed on the lower outer wall of the movable frame 2, the temperature change during welding can be monitored in real time through the infrared temperature probe 4, and a computer interactive device 9 is installed on the base 10.

[0039] During welding, the values ​​of the first pressure sensor 24 and the second pressure sensor 26 should be the same or within a reasonable difference. A large difference will cause the welding part 16 to be unable to effectively contact the welding material. At the same time, in order to reduce the dimensional error caused by wear, a nylon bearing head is provided, which has wear resistance and a certain flexibility, so that the welding part 16 can have a certain flexible contact during welding, and at the same time, the larger wear position can be transferred to the contact surface between the convex head 19 and the nylon bearing head 23. When the nylon bearing head 23 is subjected to multiple extrusion wear, the second servo motor 8 drives the two second transmission screws to synchronously descend the adjustment plate 12 so that the nylon bearing head 23 can move downward to compensate for the dimensional difference caused by wear. At the same time, the high-elastic rubber plate 21 can cooperate with the adjustment plate 12 to press downward to avoid the deviation of the nylon bearing head 23. The wear size is small, so that the flexibility of the high-elastic rubber plate 21 can be fully utilized to achieve the effect of compensating the size, and then the effect of adjusting the pressure can be reduced under a fixed stroke. The situation that the pressure is not enough due to wear affects the welding.

[0040] In this embodiment, if Figure 1-8 As shown, a welding method of a thermoplastic composite material ultrasonic intelligent welding device comprises the following steps:

[0041] Step 1: Pre-preparation adjustment, adjust the equipment according to the welding requirements, and conduct experimental welding. The temperature and pressure state data of the welding area are recorded by the infrared temperature probe 4, the first pressure sensor 24 and the second pressure sensor 26 as the reference value, and the ultrasonic detection module 25 is used to detect and analyze whether there are pores, cracks, etc.;

[0042] Step 2: The welding process is automatically optimized, and the computer interactive device 9 is used to analyze the real-time monitoring data, and timely adjustments and feedback are made when the pressure and temperature data fluctuate;

[0043] Step 3: Automatically adjust the pressure and temperature. Adjust the pressure and temperature when the data of the upper and lower first pressure sensors 24 and the second pressure sensors 26 are different. When the temperature is too high, the duration of welding should be reduced and the interval time of welding should be increased.

[0044] Step 4: Data storage: The data of each welding process is recorded in time and stored through the computer interactive device 9 to facilitate subsequent data tracing.

[0045] Step 3 also protects the following steps:

[0046] Step A: Wear adjustment: the position of the adjustment plate 12 can be adjusted by the second servo motor 8, and the pressure bearing member 14 can be pressed downward by the adjustment plate 12 to enable the nylon bearing head 23 to move downward to compensate for the wear size;

[0047] Step B: Operator intervention: If the data still does not meet the standard after the automatic adjustment is completed, a warning will be issued and the welding operation will be stopped, allowing the operator to manually adjust the operation.

[0048] The above description is only a further embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical solutions and concepts of the present invention within the scope disclosed by the present invention, which belong to the protection scope of the present invention.

Claims

1. A thermoplastic composite ultrasonic intelligent welding device, characterized in that: The invention comprises a base (10) and a support frame (3) arranged on the base (10), a first servo motor (6) being installed at the upper end of the support frame (3), an output end of the first servo motor (6) being connected to a movable frame (2) via a first transmission screw, limiting sliders (7) being arranged on both side outer walls of the movable frame (2), an assembly frame (18) being installed at the upper end of the limiting sliders (7), a fixing plate (11) being installed at the upper end of the movable frame (2), and the fixing plate (12) being installed at the upper end of the movable frame (2). A second servo motor (8) is arranged above the fixing plate (11), the output end of the second servo motor (8) is connected to a second transmission screw via a synchronous belt, an adjustment plate (12) is arranged below the fixing plate (11), a pressure-bearing member (14) is arranged below the adjustment plate (12), a top plate (13) is arranged below the pressure-bearing member (14), the lower end of the top plate (13) is connected to a driving part (15), and the lower end of the driving part (15) is installed with a welding part (16).

