Multi-defense-mode welding process method for liquid cooling radiator

Abstract

The invention relates to the technical field of red copper radiator machining, in particular to a multi-defense-mode welding process method for a liquid cooling radiator. The method comprises the steps that the moving speed of a gas brazing gun is adjusted according to the thickness of a welding layer and the size of a workpiece; adjusting the gas flow of the gas cylinder according to the current, the voltage and the moving speed; a gas brazing gun is used for moving along the edge of the workpiece to form a preliminary welding seam, and the current, voltage and gas flow of the gas brazing gun are adjusted according to the material and thickness of the workpiece; in combination with the melting effect rules of brazing materials in different temperature states in the welding melting process, a brazing filler metal placing runner is designed and arranged, and a multi-defense mode is formed through brazing filler metal arrangement of inner and outer multi-layer stepped distribution; after welding of the first layer is completed, the parameters and the position of a gas brazing gun are adjusted, and welding of the middle layer is conducted; parameters of a gas brazing gun are adjusted, and the last layer is welded; and after welding is completed, a welding seam is checked. The welding fault rate is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of copper radiator processing, and in particular to a multiple defense mode welding process method for a liquid cooling radiator. Background Art

[0002] The coolant used in the copper radiator is a scarce material with high value. In order to improve the utilization efficiency of the coolant, the internal liquid cooling passage structure is complex and needs to be welded to the cover plate after processing to achieve integration. This radiator is made of all copper, with a large volume and a large cover welding area. Under the same pressure state, the welding part of this radiator is under higher pressure, which may cause uneven heating during welding, and it is very easy to produce welding defects such as pores and sand holes, and the probability of water leakage is very high. The welding method suitable for this type of structure is generally silver-copper brazing, but due to the particularity of the product, the conventional silver-copper brazing process cannot guarantee reliable welding. After analyzing and discussing the state requirements of the new radiator, it is concluded that only by creatively improving the conventional silver-copper brazing process, exploring a new welding method, combining the welding principle of silver-copper brazing, and creatively researching and designing a welding mode with multiple defenses, can we break the constraints of conventional welding theory and technology in books, change ideas, and make changes and breakthroughs in welding details, so as to solve the welding defects and problems that are easy to occur in conventional silver-copper brazing, and ensure the airtight and leak-proof performance of the radiator.

[0003] Prior art 1, Chinese patent, application number: 202110142553.0 discloses a brazed copper radiator processing process and its copper radiator, including: butt-joining a stainless steel tube and a copper tube by flame brazing; welding the other end of the copper tube to the copper radiator base by argon arc welding, with a welding temperature of 600-800°C; connecting the other end of the stainless steel tube to a stainless steel ferrule, and the copper radiator made by this step. Although it eliminates the risk of water leakage and solves the conflict between copper brazing experienced during the manufacture of copper radiators and flame brazing required for secondary welding of stainless steel tubes; however, the alternating use of high and low temperatures in multiple welding processes will affect the welding quality.

[0004] Prior art 2, Chinese patent, application number 202310582775.3 discloses a brazed copper radiator processing technology, including the following steps: surface treatment, first of all, the surface treatment of the items to be processed; welding preparation; start welding; heating the copper tube and the stainless steel tube; post-welding treatment. Although the brazed copper radiator processing technology requires careful surface treatment of the copper tube during brazing to avoid untreated surfaces, the interface at the weld seam will be stable and flat, the welding effect will be firm, and the efficient treatment of oxides can effectively reduce the impact of oxides or oil on the welding process. Secondly, pollutants greatly improve the conductivity of the copper tube water film, accelerate the electrochemical corrosion process, that is, accelerate the speed of oxidation and discoloration of the copper tube surface, thereby reducing the service life of the copper tube; However, the heating temperature and time need to be precisely controlled during the welding process, which increases the difficulty of the welding process.

[0005] Prior art three, Chinese patent, application number 202411240745.5 discloses a method for designing a motherboard heat sink, the heat sink includes: a heat sink middle frame, an ultra-thin vacuum cavity temperature plate and copper fins; the heat sink includes from top to bottom: copper fins, ultra-thin vacuum cavity temperature plate and heat sink middle frame; the copper fins and the ultra-thin vacuum cavity temperature plate are welded on the heat sink middle frame by low-temperature brazing; a first heat-conducting boss is arranged below the heat sink middle frame, and after the ultra-thin vacuum cavity temperature plate is brazed with the heat sink middle frame, the ultra-thin vacuum cavity temperature plate is connected to the first heat-conducting boss as a whole. Although it has the characteristics of reducing the thermal resistance in the heat transfer process on the motherboard, increasing the heat dissipation area of ​​the heat sink, reducing the risk of failure, and also increasing the flexibility of using components of the motherboard circuit; however, the welding process is complicated, and the technical and material costs are high.

[0006] At present, the existing technologies 1, 2 and 3 have multiple welding processes that are used alternately, which will affect the welding quality. The heating temperature and time need to be precisely controlled during the welding process, which increases the difficulty of the welding process, complicates the welding process, and has high technical and material costs. Therefore, compared with the general copper-silver-copper brazing technology, the present invention has a multi-channel defensive mode, and the local details take into account both conventional and innovative characteristics, which can solve many welding defects and problems that occur in the same type of welding. The operation is feasible, the welding consistency is good, and the welding safety and reliability are greatly improved. It has a far-leading effect in similar welding; it can meet the welding needs of high-power and large-volume copper radiators. Summary of the invention

[0007] In order to achieve the above object, the present invention adopts the following technical scheme:

[0008] In one aspect of the present invention, a multi-defense mode welding process method for a liquid cooling radiator is provided, comprising the following steps:

[0009] Fix the workpiece on the bracket between the workbench and the track, adjust the horizontal adjustment nut to keep the workbench level; place the gas cylinder on one side of the device; adjust the current and voltage of the gas brazing gun according to the material and thickness of the workpiece; adjust the moving speed of the gas brazing gun according to the thickness of the welding layer and the size of the workpiece; adjust the gas flow of the gas cylinder according to the current, voltage and moving speed;

[0010] Use a gas brazing gun to move along the edge of the workpiece to form a preliminary weld. Adjust the current, voltage and gas flow of the gas brazing gun according to the material and thickness of the workpiece. Combined with the melting effect of the brazing material at different temperature states during the welding melting process, design and layout the flow channel for the brazing filler metal. Through the multi-layer stepped distribution of the filler metal inside and outside, a multiple defense mode is formed. After the first layer of welding is completed, adjust the parameters and position of the gas brazing gun to weld the middle layer. Adjust the parameters of the gas brazing gun to weld the last layer.

[0011] After welding is completed, the weld is inspected for uniformity, strength and surface quality.

[0012] In an optional embodiment, the process of adjusting the gas brazing gun includes:

[0013] According to the material and thickness of the all-red copper liquid cooling radiator to be welded, the lowest current and voltage are selected from the historical data as the starting current and starting voltage; the current and voltage are gradually increased, and test welding is performed on the test board, and the current and voltage are adjusted according to the test welding results;

[0014] According to the material, thickness and welding process requirements of the all-copper liquid-cooled radiator to be welded, set the initial welding speed, conduct trial welding, and adjust the moving speed of the gas brazing gun according to the weld results;

[0015] After the welding current, welding voltage and moving speed of the gas brazing gun are determined, the mapping relationship between the value change of the gas cylinder pressure gauge and the changes in current, voltage and moving speed is detected during the trial welding process, and a mapping relationship table is established. The gas cylinder flow is adjusted according to the mapping relationship table.

[0016] In an optional embodiment, in the temperature field distribution model, the distribution of the temperature field T(x, y, z, t) of the solder during the melting process is described by the heat conduction equation:

[0017]

[0018] In the formula, T(x,y,z,t) represents the temperature field function, which indicates the temperature at the spatial coordinates (x,y,z) and time t; α represents the thermal diffusion coefficient, which indicates the thermal conductivity of the solder; Q(x,y,z,t) represents the heat source function, which indicates the influence of external heat input on the temperature field;

[0019] Solder melting rate model, solder melting rate Related to the temperature field and material properties, it is described by the following formula:

[0020]

[0021] In the formula, represents the melting rate of the solder, which indicates the amount of solder melted per unit time; β represents the melting rate constant, which is related to the thermophysical properties of the solder; E a represents activation energy, which means the energy required for solder melting; R ′ represents the universal gas constant; T m It represents the melting point temperature of solder; n represents the melting index, which represents the nonlinear characteristics of solder melting;

[0022] Solder flow dynamics model, the flow behavior of the solder in the flow channel is described by the Navier-Stokes equation, combined with the influence of the temperature field:

[0023]

[0024] In the formula, ρ ′ Indicates solder density; v ′ represents the solder flow velocity vector; p ′ Indicates fluid pressure; μ ′ represents dynamic viscosity, which indicates the flow resistance of solder; g represents the gravity acceleration vector; γ represents the temperature gradient coefficient, which indicates the effect of temperature on the fluid;

[0025] The optimization model of the flow channel layout of multiple defense modes is used to optimize the solder flow channel layout. The objective function J is established to meet the needs of multiple defense modes:

[0026]

[0027] In the formula, t f represents the final time of the brazing process; Ω represents the flow channel space domain; η1, η2, η3 represent weight coefficients, which represent the optimization targets of melting rate, flow stability and temperature gradient respectively;

[0028] Comprehensive optimization constraints:

[0029]

[0030] In the formula, v max Indicates the maximum permissible flow rate.

