Dual-system wire harness ultrasonic welding machine and control method

Abstract

The invention discloses a dual-system wire harness ultrasonic welding machine and a control method. The dual-system wire harness ultrasonic welding machine comprises a first welding system, a second welding system and a system identification module. The first welding system is used for welding a first material, and the second welding system is used for welding a second material; the system identification module switches the ultrasonic welding system according to the identified type of the welding material and a judgment result, and after the corresponding welding system is selected, whether the welding system is a first welding system or a second welding system is judged through a voltage signal detected by the system identification module; according to the ultrasonic welding system, ultrasonic welding of the copper wire and aluminum wire double systems is achieved by arranging the first welding system and the second welding system, the universality and applicability of welding equipment are greatly improved, and the welding efficiency is improved. And the welding requirements of different materials are met.

Description

Technical Field

[0001] The invention relates to the technical field of ultrasonic welding, and in particular to a dual-system wire harness ultrasonic welding machine and a control method. Background Art

[0002] Ultrasonic welding is a method of connection between two or more materials by applying ultrasonic waves. The ultrasonic welding process is to use a device to make ultrasonic waves vibrate back and forth between two objects. In the electronics, electrical and other industries, there is a widespread demand for welding copper wires and aluminum wires, especially in the new energy wire harness welding market, which is expanding with the rapid development of the new energy vehicle industry, and the demand for high-performance and high-reliability wire harnesses is becoming increasingly prominent. However, due to the differences in the physical and chemical properties of copper wires and aluminum wires, traditional welding methods are difficult to meet the high-quality welding requirements of both wires at the same time. As an advanced welding technology, ultrasonic welding has the advantages of fast welding speed, high welding strength, and low environmental pollution. However, existing ultrasonic welding machines can usually only weld a single wire, and cannot meet the needs of switchable welding of copper wires and aluminum wires. Summary of the invention

[0003] In view of this, the purpose of the present invention is to overcome the defects in the prior art and provide a dual-system wire harness ultrasonic welding machine and a control method, which can realize system conversion by judging the welding line to achieve efficient and high-quality welding of copper wire and aluminum wire and improve the welding effect.

[0004] In order to achieve the above-mentioned object of the invention, the present invention adopts the following technical solutions:

[0005] The present invention provides a dual-system wire harness ultrasonic welding machine, the ultrasonic welding machine comprising a first welding system, a second welding system and a system identification module;

[0006] The first welding system is used for welding the first material, and the second welding system is used for welding the second material; the system identification module switches the ultrasonic welding system according to the type of the identified welding material and the judgment result.

[0007] As a preferred embodiment, the first welding system includes a control module, an ultrasonic control box, and an ultrasonic generator. The second welding system and the first welding system share the control module, the ultrasonic control box and the ultrasonic generator. The control module is communicatively connected to the ultrasonic control box, and the ultrasonic control box is electrically connected to the ultrasonic generator.

[0008] As a preferred solution, the control module is provided with a first control module and a second control module, the ultrasonic control box is provided with a first ultrasonic control and a second ultrasonic control, the ultrasonic generator is provided with a first ultrasonic generation and a second ultrasonic generation, the first welding system applies the first control module, the first ultrasonic control and the first ultrasonic generation; the second welding system applies the second control module, the second ultrasonic control and the second ultrasonic generation.

[0009] As a preferred solution, the first welding system further includes a first transducer, a first welding head, a first bottom mold and a first clamp; the second welding system further includes a second transducer, a second welding head, a second bottom mold and a second clamp.

[0010] As a preferred embodiment, the first welding system also includes a first welding system setting module, and the second welding system also includes a second welding system setting module; the first welding system setting module is used to pre-set the welding settings and save the setting parameters of the first welding system; the second welding system setting module is used to pre-set the welding settings and save the setting parameters of the second welding system.

[0011] As a preferred solution, the system identification module includes a visual camera and an analysis module. The visual camera is used to take pictures and upload image information. The analysis module determines the welding material based on the information obtained by the visual camera.

[0012] As a preferred solution, the system identification module further includes a first signal sensor and a second signal sensor, wherein the first signal sensor is used to detect a voltage signal set by the first welding system, and the second signal sensor is used to detect a voltage signal set by the second welding system.