2. The ultrasonic intelligent welding equipment for thermoplastic composite materials according to claim 1, characterized in that: A welding platform (1) is arranged below the movable frame (2), a welding plate (5) is installed in the middle of the welding platform (1), a first pressure sensor (24) is arranged below the welding plate (5), and an ultrasonic detection module (25) is arranged on one side of the first pressure sensor (24).

3. The ultrasonic intelligent welding equipment for thermoplastic composite materials according to claim 2, characterized in that: The pressure-bearing member (14) comprises a high-elasticity rubber plate (21) and a nylon bearing head (23) arranged in the middle of the high-elasticity rubber plate (21); an upper locking plate (20) and a lower locking plate (22) are respectively arranged above and below the high-elasticity rubber plate (21).

4. The ultrasonic intelligent welding equipment for thermoplastic composite materials according to claim 3, characterized in that: A second pressure sensor (26) is installed on the lower end surface of the adjustment plate (12), two second transmission screws are provided, and the upper ends are connected via a synchronous belt and a synchronous pulley, and the two ends of the adjustment plate (12) are respectively threadedly connected to the two second transmission screws.

5. The ultrasonic intelligent welding equipment for thermoplastic composite materials according to claim 2, characterized in that: The nylon bearing head (23) is slidably connected to the high elastic rubber plate (21), and a hole for the nylon bearing head (23) to pass through is provided on the lower locking plate (22).

6. The ultrasonic intelligent welding equipment for thermoplastic composite materials according to claim 5, characterized in that: The upper section of the top plate (13) is provided with a convex head (19), and the convex head (19) is adapted to a hole opened in the middle of the lower locking plate (22).

7. The ultrasonic intelligent welding equipment for thermoplastic composite materials according to claim 6, characterized in that: A plurality of guide rods (17) are arranged at the upper end of the movable frame (2), and a cavity for sliding the adjusting plate (12) is provided on the inner side of the limiting sliding block (7).

8. The ultrasonic intelligent welding equipment for thermoplastic composite materials according to claim 7, characterized in that: An infrared temperature probe (4) with an adjustable angle is installed on the lower outer wall of the movable frame (2), and a computer interaction device (9) is installed on the base (10).

9. A welding method of thermoplastic composite ultrasonic intelligent welding equipment, characterized in that: The steps include: Step 1: Pre-preparation adjustment, adjust the equipment according to the welding requirements, and conduct experimental welding. The temperature and pressure state data of the welding area are recorded by the infrared temperature probe, the first pressure sensor and the second pressure sensor as the reference value, and the ultrasonic detection module is used to detect and analyze whether there are pores and cracks; Step 2: Automatically optimize the welding process, analyze the real-time monitoring data through computer interactive equipment, and make timely adjustments and feedback when the pressure and temperature data fluctuate; Step 3: Automatically adjust the pressure and temperature. Adjust the pressure and temperature according to the different data of the first and second pressure sensors. When the temperature is too high, the duration of welding should be reduced and the interval time of welding should be increased. Step 4: Data storage: The data of each welding process is recorded in a timely manner and stored through computer interactive equipment to facilitate subsequent data tracing.

10. The welding method of a thermoplastic composite material ultrasonic intelligent welding device according to claim 9, characterized in that: The following steps are also protected in step 3: Step A: Wear adjustment: the position of the adjustment plate can be adjusted by the second servo motor, and the pressure bearing member can be pressed downward by the adjustment plate to enable the nylon bearing head to move downward to compensate for the wear size; Step B: Operator intervention: If the data still does not meet the standard after the automatic adjustment is completed, a warning will be issued and the welding operation will be stopped, allowing the operator to manually adjust the operation.

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