[0031] In an optional embodiment, the process of welding the first layer, the middle layer and the last layer includes:

[0032] The initial current and voltage of the gas brazing gun are calculated according to the thickness of the welding layer and the size of the workpiece; after the welding is completed according to the initial current and voltage, the first gas brazing gun control program of the middle layer is triggered, and the first adjustment current and voltage of the gas brazing gun of the middle layer are calculated according to the welding effect of the first weld;

[0033] According to the first adjusted current and voltage, the gas brazing gun welds the middle layer of the workpiece. After the middle layer is welded, the second gas brazing gun control program of the last layer is triggered, and the second adjusted current and voltage of the last layer are calculated according to the welding effect of the second weld.

[0034] According to the second adjustment of current and voltage, the gas brazing gun welds the last layer of the workpiece. After the last layer of welding is completed, the weld inspection program is started.

[0035] In an optional embodiment, the process of obtaining the first adjustment current and voltage of the intermediate layer gas brazing gun includes:

[0036] According to the thickness of the welding layer and the size data of the workpiece, the mapping relationship comparison table is retrieved to calculate the initial current and voltage of the gas brazing gun, and the welding layer is welded after adjusting the parameters of the gas brazing gun;

[0037] After the first weld is completed according to the initial current and voltage, the first gas brazing gun control program of the middle layer is automatically triggered;

[0038] According to the weld shape, penetration depth and quality of the first weld layer, the current and voltage of the intermediate layer gas brazing gun are calculated and adjusted by an empirical formula to obtain a first adjusted current and voltage.

[0039] In an optional implementation manner, the process of obtaining the first adjustment current and voltage includes:

[0040] Conduct detailed inspection and evaluation of the weld morphology, penetration depth and quality of the first layer of welds; select empirical formulas for welding current and welding voltage based on the evaluation results;

[0041] Use empirical formulas to calculate preliminary adjustment current and voltage values, and verify whether the preliminary calculated adjustment current and voltage are appropriate through trial welding. Further optimize the current and voltage according to the shape of the trial weld and the shape of the molten pool.

[0042] Among them, the calculation formula of welding current is:

[0043]

[0044] Where I is the welding current, k1 is the current base coefficient, which is related to the welding material and wire diameter; P is the penetration depth; W is the weld width; ρ is the material density; Cp represents the specific heat capacity of the material, which indicates the ability of the material to absorb heat; ΔT represents the difference between the welding temperature and the room temperature; v represents the welding speed; η represents the welding efficiency coefficient, which indicates the energy utilization rate during the welding process; α represents the thermal diffusion coefficient, which indicates the thermal conductivity of the material; β represents the welding environment correction factor; k2 represents the weld quality correction factor; Q represents the weld quality score; k5 represents the arc energy correction factor; E represents the arc energy, which indicates the energy released by the arc during the welding process; E0 represents the reference arc energy;

[0045] The calculation formula of welding voltage is:

[0046]

[0047] Wherein, U represents welding voltage; k3 represents voltage base coefficient, which is related to arc characteristics and welding method; I represents welding current; L represents arc length; μ represents arc stability coefficient, which represents arc stability; γ represents welding wire melting efficiency coefficient, which represents welding wire melting efficiency; d represents welding wire diameter; σ represents material conductivity; τ represents time correction coefficient; φ represents welding position correction coefficient; k4 represents temperature correction coefficient; T represents ambient temperature; k6 represents welding wire feed speed correction coefficient; F represents welding wire feed speed; F0 represents reference welding wire feed speed;

[0048] The optimized first adjusted current and voltage are recorded, the gas brazing gun parameters are adjusted, and frequent parameter changes are avoided.

[0049] In an optional implementation manner, the process of obtaining the second adjusted current and voltage of the last layer includes:

[0050] Adjust the parameters of the gas brazing gun according to the first adjustment current and voltage, weld the middle layer of the workpiece after the adjustment is completed, continuously monitor the weld quality, and adjust the current and voltage in time to maintain the welding effect;

[0051] When the middle layer is welded, the gas brazing gun stops working and automatically triggers the second gas brazing gun control program for the last layer; and the welding effect of the weld of the middle layer is evaluated;

[0052] According to the weld morphology, penetration depth and quality of the first and middle welds, the current and voltage of the gas brazing gun of the last layer are calculated and adjusted by an empirical formula to obtain the second adjusted current and voltage of the last layer.

[0053] In an optional embodiment, the process of calculating and adjusting the current and voltage of the last layer of gas brazing gun by an empirical formula includes:

[0054] Evaluate the penetration depth and uniformity of the first and middle layer welds of the all-copper liquid-cooled radiator; select an empirical formula based on the evaluation results of the first and middle layer welds;

[0055] Calculate preliminary second adjustment current and voltage values ​​according to empirical formulas, use the preliminary second adjustment current and voltage values ​​to conduct test welding, and fine-tune the current and voltage according to the test welding results;

[0056] The adjusted second adjustment current and voltage are input into the gas brazing gun, the last layer is welded, and the current and voltage are adjusted in time according to the actual situation.

[0057] In an optional implementation manner, the process of inspecting the weld includes:

[0058] Perform ultrasonic testing on the welded all-copper liquid cooling radiator, and judge the uniformity of the weld based on the ultrasonic testing image;

[0059] Static stretching is performed on the weld of the all-copper liquid cooling radiator, tension is gradually applied, the tension and displacement data are recorded, the tensile strength and elongation parameters of the weld are calculated, and the weld strength is judged;

[0060] The magnetic particle surface flaw detection is carried out on the weld of the all-copper liquid-cooled radiator, and a surface quality threshold is set. If the surface flaw detection result exceeds the preset surface quality threshold, the all-copper liquid-cooled radiator is judged to be unqualified.

[0061] In an optional embodiment, the ultrasonic detection weld uniformity expression is:

[0062]

[0063] Where V represents the weld uniformity score; k7, k8, k9, k 10 Indicates the weight coefficient, which can be adjusted according to actual needs; A max Indicates the maximum amplitude value in the ultrasonic detection image; A min Indicates the minimum amplitude value in the ultrasonic detection image; A avg Represents the average amplitude value in the ultrasonic detection image; σ A Indicates the standard deviation of the amplitude in the ultrasonic detection image; D max Indicates the maximum defect depth in the ultrasonic detection image; D min Indicates the minimum defect depth in the ultrasonic detection image; D avg Represents the average defect depth in the ultrasonic detection image; σ D Indicates the standard deviation of the defect depth in the ultrasonic inspection image.

[0064] The present invention changes the conventional silver-copper brazing low-channel passive single sealing mode and converts it to an active defense type multi-channel welding mode, takes multiple precautions against possible welding defects, reduces the probability of pores and sand holes and the possibility of permeability, and greatly reduces the welding failure rate; breaks through the limitations of the book theoretical framework of conventional welding technology, independently innovates and explores welding process data, fully combines welding principles with practice, subverts theoretical data from the source, and is proven to be feasible and effective through practical verification, which solves the welding quality problem that has occurred very frequently in the past, and denies the statement that the welding quality of such copper products is highly random and the reliability cannot be guaranteed. BRIEF DESCRIPTION OF THE DRAWINGS

[0065] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0066] Figure 1 It is a flow chart of the multiple defense mode welding process method of the liquid cooling radiator provided in Example 1 of the present invention;

[0067] Figure 2 A flow chart of adjusting a gas brazing gun in a liquid-cooled radiator multi-defense mode welding process method provided in Example 2 of the present invention;

[0068] Figure 3 A flow chart of the first layer, the middle layer and the last layer welding of the multiple defense mode welding process method of the liquid cooling radiator provided in Example 3 of the present invention;

[0069] Figure 4 A flow chart of obtaining the first adjustment current and voltage of the intermediate layer gas brazing gun in the multi-defense mode welding process method for the liquid-cooled radiator provided in Example 4 of the present invention;