[0013] The present invention also provides a control method for a dual-system wire harness ultrasonic welding machine, which uses the dual-system wire harness ultrasonic welding machine as described above, and comprises the following steps:

[0014] S1. Before setting welding parameters, the system identification module identifies the type of material to be welded;

[0015] S2, identifying the type of welding material, and selecting a welding system according to the welding material. If it is the first material, the first welding system is selected; if it is the second material, the second welding system is selected;

[0016] S3, after selecting the corresponding welding system, judging whether it is the first welding system or the second welding system according to the voltage signal detected by the system identification module, if the first signal sensor senses a valid voltage, the system is set to the first welding system, if the second signal sensor senses a valid voltage, the system is set to the second welding system;

[0017] S4, checking whether the welding system result selected in S2 is consistent with the welding system result determined in S3, if they are consistent, outputting the selected system setting parameters for welding, if they are inconsistent, outputting an alarm signal.

[0018] As a preferred solution, it also includes setting a material sample library. In step S1, the visual camera takes a picture of the welding material, and the analysis module compares the image information of the welding material with the information in the material sample library, sets comparison features, and determines the type of welding material.

[0019] The beneficial effects of the present invention are as follows: a dual-system wire harness ultrasonic welding machine and control method disclosed in the present invention realizes dual-system ultrasonic welding of copper wires and aluminum wires by setting a first welding system and a second welding system, which greatly improves the versatility and applicability of the welding equipment and meets the needs of welding different materials.

[0020] The present invention arranges a welding system inspection module to judge the selection of the welding system again during welding, thereby ensuring the correctness of the selection of the welding system and ensuring the stability of the welding system. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present application and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without paying creative work.

[0022] Figure 1 It is a structural schematic diagram of the present invention;

[0023] Figure 2 It is a structural schematic diagram of the present invention;

[0024] Figure numerals: 1. control module, 2. ultrasonic control box, 3. ultrasonic generator, 4. system identification module, 5. transducer, 6. amplitude modulator, 7. welding head, 8. bottom mold. DETAILED DESCRIPTION

[0025] To make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments. The components of the embodiments of the present application generally described and shown in the drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the application claimed for protection, but merely represents the selected embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without making creative work belong to the scope of protection of the present application.

[0026] In the description of the embodiments of the present application, the terms "upper", "lower", "front", "rear", etc., are based on the directions or positions shown in the drawings, and are only for the convenience of description and simplification of operation, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation of the present application. In addition, the terms "first", "second", etc. are only used to distinguish in the description and have no special meaning.

[0027] Figure 1 It is a structural schematic diagram of the present invention, such as Figure 1 As shown, a dual-system wire harness ultrasonic welding machine in this embodiment includes a first welding system, a second welding system and a system identification module;

[0028] The first welding system is used for welding the first material, and the second welding system is used for welding the second material; the system identification module switches the ultrasonic welding system according to the type of the identified welding material and the judgment result.

[0029] The first welding system and the second welding system share a control system, an ultrasonic control box, an ultrasonic generator, an ultrasonic control box and an ultrasonic generator. In this embodiment, the first welding system is used to weld copper wire, and the second welding system is used to weld aluminum wire. The control system, the ultrasonic control box and the ultrasonic generator are respectively provided with a first system setting module and a second system setting module matching the first welding system and the second welding system. The control module is provided with a first control module and a second control module, the ultrasonic control box is provided with a first ultrasonic control and a second ultrasonic control, and the ultrasonic generator is provided with a first ultrasonic generation and a second ultrasonic generation.

[0030] The first welding system uses the first system setting module, and the second welding system uses the second system setting module. The first system setting module is used to pre-set the welding settings for the first welding system and save the setting parameters; the second welding system setting module is used to pre-set the welding settings for the second welding system and save the setting parameters. When the required welding system is determined, the control module will retrieve the corresponding welding parameters from the parameter database of the pre-stored recipe. Such as: welding energy, welding pressure, welding time, and welding pressure holding parameters; or welding amplitude, welding pressure, welding time, and secondary welding parameters.

[0031] When welding the first material, that is, welding a copper wire bundle, a first welding system is used, the first control module is communicatively connected to the first ultrasonic control, the first ultrasonic control is electrically connected to the first ultrasonic generator, the system identification module is communicatively connected to the first control module, and the first ultrasonic generator is connected to the first triplet group to achieve welding of the copper wire bundle.

[0032] When welding the second material, that is, welding an aluminum wire harness, a second welding system is used, the second control module is communicatively connected to the second ultrasonic control, the second ultrasonic control is electrically connected to the second ultrasonic generator, the system identification module is communicatively connected to the second control module, and the second ultrasonic generator is connected to the second triplet to achieve welding of the aluminum wire harness.

