Safety capacitor core cladding resistance welding system and process
By using the welding unit of the compression module and pressure monitoring meter in the safety capacitor core pack welding system, as well as the positioning and conveying unit of the prototyping positioning base plate and the prototyping fixture, the problems of unstable quality and inefficiency in the traditional welding methods are solved, and a high-quality and efficient welding process is achieved.
Patent Information
- Application Number
- CN202510209638.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-25
- Publication Date
- 2025-05-06
AI Technical Summary
The traditional core pack welding method has problems such as unstable welding quality, low production efficiency and welding have a great impact on the internal structure of the core pack.
A safety capacitor core-packed resistance welding system is adopted, which includes a welding unit and a positioning conveying unit. The welding unit ensures that the contact pressure between the welding electrode head and the core pack is within a reasonable range through the compression module and pressure monitoring meter, and prevents poor welding or damage. The positioning conveying unit adapts to core packs of different sizes and specifications through pronounced positioning base plates and pronounced fixtures, and improves production efficiency through automated welding processes.
The quality and production efficiency of safety capacitor core pack welding are significantly improved, ensuring that the solder joints are firm and free of welding, protecting the internal structure of the core pack, and extending the service life of the capacitor.
Smart Images
Figure CN119927390A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of resistance welding, and in particular to a safety capacitor core package resistance welding system and process. Background Art
[0002] Safety capacitors play a vital role in electronic circuits. Their performance and quality directly affect the safety and stability of the entire circuit system. The core package of safety capacitors is usually composed of multiple layers of different dielectric materials and electrode foils. The traditional core package welding method has the following main shortcomings: 1. Unstable welding quality; At present, common welding processes such as spot welding, etc., when welding the core package of safety capacitors, it is difficult to accurately control the parameters such as the contact pressure between the electrode and the weldment, the current size and the power-on time, which can easily lead to problems such as cold welding and insufficient solder joint strength; cold welding may cause poor contact of safety capacitors during use, thereby affecting their electrical performance and even causing circuit failures. 2. Low production efficiency; Conventional welding operations mostly rely on manual or semi-automatic equipment. When spot welding the core package of safety capacitors one by one, it is necessary to frequently adjust the position of the weldment and set parameters, etc. The operation is cumbersome and difficult to meet the needs of large-scale production; and the subjective factors of manual operation will further increase the uneven welding quality. 3. Welding has a great impact on the internal structure of the safety capacitor core package; some welding processes will generate a lot of heat during the process, and the heat distribution is uneven, which can easily cause thermal damage to the dielectric material and electrode foil inside the safety capacitor core package, change its original electrical characteristics, and reduce the quality and service life of the safety capacitor. Summary of the invention
[0003] In view of the defects in the prior art, the purpose of the present invention is to provide a safety capacitor core package resistance welding system, which can ensure the accuracy of the welding position and improve the welding quality; it can also flexibly adapt to safety capacitor core packages of different sizes and specifications, ensure the stability of the internal structure during welding, and enhance the versatility of the welding system device; the overall use of automated welding technology can better meet the requirements of large-scale industrial production.
[0004] The technical solution adopted by the present invention is: a safety capacitor core package resistance welding system, including a welding unit and a positioning and conveying unit; the welding unit includes a clamping module, the output end of the lower end of the clamping module is connected to a welding electrode head, the welding electrode head is driven to move vertically up and down by the clamping module, and a pressure monitoring gauge is also provided on the clamping module, the monitoring end of the pressure monitoring gauge is abutted against an assembly part provided at the upper end of the welding electrode head, and is used to monitor the contact pressure between the welding electrode head and the capacitor core package; the positioning and conveying unit includes a base, a positioning slide is provided at the upper end of the base, a guide rail module for driving the positioning slide is provided in the base, a detachable contoured positioning base plate is installed at the upper end of the positioning slide, and a contoured jig for accommodating the welding capacitor core package is provided on the contoured positioning base plate.
[0005] In this technical solution, the entire resistance welding system implements automated welding through the welding unit, and the positioning and conveying unit realizes automatic material conveying during the welding process; the clamping module of the welding unit can drive the welding electrode head to press down the capacitor core package to play a positioning and clamping role, ensuring that the safety capacitor core package will not loosen during the welding process, thereby ensuring the welding quality. During the clamping process, the pressure monitoring meter is used to monitor the downward pressure to ensure that the applied clamping force is always within a reasonable range, avoiding problems such as poor welding or damage to the safety capacitor core package due to excessive or insufficient pressure. The positioning and conveying unit used for loading and unloading is equipped with a guide rail module on the base to drive the positioning slide to move to the corresponding loading and unloading position and the position to be welded, and different specifications of contoured positioning base plates and contoured jigs are installed according to welding needs to improve the versatility of this system.
[0006] Preferably, a mounting frame is provided on the outer side of the pressing module, and an adapter plate connected to the three-dimensional robotic arm is provided on the mounting frame.
[0007] Preferably, a welding cable connector connected to the welding electrode head via a cable is provided at the upper end of the clamping module.
[0008] Preferably, photoelectric limit modules are provided at both ends of the base corresponding to the sliding direction of the positioning slide.
[0009] Preferably, a control line interface connected to the guide rail module signal is provided at the end of the base.
[0010] Preferably, it also includes a control system connected to the welding unit and the positioning and conveying system signals, and the control system is connected to the teaching pendant assembly and the control button assembly.
[0011] The beneficial effects of the present invention are:
[0012] 1. This system can significantly improve the welding quality of safety capacitor core packages, ensure that the solder joints are firm and free of cold solder joints during the welding process, ensure the reliability of electrical connections at the welding sites, and improve the overall performance stability of safety capacitors.