[0070] Figure 5 A flow chart of obtaining a first adjustment current and voltage in the liquid-cooled radiator multi-defense mode welding process method provided in Example 5 of the present invention;

[0071] Figure 6 A flow chart of obtaining the second adjustment current and voltage of the last layer of the multi-defense mode welding process method for the liquid-cooled radiator provided in Example 6 of the present invention;

[0072] Figure 7 A flow chart of calculating and adjusting the current and voltage of the last layer of the gas brazing gun by an empirical formula in the liquid-cooled radiator multi-defense mode welding process method provided in Example 7 of the present invention;

[0073] Figure 8 A flow chart of inspecting a weld in a multiple defense mode welding process method for a liquid cooling radiator provided in Example 8 of the present invention;

[0074] Fig. 9 A structural diagram of a multi-defense mode welding process device for a full copper liquid-cooled radiator provided in Example 9 of the present invention;

[0075] Fig.10 This is a functional module schematic diagram of a multi-defense mode welding process system for a full copper liquid-cooled radiator provided in Example 10 of the present invention;

[0076] Fig.11 is a block diagram of an electronic device provided in Embodiment 11 of the present invention;

[0077] Fig.12 This is a block diagram of the computer-readable storage medium provided in Example 12 of the present invention. DETAILED DESCRIPTION

[0078] The technical solutions in the embodiments of the present invention will be described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0079] In the following, the terms "first", "second", etc. are used only for convenience of description and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, a feature defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "plurality" means two or more.

[0080] In the present invention, unless otherwise clearly specified and limited, the term "connection" should be understood in a broad sense, for example, "connection" can be a fixed mechanical connection, or a detachable mechanical connection, or integrated; or, "connection" can be a direct connection, or an indirect connection through an intermediate medium. In addition, unless otherwise clearly specified and limited, the term "coupling" should be understood in a broad sense, for example, "coupling" can be a direct electrical connection, such as physical contact and electrical conduction between two components, and can also be understood as electrical connection between different components in a circuit structure through physical lines such as copper foil or wires on a printed circuit board (PCB) that can transmit electrical signals to transmit electrical signals; or, "coupling" can be an indirect electrical connection between two components through an intermediate medium; or, "coupling" can be an electrical connection between two components in an air-spaced / non-contact manner, for example, two components are electrically connected by capacitive coupling to transmit electrical signals.

[0081] In the embodiments of the present invention, directional terms such as "up", "down", "left" and "right" may be defined including but not limited to the orientation relative to the schematic placement of the components in the drawings. It should be understood that these directional terms may be relative concepts, which are used for relative description and clarification, and may change accordingly according to the change of the orientation of the components in the drawings.

[0082] The embodiments of the present invention can be used in power battery systems, energy storage systems, new energy vehicles, servers, supercomputing equipment, photovoltaic inverters, wind power converters, aerospace and medical equipment.

[0083] Embodiment 1:

[0084] like Figure 1 As shown, an embodiment of the present invention provides a liquid cooling radiator multi-defense mode welding process method, comprising the following steps:

[0085] Step S100: fix the workpiece on the bracket between the workbench and the track, adjust the horizontal adjustment nut to keep the workbench level; place the gas cylinder on one side of the device; adjust the current and voltage of the gas brazing gun according to the material and thickness of the workpiece; adjust the moving speed of the gas brazing gun according to the thickness of the welding layer and the size of the workpiece; adjust the gas flow of the gas cylinder according to the current, voltage and moving speed;

[0086] Step S200: Use a gas brazing gun to move along the edge of the workpiece to form a preliminary weld, and adjust the current, voltage and gas flow of the gas brazing gun according to the material and thickness of the workpiece; design and layout the brazing brazing material placement flow channel in combination with the melting effect law of the brazing material at different temperature states during the welding melting process, and form a multiple defense mode through the brazing material arrangement with multiple layers of stepped distribution inside and outside; after the first layer of welding is completed, adjust the parameters and position of the gas brazing gun to weld the middle layer; adjust the parameters of the gas brazing gun to weld the last layer;

[0087] The middle layer may be one or more layers, and the specific number of layers is determined according to the thickness of the welding part and the process requirements. When welding, the layout design of the solder flow channel is maintained to ensure that each layer of welding can achieve a stepped distribution of multiple sealing effects;

[0088] Step S300: After welding is completed, the weld is inspected, including the uniformity, strength and surface quality of the weld.

[0089] In the temperature field distribution model in step S200, the distribution of the temperature field T(x, y, z, t) of the solder during the melting process can be described by the heat conduction equation:

[0090]

[0091] In the formula, T(x,y,z,t) represents the temperature field function, which indicates the temperature at the spatial coordinates (x,y,z) and time t; α represents the thermal diffusion coefficient, which indicates the thermal conductivity of the solder; Q(x,y,z,t) represents the heat source function, which indicates the influence of external heat input on the temperature field;

[0092] Solder melting rate model, solder melting rate Related to the temperature field and material properties, it can be described by the following formula:

[0093]

[0094] In the formula, represents the melting rate of the solder, which indicates the amount of solder melted per unit time; β represents the melting rate constant, which is related to the thermophysical properties of the solder; E a represents activation energy, which means the energy required for solder melting; R ′ represents the universal gas constant; T m It represents the melting point temperature of solder; n represents the melting index, which represents the nonlinear characteristics of solder melting;

[0095] Solder flow dynamics model, the flow behavior of the solder in the flow channel can be described by the Navier-Stokes equation, combined with the influence of the temperature field:

[0096]

[0097] In the formula, ρ ′ Indicates solder density; v ′ represents the solder flow velocity vector; p ′ Indicates fluid pressure; μ ′ represents dynamic viscosity, which indicates the flow resistance of solder; g represents the gravity acceleration vector; γ represents the temperature gradient coefficient, which indicates the effect of temperature on the fluid;

[0098] The optimization model of the flow channel layout of multiple defense modes is used to optimize the solder flow channel layout. The objective function J is established to meet the needs of multiple defense modes:

[0099]

[0100] In the formula, t f represents the final time of the brazing process; Ω represents the flow channel space domain; η1, η2, η3 represent weight coefficients, which represent the optimization targets of melting rate, flow stability and temperature gradient respectively;

[0101] Comprehensive optimization constraints:

[0102]

[0103] In the formula, v maxIt indicates the maximum allowable flow rate to prevent the solder from overflowing or flowing unstably. Through the above complex mathematical models and formulas, the melting and flow behavior of the solder during the brazing process can be accurately described, and the flow channel layout can be optimized to achieve the design of multiple defense modes.

[0104] In the above embodiment, step S100 ensures that the workpiece remains horizontal during the work process by fixing the workpiece on the bracket between the workbench and the track and adjusting the horizontal adjustment nut; it can avoid welding defects caused by tilting or instability of the workpiece and ensure welding accuracy; according to the material and thickness of the workpiece, adjust the current, voltage and moving speed of the gas brazing gun, and adjust the gas flow of the gas cylinder; ensure accurate control of heat input during welding and avoid poor welding caused by parameter mismatch. Step S100 provides stable workpiece fixation and accurate process parameter setting for welding, lays the foundation for high-quality welding, and effectively reduces uncertainties in the welding process. Step S200 uses a gas brazing gun to move along the edge of the workpiece to form a preliminary weld. Adjust the current, voltage and gas flow rate according to the material and thickness of the workpiece to ensure the uniformity and strength of the first layer of welding; design the brazing material placement flow channel in combination with the melting effect law of the brazing material under different temperature states, and form a multiple defense mode through the brazing material arrangement with multiple layers of stepped distribution inside and outside; significantly improve the sealing performance of the welding part, and solve the technical problem of high welding defect rate when traditional silver copper brazing copper is brazed; after the first layer of welding is completed, adjust the parameters and position of the gas brazing gun to weld the middle layer; the middle layer may be one or more layers, and the specific number of layers is determined according to the thickness of the welding part and the process requirements; during the welding process, maintain the layout design of the brazing material flow channel to ensure that each layer of welding can achieve the multiple sealing effects of stepped distribution; adjust the parameters of the gas brazing gun to perform the last layer of welding to ensure that the welding part is fully melted and a high-strength connection is formed; after the welding is completed, perform natural cooling treatment to further solidify the workpiece. Step S200 achieves multiple sealing effects of the welding part through scientific brazing material flow channel design and multi-layer stepped distribution welding method, effectively improving the welding quality. It not only makes up for the shortcomings of traditional brazing welding, but also meets the high-end heat dissipation requirements of all-copper liquid cooling radiators, significantly enhancing the reliability and safety of the product. After step S300 welding is completed, a comprehensive inspection of the uniformity, strength and surface quality of the weld is carried out to ensure that the weld is defect-free, crack-free, and meets the process requirements; through inspection, the stability and consistency of the welding process are verified to ensure that each welded part meets the design requirements. Step S300 is the last quality assurance link in the welding process. Through strict weld inspection, it ensures that the welding quality meets the standards, providing the ultimate guarantee for the reliability and safety of the product.