[0033] In this embodiment, the triple group includes a transducer 5, an amplitude modulator 6, and a welding head 7. In actual use, the transducer 5 and the welding head 7, as well as the corresponding bottom mold 8 and the clamp need to be replaced when welding a copper wire bundle and an aluminum wire bundle. Therefore, in this embodiment, after selecting a welding system, a matching triple group needs to be selected, that is, the first welding system also includes a first transducer, a first welding head, a first bottom mold and a first clamp; the second welding system also includes a second transducer, a second welding head, a second bottom mold and a second clamp. The amplitude modulator determines whether to be replaced according to the actual use.

[0034] The present invention can realize the welding of copper wire bundles and aluminum wire bundles by setting up a dual ultrasonic welding system. When welding wires, only the second transducer, the second welding head, the second bottom mold and the second clamp, the control module, the ultrasonic control box and the ultrasonic generator need to be replaced. The ultrasonic welding of copper wire and aluminum wire dual system is realized by setting up the first welding system and the second welding system, which greatly improves the versatility and applicability of the welding equipment and meets the needs of welding different materials.

[0035] Compared with the traditional single-machine welding system, by adding a system identification module, the dual-system welding control program identification and switching of the wire harness welding machine can be completed, and the purpose of control can achieve the goal of cost reduction.

[0036] In this embodiment, the system identification module includes a visual camera and an analysis module. The visual camera is used to take pictures of the wires to be welded and upload the picture information to the control module. The analysis module determines the welding material according to the information obtained by the visual camera. If it is a copper wire, the first welding system is selected for parameter configuration. If it is an aluminum wire, the second welding system is selected for parameter configuration. The system identification module can automatically identify and select the welding system to achieve efficient conversion of system settings.

[0037] In this embodiment, the system identification module further includes a first signal sensor and a second signal sensor, wherein the first signal sensor is used to detect a voltage signal set by the first welding system, and the second signal sensor is used to detect a voltage signal set by the second welding system. When the setting system is the first welding system, the first signal sensor will sense a valid voltage signal, and when the setting system is the second welding system, the second signal sensor will sense a valid voltage signal.

[0038] like Figure 2 The present invention also provides a control method for a dual-system wire harness ultrasonic welding machine, which uses the dual-system wire harness ultrasonic welding machine as described above, and comprises the following steps:

[0039] S1. Before setting welding parameters, the system identification module identifies the type of material to be welded;

[0040] S2, identifying the type of welding material, and selecting a welding system according to the welding material. If it is the first material, the first welding system is selected; if it is the second material, the second welding system is selected;

[0041] S3, after selecting the corresponding welding system, judging whether it is the first welding system or the second welding system according to the voltage signal, if the first signal sensor senses a valid voltage, the system is set to the first welding system, if, if the second signal sensor senses a valid voltage, the system is set to the second welding system;

[0042] S4, checking whether the welding system result selected in S2 is consistent with the welding system result determined in S3, if they are consistent, outputting the selected system setting parameters for welding, if they are inconsistent, outputting an alarm signal.

[0043] The welding system is set up according to the selected welding material. At the same time, the first signal sensor and the second signal sensor set in the system identification module receive valid voltage signals to determine whether the set system matches the system required by the welding material, thereby ensuring the correctness of the welding system selection and guaranteeing the welding quality.

[0044] In this embodiment, it also includes setting a material sample library. In step S1, the visual camera takes a picture of the welding material, and the analysis module compares the image information of the welding material with the information in the material sample library, sets the comparison feature, and determines the type of welding material.

[0045] The contrast feature may be color recognition, brightness recognition, etc., and one or more feature values ​​may be set. In this embodiment, the type of welding is determined according to the color of the welding material. The colors of copper wire and aluminum wire are different. The color, etc. may be used as an indicator to compare and analyze the pictures taken by the visual camera with the material sample library to obtain the type of welding material. If it is a copper wire bundle, the first welding system is selected, and the matching first control module is set to communicate with the first ultrasonic control, the first ultrasonic control is electrically connected to the first ultrasonic, and the first transducer, the first welding head, the first bottom mold and the first clamp of the welding copper wire bundle are replaced; if it is an aluminum wire bundle, the second welding system is selected, and the matching second control module is set to communicate with the second ultrasonic control, the second ultrasonic control is electrically connected to the second ultrasonic, and the second transducer, the second welding head, the second bottom mold and the second clamp of the welding copper wire bundle are replaced.