[0105] In summary, the various steps of this embodiment, through precise process control, scientific solder flow channel design and strict weld inspection, jointly achieve high quality, high sealing and high reliability of the welding of the all-copper liquid-cooled radiator, meeting the technical requirements of high-end heat dissipation products.

[0106] In this embodiment, the workpiece is fixed on the bracket between the workbench and the track, and the workbench is kept level by adjusting the horizontal nut. When using multi-channel welding equipment, the positioning accuracy of each welding channel must be ensured to avoid a decrease in welding quality due to the tilt of the workpiece. Place the gas cylinder on one side of the device, and adjust the current, voltage and gas flow of the gas brazing gun according to the material, thickness and welding requirements of the workpiece; in multi-channel mode, the gas flow of each welding channel needs to be adjusted independently to meet the needs of different welding areas. Adjust the moving speed of the gas brazing gun according to the thickness of the welding layer and the size of the workpiece. In multi-channel mode, the moving speed and welding parameters (such as current and voltage) of each welding channel need to be dynamically adjusted according to the specific welding area.

[0107] Use a multi-channel gas brazing gun to weld the first layer. Each welding channel moves along the edge of the workpiece to form a preliminary weld. The active defense mechanism monitors the temperature, arc stability and gas flow of each welding channel in real time to ensure welding quality. After the first layer of welding is completed, adjust the position and parameters of each welding channel to weld the middle layer. The active defense mechanism dynamically adjusts the welding parameters (such as current, voltage, gas flow) based on the real-time monitoring data to avoid welding defects. When welding the last layer, further optimize the parameters of each welding channel to ensure the uniformity and strength of the weld. The active defense mechanism predicts potential defects (such as pores and cracks) in real time during the welding process and takes preventive measures. After welding is completed, cooling treatment is carried out. The active defense mechanism monitors the cooling process in real time through temperature sensors to avoid deformation or cracking of the workpiece due to uneven cooling. Use multi-channel detection equipment to check the uniformity of the weld to ensure the consistent quality of the weld of each welding channel. The active defense mechanism evaluates the uniformity of the weld through data analysis and provides optimization suggestions. The weld is strength tested to ensure that it meets the design requirements. The active defense mechanism predicts the strength of the weld through real-time monitoring data and provides improvement plans. Check the surface quality of the weld to ensure there are no defects such as pores and cracks; the active defense mechanism uses image recognition technology to automatically detect weld surface defects and provide repair suggestions.

[0108] The multi-channel welding of this embodiment can process multiple welding areas at the same time, greatly improving production efficiency; the active defense mechanism ensures the stability of the welding process and reduces the defect rate; real-time monitoring and dynamic adjustment make the welding process more accurate and reliable; the active defense mechanism can effectively avoid welding accidents and ensure the safety of operators.

[0109] Example 2: Figure 2 As shown, based on Example 1, the process of adjusting the gas brazing gun in step S100 provided in the embodiment of the present invention specifically includes the following steps:

[0110] Step S101: according to the material and thickness of the all-red copper liquid-cooled radiator to be welded, the lowest current and voltage are selected from the historical data as the starting current and starting voltage; the current and voltage are gradually increased, a test welding is performed on the test plate, and the current and voltage are adjusted according to the test welding results;

[0111] Step S102: according to the material, thickness and welding process requirements of the all-copper liquid-cooled radiator to be welded, the initial welding speed is set, and a test welding is performed, and the moving speed of the gas brazing gun is adjusted according to the weld results;

[0112] Step S103: After the welding current, welding voltage and moving speed of the gas brazing gun are determined, the mapping relationship between the value change of the gas cylinder pressure gauge and the current, voltage and moving speed changes is detected during the trial welding process, and a mapping relationship table is established, and the gas cylinder flow is adjusted according to the mapping relationship table.

[0113] In the above embodiment, step S101 of this embodiment selects the starting current and voltage from historical data according to the material and thickness of the all-red copper liquid-cooled radiator to be welded, which helps to avoid using too high or too low parameters at the beginning, resulting in poor welding quality or equipment damage; gradually increasing the current and voltage, and conducting trial welding on the test plate, helps to gradually approach the optimal welding parameters and ensure the welding quality; adjusting the current and voltage according to the trial welding results to ensure that the welding parameters finally used are optimal; ensuring that the parameters match the material and thickness of the all-red copper liquid-cooled radiator, thereby improving the welding quality and efficiency; step S102 of this embodiment sets the initial welding speed according to the welding process requirements and the material and thickness, which helps to ensure the stability of the welding process and the quality of the weld; Conducting trial welding and adjusting the moving speed of the gas brazing gun according to the weld results helps to find the optimal welding speed and ensure the uniformity and strength of the weld; by adjusting the moving speed of the gas brazing gun, the welding process can be further optimized and the quality and consistency of the weld can be improved; after the welding parameters are determined in step S103 of this embodiment, the mapping relationship between the change in the value of the gas cylinder pressure gauge and the change in current, voltage and moving speed is detected, which helps to understand the change in gas flow demand during welding; a mapping relationship table is established and the gas cylinder flow is adjusted according to it to ensure the stability and suitability of the gas flow during welding and improve the welding quality; by accurately controlling the gas flow, the gas protection effect during welding is guaranteed, the weld is prevented from being oxidized and contaminated, and the welding quality is improved.

[0114] Example 3: Figure 3As shown, based on Example 1, the process of welding the first layer, the middle layer and the last layer in step S200 provided in the embodiment of the present invention specifically includes the following steps:

[0115] Step S201: Calculate the initial current and voltage of the gas brazing gun according to the thickness of the welding layer and the size of the workpiece; after welding is completed according to the initial current and voltage, trigger the first gas brazing gun control program of the middle layer, and calculate the first adjustment current and voltage of the gas brazing gun of the middle layer according to the welding effect of the first weld;

[0116] Step S202: according to the first adjusted current and voltage, the gas brazing gun performs welding of the middle layer of the workpiece. After the welding of the middle layer is completed, the second gas brazing gun control program of the last layer is triggered, and the second adjusted current and voltage of the last layer are calculated according to the welding effect of the second weld.

[0117] Step S203: according to the second adjusted current and voltage, the gas brazing gun performs welding of the last layer on the workpiece, and after the last layer of welding is completed, the weld inspection program is started;

[0118] In the above embodiment, step S201 of this embodiment calculates the initial current and voltage according to the thickness of the welding layer and the size of the workpiece; after welding, the gas brazing gun parameters are adjusted according to the first weld effect; the parameter settings at the beginning of welding are ensured to be reasonable, and welding defects caused by improper parameters are reduced; the parameters are adjusted through the first weld effect to improve the accuracy and adaptability of welding; a good foundation is laid for the welding layer, and the overall welding quality and efficiency are improved; step S202 of this embodiment uses the first adjusted current and voltage to weld the middle layer; after completion, the parameters are adjusted again according to the second weld effect; the welding quality of the middle layer is guaranteed, and welding defects are further reduced; by continuously adjusting the parameters, the welding process is continuously optimized; the quality of each layer in the multi-layer welding is guaranteed, and the structural strength of the entire workpiece is improved; step S203 of this embodiment uses the second adjusted current and voltage to weld the last layer; after completion, the weld inspection program is started; the welding quality of the last layer is optimally guaranteed, and the weld inspection program ensures the comprehensiveness and accuracy of the welding quality; the perfect ending of the entire welding process is ensured, and possible welding defects are timely discovered and corrected through the weld inspection program, thereby improving the overall quality of the workpiece.

[0119] Example 4: Figure 4 As shown, based on Example 3, the process of obtaining the first adjustment current and voltage of the intermediate layer gas brazing gun in step S201 provided in the embodiment of the present invention specifically includes the following steps:

[0120] Step S2011: according to the thickness of the welding layer and the workpiece size data, the mapping relationship comparison table is retrieved, the initial current and voltage of the gas brazing gun are calculated, and the welding layer is welded after the gas brazing gun parameters are adjusted;

[0121] Step S2012: After the first weld is welded according to the initial current and voltage, the first gas brazing gun control program of the middle layer is automatically triggered;

[0122] Step S2013: According to the weld shape, penetration depth and quality of the first weld layer, the current and voltage of the intermediate layer gas brazing gun are calculated and adjusted by an empirical formula to obtain a first adjusted current and voltage.

[0123] In the above embodiment, step S2011 of this embodiment can accurately calculate the initial current and voltage of the gas brazing gun according to the thickness of the welding layer and the workpiece size data by using the mapping relationship comparison. By adjusting the gas brazing gun parameters, it can be ensured that the welding layer has appropriate heat input at the beginning of welding, thereby obtaining good welding quality; the accuracy and controllability of the welding process are improved; the accurate setting of the initial parameters helps to reduce welding defects; after completing the welding of the first weld, step S2012 of this embodiment automatically triggers the first gas brazing gun control program of the middle layer; realizes the automatic control of the welding process, reduces manual intervention, and improves product quality; step S2013 of this embodiment adjusts the current and voltage of the middle layer gas brazing gun through an empirical formula according to the weld morphology, penetration depth and quality of the first layer weld; the first adjusted current and voltage obtained after adjustment can better adapt to the current welding conditions and further improve the welding quality; the dynamic adjustment of the welding parameters is realized, and the flexibility and adaptability of the welding process are enhanced; by optimizing the welding parameters, the strength and reliability of the weld can be further improved to meet higher quality requirements.

[0124] Example 5: Figure 5 As shown, based on Example 4, the process of obtaining the first adjustment current and voltage in step S2013 provided in the embodiment of the present invention specifically includes the following steps:

[0125] Step S20131: Detailed inspection and evaluation of the weld shape, penetration depth and quality of the first layer of weld; based on the evaluation results, an empirical formula for welding current and welding voltage is selected;

[0126] Step S20132: Calculate preliminary adjustment current and voltage values ​​using empirical formulas, and verify whether the preliminary calculated adjustment current and voltage are appropriate through trial welding, and further optimize the current and voltage according to the shape of the trial weld and the shape of the molten pool;

[0127] Among them, the calculation formula of welding current is:

[0128]

[0129] Where I is the welding current (unit: ampere, A), k1 is the current base coefficient, which is related to the welding material and wire diameter; P is the penetration depth (unit: millimeter, mm); W is the weld width (unit: millimeter, mm); ρ is the material density (unit: grams / cubic centimeter, g / cm 3 );C p It represents the specific heat capacity of the material (unit: joule / gram·degree Celsius, J / g·℃), which indicates the ability of the material to absorb heat; ΔT represents the difference between the welding temperature and the room temperature (unit: degree Celsius, ℃); v represents the welding speed (unit: millimeter / second, mm / s); η represents the welding efficiency coefficient, which indicates the energy utilization rate during the welding process; α represents the thermal diffusion coefficient (unit: square millimeter / second, mm 2 / s), which indicates the thermal conductivity of the material; β indicates the welding environment correction factor, which takes into account factors such as ambient humidity and air pressure; k2 indicates the weld quality correction factor; Q indicates the weld quality score (unit: dimensionless); k5 indicates the arc energy correction factor; E indicates the arc energy (unit: joule, J), which indicates the energy released by the arc during welding; E0 indicates the reference arc energy (unit: joule, J), which is usually 1000 J;

[0130] The calculation formula of welding voltage is:

[0131]

[0132] In the formula, U represents welding voltage (unit: volt, V); k3 represents voltage base coefficient, which is related to arc characteristics and welding method; I represents welding current (unit: ampere, A); L represents arc length (unit: millimeter, mm); μ represents arc stability coefficient, which represents arc stability; γ represents welding wire melting efficiency coefficient, which represents welding wire melting efficiency; d represents welding wire diameter (unit: millimeter, mm); σ represents material conductivity (unit: Siemens / meter, S / m); τ represents time correction coefficient, which is considered Consider the influence of welding time on voltage; φ represents the welding position correction coefficient, considering the influence of welding position (flat welding, vertical welding, etc.) on voltage; k4 represents the temperature correction coefficient; T represents the ambient temperature (unit: Celsius, ℃); k6 represents the wire feed speed correction coefficient; F represents the wire feed speed (unit: millimeter / second, mm / s); F0 represents the reference wire feed speed (unit: millimeter / second, mm / s), usually 10mm / s; it can more comprehensively reflect the complexity and dynamic changes in the welding process;

[0133] Step S20133: Record the optimized first adjustment current and voltage, adjust the gas brazing gun parameters, and avoid frequent parameter changes.

[0134] In the above embodiment, step S20131 of this embodiment performs detailed inspection and evaluation on the weld morphology, penetration depth and quality of the first layer of weld; based on the evaluation results, an empirical formula for welding voltage is selected; through detailed inspection and evaluation, an accurate understanding of the initial state of the weld can be ensured; selecting a suitable empirical formula can predict and adjust welding parameters based on known conditions; step S20132 of this embodiment uses empirical formulas to calculate preliminary adjustment current and voltage values, and verifies whether the preliminary calculated adjustment current and voltage are appropriate through trial welding, and further optimizes the current and voltage according to the morphology of the trial weld and the shape of the molten pool; through calculation and trial welding verification, the welding parameters can be preliminarily determined and adjusted to ensure the stability of the welding process and the quality of the weld. quality; further optimization can be fine-tuned based on the actual welding effect to improve the accuracy of welding; ensure the accuracy of welding parameters and the quality of welds, and improve the reliability and efficiency of welding through practical verification and optimization; in this embodiment, step S20133 records the optimized first adjustment current and voltage, adjusts the gas brazing gun parameters, and avoids frequent parameter changes; recording the optimized parameters can ensure the consistency and traceability of the welding process, and adjusting the gas brazing gun parameters can ensure that the welding process is carried out according to the optimized parameters; avoiding frequent parameter changes can reduce uncertainty and errors in the welding process; ensuring the stability and consistency of the welding process, and improving the controllability and efficiency of the welding process by recording and fixing the parameters.

[0135] Example 6: Figure 6 As shown, based on Example 3, the process of obtaining the second adjusted current and voltage of the last layer in step S202 provided in the embodiment of the present invention specifically includes the following steps:

[0136] Step S2021: adjusting the parameters of the gas brazing gun according to the first adjustment current and voltage, welding the middle layer of the workpiece after the adjustment is completed, continuously monitoring the weld quality, and adjusting the current and voltage in time to maintain the welding effect;

[0137] Step S2022: When the welding of the middle layer is completed, the gas brazing gun stops working and automatically triggers the control program of the second gas brazing gun of the last layer; and the welding effect of the weld of the middle layer is evaluated;

[0138] Step S2023: According to the weld morphology, penetration depth and quality of the first weld layer and the middle weld layer, the current and voltage of the gas brazing gun of the last layer are calculated and adjusted by an empirical formula to obtain the second adjusted current and voltage of the last layer.

[0139] In the above embodiment, in step S2021 of this embodiment, the gas brazing gun parameters are adjusted according to the first adjustment current and voltage to ensure the stability and controllability of the welding process; during the welding process of the middle layer, the weld quality is continuously monitored, and the current and voltage are adjusted in time according to the actual situation to maintain the best welding effect; by accurately adjusting the gas brazing gun parameters and real-time monitoring the weld quality, the welding quality of the middle layer can be ensured, and the overall welding efficiency and genuine quality can be improved; after the middle layer welding is completed in step S2022 of this embodiment, the gas brazing gun stops working and automatically triggers the second gas brazing gun control program of the last layer; by Automatically triggering the welding procedure for the next stage can improve the degree of automation of the welding process and reduce human intervention. At the same time, the evaluation of the intermediate layer weld can timely discover and solve potential problems and ensure the overall welding quality. In this embodiment, step S2023 calculates and adjusts the current and voltage of the last layer of gas brazing gun through empirical formulas based on the weld morphology, welding head depth and quality of the first layer weld and the intermediate layer weld. By comprehensively considering the quality parameters of the previous layers of welds, the parameters of the last layer of gas brazing gun can be adjusted more accurately, thereby ensuring the stability and consistency of the overall welding quality, which helps to improve welding efficiency and finished product quality.

[0140] Example 7: Figure 7 As shown, based on Example 6, the process of calculating and adjusting the current and voltage of the last layer of gas brazing gun by the empirical formula in step S2023 provided in the embodiment of the present invention specifically includes the following steps:

[0141] Step S20231: evaluating the penetration depth and uniformity of the first layer and the middle layer welds of the all-copper liquid-cooled radiator; selecting an empirical formula according to the evaluation results of the first layer and the middle layer welds;

[0142] Step S20232: Calculate preliminary second adjustment current and voltage values ​​according to an empirical formula, use the preliminary second adjustment current and voltage values ​​to perform test welding, and fine-tune the current and voltage according to the test welding results;

[0143] Step S20233: input the adjusted second adjustment current and voltage into the gas brazing gun, weld the last layer, and adjust the current and voltage in time according to the actual situation.