[0046] After the welding material is determined in step S3, when the welding material enters the welding system inspection module area, the welding system required by different welding materials is different. If it is copper wire harness welding, the first signal sensor will sense a valid voltage signal, and if it is aluminum wire harness welding, the second signal sensor will sense a valid voltage signal. When the system selected in step S2 is inconsistent with the system setting detected in step S3, an alarm will be generated. When the system selected in step S2 is consistent with the system setting detected in step S3, welding will continue.

[0047] The present invention sets a welding system inspection module, judges and sets the welding system according to the welding wire, and then judges the selection of the welding system again, thereby ensuring the correctness of the selection of the welding system and ensuring the stability of the welding system.

[0048] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution of the present invention, which should be included in the scope of the claims of the present invention.

Claims

1. A dual-system wire harness ultrasonic welding machine, characterized in that: The ultrasonic welding machine includes a first welding system, a second welding system and a system identification module; The first welding system is used for welding the first material, and the second welding system is used for welding the second material; the system identification module switches the ultrasonic welding system according to the type of the identified welding material and the judgment result.

2. A dual-system wire harness ultrasonic welding machine according to claim 1, characterized in that: The first welding system includes a control module, an ultrasonic control box, and an ultrasonic generator. The second welding system shares the control module, the ultrasonic control box, and the ultrasonic generator with the first welding system. The control module is communicatively connected to the ultrasonic control box, and the ultrasonic control box is electrically connected to the ultrasonic generator.

3. A dual-system wire harness ultrasonic welding machine according to claim 1, characterized in that: The control module is provided with a first control module and a second control module, the ultrasonic control box is provided with a first ultrasonic control and a second ultrasonic control, the ultrasonic generator is provided with a first ultrasonic generation and a second ultrasonic generation, the first welding system applies the first control module, the first ultrasonic control and the first ultrasonic generation; the second welding system applies the second control module, the second ultrasonic control and the second ultrasonic generation.

4. A dual-system wire harness ultrasonic welding machine according to claim 1, characterized in that: The first welding system further includes a first transducer, a first welding head, a first bottom mold and a first fixture; the second welding system further includes a second transducer, a second welding head, a second bottom mold and a second fixture.

5. A dual-system wire harness ultrasonic welding machine according to claim 2, characterized in that: The first welding system also includes a first welding system setting module, and the second welding system also includes a second welding system setting module; the first welding system setting module is used to pre-set the welding settings and save the setting parameters of the first welding system; the second welding system setting module is used to pre-set the welding settings and save the setting parameters of the second welding system.

6. A dual-system wire harness ultrasonic welding machine according to claim 3, characterized in that: The system identification module includes a visual camera and an analysis module. The visual camera is used to take pictures and upload image information. The analysis module determines the welding material according to the information obtained by the visual camera.

7. The dual-system wire harness ultrasonic welding machine according to claim 3, characterized in that: The system identification module further includes a first signal sensor and a second signal sensor, wherein the first signal sensor is used to detect a voltage signal set by the first welding system, and the second signal sensor is used to detect a voltage signal set by the second welding system.

8. A control method for a dual-system wire harness ultrasonic welding machine, using the dual-system wire harness ultrasonic welding machine as claimed in claims 1 to 7, comprising the following steps: S1. Before setting welding parameters, the system identification module identifies the type of material to be welded; S2, identifying the type of welding material, and selecting a welding system according to the welding material. If it is the first material, the first welding system is selected; if it is the second material, the second welding system is selected; S3, after selecting the corresponding welding system, judging whether it is the first welding system or the second welding system according to the voltage signal, if the first signal sensor senses a valid voltage, the system is set to the first welding system, if, if the second signal sensor senses a valid voltage, the system is set to the second welding system; S4, checking whether the welding system result selected in S2 is consistent with the welding system result determined in S3, if they are consistent, outputting the selected system setting parameters for welding, if they are inconsistent, outputting an alarm signal.

9. The control method of the dual-system wire harness ultrasonic welding system according to claim 8, characterized in that: It also includes setting a material sample library. In step S1, the visual camera takes a picture of the welding material, and the analysis module compares the image information of the welding material with the information in the material sample library, sets the comparison feature, and determines the type of welding material.

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