[0144] In the above embodiment, step S20231 of this embodiment evaluates the penetration depth and uniformity of the first layer and middle layer welds of the all-copper liquid-cooled radiator, which can ensure that the quality of the weld meets the requirements and timely discover possible problems; select an empirical formula based on the evaluation results, and determine the appropriate current and voltage adjustment strategy based on the actual situation; ensure the quality of the weld and avoid the degradation of heat dissipation performance due to insufficient or uneven penetration depth; step S20232 of this embodiment calculates the preliminary second adjustment current and voltage values ​​according to the empirical formula, which can provide a near-optimal welding parameter combination; use the preliminary second adjustment current and voltage values ​​for test welding, and micro-adjust the current and voltage through the test welding results. Adjustment can ensure that the welding parameters are consistent with the actual situation and improve the welding quality; through calculation and trial welding, the optimal welding parameters are gradually approached to improve the welding efficiency and weld quality; the fine-tuning process can ensure the accuracy and adaptability of the welding parameters to meet the needs under different welding conditions; in step S20233 of this embodiment, the adjusted second adjustment current and voltage are input into the gas brazing gun to ensure the quality of the last layer of welding; adjusting the current and voltage in time according to the actual situation can cope with the uncertain factors in the welding process; ensuring the quality of the last layer of welds to meet the overall performance requirements of the all-copper liquid-cooled radiator; adjusting the parameters in time can improve the flexibility and adaptability of the welding process and ensure the stability and reliability of the welding process.

[0145] Example 8: Figure 8 As shown, based on Example 1, the process of inspecting the weld in step S300 provided in the embodiment of the present invention specifically includes the following steps:

[0146] Step S301: performing ultrasonic testing on the welded all-copper liquid-cooled radiator, and judging the uniformity of the weld according to the ultrasonic testing image;

[0147] Step S302: statically stretch the weld of the all-copper liquid-cooled radiator, gradually apply tension, record tension and displacement data, calculate the tensile strength and elongation parameters of the weld, and judge the weld strength;

[0148] Step S303: Perform magnetic particle surface flaw detection on the weld of the all-copper liquid-cooled radiator, and set a surface quality threshold. If the surface flaw detection result exceeds the preset surface quality threshold, the all-copper liquid-cooled radiator is judged to be unqualified.

[0149] Among them, step S301 ultrasonically detects the uniformity of the weld:

[0150]

[0151] Where V represents the weld uniformity score (unit: dimensionless), the smaller the value, the better the uniformity; k7, k8, k9, k10 Indicates the weight coefficient, which can be adjusted according to actual needs; A max Indicates the maximum amplitude value in the ultrasonic detection image (unit: decibel, dB); A min Indicates the minimum amplitude value in the ultrasonic detection image (unit: decibel, dB); A avg Represents the average amplitude value in the ultrasonic detection image (unit: decibel, dB); σ A Indicates the standard deviation of the amplitude in the ultrasonic detection image (unit: decibel, dB); D max Indicates the maximum defect depth in the ultrasonic detection image (unit: millimeter, mm); D min Indicates the minimum defect depth in the ultrasonic detection image (unit: millimeter, mm); D avg Represents the average defect depth in the ultrasonic test image (unit: millimeter, mm); σ D Indicates the standard deviation of the defect depth in the ultrasonic test image (unit: millimeter, mm); comprehensively evaluates the uniformity of the weld by comparing the maximum, minimum, average and standard deviation of the amplitude and defect depth; the weight coefficient can be adjusted according to actual testing needs;

[0152] Step S302: Static tensile test of weld strength:

[0153]

[0154] Where S represents the weld strength score (unit: dimensionless), the larger the value, the higher the strength; k 11 ,k 12 ,k 13 ,k 14 Indicates the weight coefficient, which can be adjusted according to actual needs; F max Indicates the maximum tensile force (unit: Newton, N); A weld Indicates the cross-sectional area of ​​the weld (unit: square millimeter, mm 2 );E total represents the total tensile energy (unit: joule, J), which is calculated by integrating the tension-displacement curve; ΔL represents the extension of the weld during the stretching process (unit: millimeter, mm); L0 represents the initial length of the weld (unit: millimeter, mm); σ F Indicates the standard deviation of tensile force (unit: Newton, N); F avg Indicates the average tensile force (unit: Newton, N); the strength and toughness of the weld are comprehensively evaluated through the maximum tensile force, total tensile energy, elongation and fluctuation of tensile force; the weight coefficient can be adjusted according to actual needs;

[0155] Step S303: Magnetic particle surface flaw detection to detect weld surface quality:

[0156]

[0157] Where Q represents the weld surface quality score (unit: dimensionless), the smaller the value, the better the surface quality; k 15 ,k 16 ,k 17 ,k 18 Indicates the weight coefficient, which can be adjusted according to actual needs; N defect Indicates the number of defects detected by magnetic particle inspection (unit: piece); A scan Indicates the flaw detection area (unit: square millimeter, mm 2 );L total Indicates the total length of all defects (unit: millimeter, mm); D max Indicates the maximum defect depth (unit: millimeter, mm); t weld Indicates the weld thickness (unit: millimeter, mm); σ L Indicates the standard deviation of defect length (unit: millimeter, mm); L avg Indicates the average defect length (unit: millimeter, mm). The surface quality of the weld is comprehensively evaluated through the number of defects, total defect length, maximum defect depth and volatility of defect length; the weight coefficient can be adjusted according to actual needs; a more accurate quantitative evaluation of the uniformity, strength and surface quality of the all-copper liquid cooling radiator weld is performed.

[0158] In the above embodiment, step S301 can obtain the internal structure image of the weld by performing ultrasonic testing on the welded all-copper liquid-cooled radiator, and can clearly show the uniformity of the weld, including whether there are defects such as pores and slag inclusions; the uniformity of the weld is the key to ensuring the stable performance of the all-copper liquid-cooled radiator, and ultrasonic testing can detect potential welding problems in advance, thereby avoiding leakage or performance degradation during use; step S302 can record the tensile force and displacement data by performing a static tensile test on the weld, and then calculate the tensile strength and elongation of the weld; the strength of the weld is directly It is related to the pressure-bearing capacity and service life of the all-copper liquid-cooled radiator; through static tensile testing, it can be ensured that the weld has sufficient strength to meet the needs of practical applications; step S303 this surface flaw detection can find tiny cracks, rust and other defects on the weld surface; by setting the surface quality threshold, the weld surface quality can be quantitatively evaluated; the surface quality of the weld not only affects the aesthetics of the all-copper liquid-cooled radiator, but also is related to the overall reliability and safety; magnetic particle surface flaw detection can promptly detect and deal with surface defects to prevent performance degradation or safety accidents caused by surface problems.

[0159] Example 9: Fig. 9As shown, on the basis of Example 1 to Example 8, the multi-defense mode welding process device of the all-copper liquid-cooled radiator provided in the embodiment of the present invention comprises: a workpiece 1, a workbench 2, a horizontal adjustment nut 3, a gas brazing gun 4, a pulley 5, a gas brazing gun adjustment bracket 6, a track 7 and a gas cylinder 8;

[0160] Among them, the workbench 2 is connected to two tracks 7, the workpiece 1 is fixed on the bracket between the workbench 2 and the track 7 for processing, and a pulley 5 is installed at the bottom of the bracket; the horizontal adjustment nut 3 is installed at the bottom of the workbench 2; a gas brazing gun adjustment bracket 6 is fixedly installed under the workpiece 1, and four gas brazing guns 4 are installed on the gas brazing gun adjustment bracket 6 in groups of two and obliquely downward, and a gas cylinder 8 is placed on one side of the device.

[0161] In the above embodiment, the workpiece 1 of this embodiment is an object to be welded, that is, a full copper liquid-cooled radiator; the workbench 2 is used to support and fix the workpiece 1 to provide a stable working environment; the connection between the workbench 2 and the track 7 makes the entire device more stable, which is conducive to the precise welding; the horizontal adjustment nut 3 is installed at the bottom of the workbench 2 to adjust the level of the workbench; ensure that the workpiece remains horizontal during the welding process to avoid welding quality problems caused by tilting; the gas brazing gun 4 is installed obliquely downward on the gas brazing gun adjustment bracket 6, which is the key tool for performing the welding operation; the setting of four gas brazing guns can improve welding efficiency and weld quality, and may also take into account the needs of multiple defense modes, that is, through the cooperation of different gas brazing guns to achieve a more reliable welding effect; the pulley 5 is installed at the bottom of the bracket to move or adjust the bracket position; the gas brazing gun adjustment bracket 6 is used to fix and adjust the position and angle of the gas brazing gun 4 to ensure the gas brazing The welding gun 4 can accurately align with the workpiece for welding; the track 7 is connected to the workbench 2 to further stabilize the workbench or serve as a reference for the movement and positioning of the workpiece; the gas cylinder 8 is enclosed in the room and on one side of the device to provide the required gas for the gas brazing gun; the workpiece 1 is the processing object, and its quality and welding effect directly affect the performance and service life of the final product; the workbench 2 provides a stable working environment, which is the basis for ensuring welding quality; the horizontal adjustment nut 3 ensures the level of the workpiece, avoids welding defects, and improves welding quality; the gas brazing gun 4 realizes welding operation, and the setting of four gas brazing guns may improve welding efficiency and weld reliability; the pulley 5 facilitates the movement and positioning of the workpiece and improves operational flexibility; the gas brazing gun adjustment bracket 6 ensures the accuracy of the position and angle of the gas brazing gun, which is the key to achieving high-quality welding; the track 7 is used to stabilize and position the workbench or workpiece and enhance the stability of the device; the gas cylinder 8 provides necessary gas protection for welding to prevent damage to the weld quality.

[0162] Example 10: Fig.10As shown, based on Example 1 to Example 8, the multi-defense mode welding process system of the all-copper liquid-cooled radiator provided in the embodiment of the present invention comprises:

[0163] Gas brazing gun adjustment module 9: fix the workpiece on the bracket between the workbench and the track, adjust the horizontal adjustment nut to keep the workbench level; place the gas cylinder on one side of the device; adjust the current and voltage of the gas brazing gun according to the material and thickness of the workpiece; adjust the moving speed of the gas brazing gun according to the thickness of the welding layer and the size of the workpiece; adjust the gas flow of the gas cylinder according to the current, voltage and moving speed;

[0164] Welding module 10: Use a gas brazing gun to perform the first layer of welding. During welding, the gas brazing gun moves along the edge of the workpiece to form a preliminary weld. After the first layer of welding is completed, adjust the position and parameters of the gas brazing gun to perform welding of the middle layer. When performing the last layer of welding, adjust the parameters of the gas brazing gun. After welding is completed, perform cooling treatment.

[0165] The weld inspection module 11 inspects the weld after welding is completed, including the uniformity, strength and surface quality of the weld.

[0166] In the above embodiment, the workpiece of the gas brazing gun adjustment module 9 of this embodiment is firmly fixed on the bracket, and the level of the workbench is ensured by adjusting the horizontal adjustment nut, which is helpful for the stability and accuracy of the welding process; the prevention of the gas cylinder and the adjustment of the gas brazing gun parameters are carried out according to the characteristics of the workpiece and the welding requirements, so as to ensure the controllability and quality of the welding process; the welding module 10 of this embodiment ensures the uniformity and strength of the weld by layered welding; the parameter adjustment after each layer of welding and the precise control of the position of the gas brazing gun help to reduce welding defects and improve the welding quality; the cooling treatment after welding is completed helps to prevent the deformation and cracking of the weld; the comprehensive inspection of the weld by the weld inspection module 11 of this embodiment ensures the reliability of the welding quality; timely discovers and handles welding defects to avoid safety hazards in use; provides a stable working environment and precise welding parameters for the welding process, which is the basis of high-quality welding; through fine welding control and processing, high-quality welds are achieved, and the durability and safety of the workpiece are improved; through strict quality inspection, the performance and safety of the welded workpiece are guaranteed, and the overall quality of the product is improved.

[0167] Fig.11 A block diagram of an exemplary electronic device suitable for implementing embodiments of the present invention is shown.

[0168] The electronic device may include a central processing unit / microprocessor / main control chip, etc. (H1); a storage medium (H2), coupled to the central processing unit / microprocessor / main control chip, etc. (H1), and storing computer executable instructions therein, for performing the steps of each method of an embodiment of the present invention when executed by the processor.

[0169] The central processing unit / microprocessor / main control chip etc. (H1) may include but is not limited to, for example, one or more processors or microprocessors etc.

[0170] The storage medium (H2) may include, but is not limited to, for example, random access memory (RAM), read-only memory (ROM), flash memory, EPROM memory, EEPROM memory, registers, computer storage media (such as hard disk, floppy disk, solid state drive, removable disk, CD-ROM, DVD-ROM, Blu-ray disc, etc.).

[0171] In addition, the electronic device may also include (but not limited to) a data bus (H3), an input / output bus / external bus / device bus, etc. (H4), a display (H5) and input / output devices (H6) (for example, a keyboard, a mouse, a speaker, etc.), etc.

[0172] The central processing unit / microprocessor / main control chip etc. (H1) can communicate with external devices (H5, H6, etc.) through an I / O bus (H4) via a wired or wireless network (not shown).

[0173] The storage medium (H2) may also store at least one computer executable instruction for executing the various functions and / or method steps in the embodiments described in the present technology when executed by a central processing unit / microprocessor / main control chip, etc. (H1).

[0174] In one embodiment, the at least one computer executable instruction may also be compiled into or constitute a software product, wherein one or more computer executable instructions are executed by a processor to perform the various functions and / or method steps in the embodiments described in the present technology.

[0175] Fig.12 A schematic diagram of a computer-readable storage medium according to an embodiment of the present invention is shown.

[0176] like Fig.12As shown, instructions are stored on the non-transitory computer-readable storage medium 920, and the instructions are, for example, computer-readable instructions 910. When the computer-readable instructions 910 are executed by the processor, the various methods described above can be executed. The non-transitory computer-readable storage medium includes, but is not limited to, for example, volatile memory and / or non-volatile memory. Volatile memory may include, for example, random access memory (RAM) and / or cache memory (cache), etc. The non-transitory non-volatile memory may include, for example, a read-only memory (ROM), a hard disk, a flash memory, etc. For example, the non-transitory computer-readable storage medium 920 can be connected to a computing device such as a computer, and then, when the computing device runs the computer-readable instructions 910 stored on the computer-readable storage medium 920, the various methods described above can be performed.

[0177] In the several embodiments provided by the present invention, it should be understood that the disclosed devices and methods can be implemented in other ways. For example, the device embodiments described above are only schematic, for example, the division of units is only a logical function division, and there may be other division methods in actual implementation, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point, the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of devices or units, which can be electrical, mechanical or other forms. The units described as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units, that is, they may be located in one place, or they may be distributed on multiple network units. Some or all of the units can be selected according to actual needs to achieve the purpose of the scheme of this embodiment.

[0178] In addition, each functional unit in each embodiment of the present invention can be integrated into a processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The above-mentioned integrated unit can be implemented in the form of hardware or in the form of a software functional unit. If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention is essentially or the part that contributes to the prior art or all or part of the technical solution can be embodied in the form of a software product, and the computer software product is stored in a storage medium, including several instructions for executing all or part of the steps of the methods of each embodiment of the present invention through a computer device (which can be a personal computer, a server, or a network device, etc.). The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (full name in English: Read-Only Memory, English abbreviation: ROM), random access memory (full name in English: Random Access Memory, English abbreviation: RAM), disk or optical disk and other media that can store program code.

[0179] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features thereof may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A liquid cooling radiator multiple defense mode welding process method, characterized in that: The liquid cooling radiator multi-defense mode welding process method comprises the following steps: Fix the workpiece on the bracket between the workbench and the track, adjust the horizontal adjustment nut to keep the workbench level; place the gas cylinder on one side of the device; adjust the current and voltage of the gas brazing gun according to the material and thickness of the workpiece; adjust the moving speed of the gas brazing gun according to the thickness of the welding layer and the size of the workpiece; adjust the gas flow of the gas cylinder according to the current, voltage and moving speed; Use a gas brazing gun to move along the edge of the workpiece to form a preliminary weld. Adjust the current, voltage and gas flow of the gas brazing gun according to the material and thickness of the workpiece. Combined with the melting effect of the brazing material at different temperature states during the welding melting process, design and layout the flow channel for the brazing filler metal. Through the multi-layer stepped distribution of the filler metal inside and outside, a multiple defense mode is formed. After the first layer of welding is completed, adjust the parameters and position of the gas brazing gun to weld the middle layer. Adjust the parameters of the gas brazing gun to weld the last layer. After welding is completed, the weld is inspected for uniformity, strength and surface quality.

2. The liquid cooling radiator multi-defense mode welding process method according to claim 1, characterized in that: The process of adjusting a gas brazing gun includes: According to the material and thickness of the all-red copper liquid cooling radiator to be welded, the lowest current and voltage are selected from the historical data as the starting current and starting voltage; the current and voltage are gradually increased, and test welding is performed on the test board, and the current and voltage are adjusted according to the test welding results; According to the material, thickness and welding process requirements of the all-copper liquid-cooled radiator to be welded, set the initial welding speed, conduct trial welding, and adjust the moving speed of the gas brazing gun according to the weld results; After the welding current, welding voltage and moving speed of the gas brazing gun are determined, the mapping relationship between the value change of the gas cylinder pressure gauge and the changes in current, voltage and moving speed is detected during the trial welding process, and a mapping relationship table is established. The gas cylinder flow is adjusted according to the mapping relationship table.

3. The multi-defense mode welding process method for a liquid cooling radiator according to claim 1, characterized in that: in, Temperature field distribution model: The distribution of the temperature field T(x, y, z, t) of the solder during the melting process is described by the heat conduction equation: In the formula, T(x,y,z,t) represents the temperature field function, which indicates the temperature at the spatial coordinates (x,y,z) and time t; α represents the thermal diffusion coefficient, which indicates the thermal conductivity of the solder; Q(x,y,z,t) represents the heat source function, which indicates the influence of external heat input on the temperature field; Solder melting rate model, solder melting rate Related to the temperature field and material properties, it is described by the following formula: In the formula, represents the melting rate of the solder, which indicates the amount of solder melted per unit time; β represents the melting rate constant, which is related to the thermophysical properties of the solder; E a represents activation energy, which represents the energy required for solder melting; R′ represents the universal gas constant; T m It represents the melting point temperature of solder; n represents the melting index, which represents the nonlinear characteristics of solder melting; Solder flow dynamics model, the flow behavior of the solder in the flow channel is described by the Navier-Stokes equation, combined with the influence of the temperature field: In the formula, ρ′ represents the solder density; v′ represents the solder flow velocity vector; p′ represents the fluid pressure; μ′ represents the dynamic viscosity, which represents the flow resistance of the solder; g represents the gravity acceleration vector; γ represents the temperature gradient coefficient, which represents the effect of temperature on the fluid; The optimization model of the flow channel layout of multiple defense modes is used to optimize the solder flow channel layout. The objective function J is established to meet the needs of multiple defense modes: Where, t f represents the final time of the brazing process; Ω represents the flow channel space domain; η1, η2, and η3 represent weight coefficients, which represent the optimization targets of melting rate, flow stability, and temperature gradient, respectively; Comprehensive optimization constraints: In the formula, v max Indicates the maximum permissible flow rate.

4. The multi-defense mode welding process method for a liquid cooling radiator according to claim 1, characterized in that: The process of welding the first layer, the middle layer and the last layer includes: The initial current and voltage of the gas brazing gun are calculated according to the thickness of the welding layer and the size of the workpiece; after the welding is completed according to the initial current and voltage, the first gas brazing gun control program of the middle layer is triggered, and the first adjustment current and voltage of the gas brazing gun of the middle layer are calculated according to the welding effect of the first weld; According to the first adjusted current and voltage, the gas brazing gun welds the middle layer of the workpiece. After the middle layer is welded, the second gas brazing gun control program of the last layer is triggered, and the second adjusted current and voltage of the last layer are calculated according to the welding effect of the second weld. According to the second adjustment of current and voltage, the gas brazing gun welds the last layer of the workpiece. After the last layer of welding is completed, the weld inspection program is started.

5. The multi-defense mode welding process method for a liquid cooling radiator according to claim 4, characterized in that: The process of first adjusting the current and voltage of the intermediate layer gas brazing gun includes: According to the thickness of the welding layer and the size data of the workpiece, the mapping relationship comparison table is retrieved to calculate the initial current and voltage of the gas brazing gun, and the welding layer is welded after adjusting the parameters of the gas brazing gun; After the first weld is completed according to the initial current and voltage, the first gas brazing gun control program of the middle layer is automatically triggered; According to the weld shape, penetration depth and quality of the first weld layer, the current and voltage of the intermediate layer gas brazing gun are calculated and adjusted by an empirical formula to obtain a first adjusted current and voltage.

6. The multi-defense mode welding process method for a liquid cooling radiator according to claim 5, characterized in that: The process of obtaining the first adjustment current and voltage includes: Conduct detailed inspection and evaluation of the weld morphology, penetration depth and quality of the first layer of welds; select empirical formulas for welding current and welding voltage based on the evaluation results; Use empirical formulas to calculate preliminary adjustment current and voltage values, and verify whether the preliminary calculated adjustment current and voltage are appropriate through trial welding. Further optimize the current and voltage according to the morphology of the trial weld and the shape of the molten pool; Among them, the calculation formula of welding current is: Where I is the welding current, k1 is the current base coefficient, which is related to the welding material and wire diameter; P is the penetration depth; W is the weld width; ρ is the material density; C p represents the specific heat capacity of the material, which indicates the ability of the material to absorb heat; ΔT represents the difference between the welding temperature and the room temperature; v represents the welding speed; η represents the welding efficiency coefficient, which indicates the energy utilization rate during the welding process; α represents the thermal diffusion coefficient, which indicates the thermal conductivity of the material; β represents the welding environment correction factor; k2 represents the weld quality correction factor; Q represents the weld quality score; k5 represents the arc energy correction factor; E represents the arc energy, which indicates the energy released by the arc during the welding process; E0 represents the reference arc energy; The calculation formula of welding voltage is: Wherein, U represents welding voltage; k3 represents voltage base coefficient, which is related to arc characteristics and welding method; I represents welding current; L represents arc length; μ represents arc stability coefficient, which represents arc stability; γ represents welding wire melting efficiency coefficient, which represents welding wire melting efficiency; d represents welding wire diameter; σ represents material conductivity; τ represents time correction coefficient; φ represents welding position correction coefficient; k4 represents temperature correction coefficient; T represents ambient temperature; k6 represents welding wire feed speed correction coefficient; F represents welding wire feed speed; F0 represents reference welding wire feed speed; The optimized first adjusted current and voltage are recorded, the gas brazing gun parameters are adjusted, and frequent parameter changes are avoided.

7. The multi-defense mode welding process method for a liquid cooling radiator according to claim 4, characterized in that: The process of adjusting the current and voltage of the second layer to obtain the final layer includes: Adjust the parameters of the gas brazing gun according to the first adjustment current and voltage, weld the middle layer of the workpiece after the adjustment is completed, continuously monitor the weld quality, and adjust the current and voltage in time to maintain the welding effect; When the middle layer is welded, the gas brazing gun stops working and automatically triggers the second gas brazing gun control program for the last layer; and the welding effect of the weld of the middle layer is evaluated; According to the weld morphology, penetration depth and quality of the first and middle welds, the current and voltage of the gas brazing gun of the last layer are calculated and adjusted by an empirical formula to obtain the second adjusted current and voltage of the last layer.

8. The multi-defense mode welding process method for a liquid cooling radiator according to claim 7, characterized in that: The process of calculating and adjusting the current and voltage of the last layer of gas brazing gun through empirical formulas includes: Evaluate the penetration depth and uniformity of the first and middle layer welds of the all-copper liquid-cooled radiator; select an empirical formula based on the evaluation results of the first and middle layer welds; Calculate preliminary second adjustment current and voltage values ​​according to empirical formulas, use the preliminary second adjustment current and voltage values ​​to conduct test welding, and fine-tune the current and voltage according to the test welding results; The adjusted second adjustment current and voltage are input into the gas brazing gun, the last layer is welded, and the current and voltage are adjusted in time according to the actual situation.

9. The liquid cooling radiator multi-defense mode welding process method according to claim 1, characterized in that: The process of inspecting welds includes: Perform ultrasonic testing on the welded all-copper liquid cooling radiator, and judge the uniformity of the weld based on the ultrasonic testing image; Static stretching is performed on the weld of the all-copper liquid cooling radiator, tension is gradually applied, the tension and displacement data are recorded, the tensile strength and elongation parameters of the weld are calculated, and the weld strength is judged; The magnetic particle surface flaw detection is carried out on the weld of the all-copper liquid-cooled radiator, and a surface quality threshold is set. If the surface flaw detection result exceeds the preset surface quality threshold, the all-copper liquid-cooled radiator is judged to be unqualified.

10. The multi-defense mode welding process method for a liquid cooling radiator according to claim 9, characterized in that: in, Ultrasonic testing weld uniformity expression: Where V represents the weld uniformity score; k7, k8, k9, k 10 Indicates the weight coefficient, which can be adjusted according to actual needs; A max Indicates the maximum amplitude value in the ultrasonic detection image; A min Indicates the minimum amplitude value in the ultrasonic detection image; A avg Represents the average amplitude value in the ultrasonic detection image; σ A Indicates the standard deviation of the amplitude in the ultrasonic detection image; D max Indicates the maximum defect depth in the ultrasonic detection image; D min Indicates the minimum defect depth in the ultrasonic detection image; D avg Represents the average defect depth in the ultrasonic detection image; σ D Indicates the standard deviation of the defect depth in the ultrasonic inspection image.

Images