[0013] 2. This system can improve the production efficiency of safety capacitor core package welding, realize automatic or semi-automatic control of the welding process, reduce manual intervention, reduce the quality difference caused by manual operation, and meet the needs of mass production.
[0014] 3. This system can optimize the heat generation and distribution during the welding process, reduce the damage of welding heat conduction to the internal structure of the safety capacitor core package, ensure that the original electrical characteristics of the dielectric material in the safety capacitor core package are not damaged, and extend the service life of the safety capacitor. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following is a brief introduction to the drawings required for the specific embodiments or the description of the prior art. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn according to the actual scale.
[0016] Figure 1 It is a structural diagram of the safety capacitor core resistance welding system provided in an embodiment of the present invention.
[0017] Figure 2 Schematic diagram of the welding unit of the safety capacitor core resistance welding system provided in the embodiment of the present invention Figure 1 .
[0018] Figure 3 Schematic diagram of the welding unit of the safety capacitor core resistance welding system provided in the embodiment of the present invention Figure 2 .
[0019] Figure 4 Schematic diagram of the positioning and conveying unit of the safety capacitor core package resistance welding system provided in an embodiment of the present invention Figure 1 .
[0020] Figure 5 Schematic diagram of the positioning and conveying unit of the safety capacitor core package resistance welding system provided in an embodiment of the present invention Figure 2 .
[0021] Figure 6 A control schematic diagram of a safety capacitor core resistance welding system provided in an embodiment of the present invention.
[0022] Figure numerals: clamping module 100, welding electrode head 200, assembly part 210, pressure monitoring gauge 300, base 400, positioning slide 500, guide rail module 600, contour positioning base plate 700, contour fixture 800, mounting frame 900, adapter plate 910, welding cable connector 1000, photoelectric limit module 1100, control line interface 1200, teaching pendant assembly 1300, control button assembly 1400, robotic arm 1500, safety capacitor core package 1600. DETAILED DESCRIPTION
[0023] The following embodiments of the technical solution of the present invention are described in detail in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and are therefore only used as examples, and cannot be used to limit the protection scope of the present invention.
[0024] It should be noted that, unless otherwise specified, the technical terms or scientific terms used in this application should have the common meanings understood by those skilled in the art to which the invention belongs.
[0025] like Figures 1 to 5 As shown, a specific embodiment of the present invention provides a safety capacitor core package resistance welding system, which is used to achieve high efficiency and high quality welding of safety capacitor core packages, including a welding unit and a positioning and conveying unit; the welding unit includes a clamping module 100, the output end of the lower end of the clamping module 100 is connected to a welding electrode head 200, the welding electrode head 200 is driven by the clamping module 100 to move vertically up and down, and the clamping module 100 is also provided with a pressure monitoring gauge 300, and the monitoring of the pressure monitoring gauge 300 The end is abutted against the assembly part 210 provided on the upper end of the welding electrode head 200, and is used to monitor the contact pressure between the welding electrode head 200 and the safety capacitor core package 1600; the positioning and conveying unit includes a base 400, a positioning slide 500 is provided on the upper end of the base 400, a guide rail module 600 for driving the positioning slide 500 is provided in the base 400, a detachable contoured positioning base plate 700 is installed on the upper end of the positioning slide 500, and a contoured fixture 800 for accommodating the safety capacitor core package 1600 to be welded is provided on the contoured positioning base plate 700.
[0026] like Figures 1 to 5 As shown, the entire resistance welding system provided by this embodiment implements automated welding through the welding unit, and the positioning and conveying unit realizes automatic material conveying during the welding process. Specifically, the clamping module 100 of the welding unit can drive the welding electrode head 200 to press down the safety capacitor core package 1600 to play a positioning and clamping role, ensuring that the safety capacitor core package 1600 will not become loose during the welding process, thereby ensuring the welding quality. During the clamping process, the pressure monitoring meter is used to monitor the downward pressure to ensure that the applied clamping force is always within a reasonable range, avoiding problems such as poor welding or damage to the safety capacitor core package 1600 due to excessive or insufficient pressure. In actual applications, the clamping module 100 uses a pneumatic clamping structure to apply appropriate pressure to the safety capacitor core package 1600.
[0027] like Figures 1 to 5 As shown, in this embodiment, the positioning and conveying unit for loading and unloading is provided with a guide rail module 600 on the base 400 for driving the positioning slide 500 to move to the corresponding loading and unloading positions and the positions to be welded. According to the welding needs, different specifications of the profiling positioning base plate 700 and the profiling fixture 800 are installed to improve the versatility of the system. The profiling fixture 800 and the profiling positioning base plate 700 are developed according to the different sizes of the existing safety capacitor core package 1600. Before welding, the corresponding specifications can be selected and installed on the positioning slide 500. The guide rail module 600 can adopt a servo motor combined with a ball screw structure, which has the advantages of high positioning accuracy and stable transmission.
[0028] like Figure 2 and Figure 3As shown, in this embodiment, in order to install the welding electrode head 200 on the output end of the pressing module 100, the upper end of the welding electrode head 200 is provided with an assembly part 210 connected to the output end of the pressing module 100, and the monitoring end of the pressure monitoring gauge 300 is against the assembly part 210. In this way, when the assembly part 210 is connected to the pressing module 100, the pressing force during welding can be monitored by the contact between the pressure monitoring gauge 300 and the assembly part 210. In actual production applications, the pressure monitoring gauge 300 adopts a product in the prior art, and its model and specifications are selected according to design requirements, which will not be repeated here.
[0029] like Figure 2 and Figure 3 As shown, the system needs to be moved to the corresponding welding position in real time when in use. In order to improve the degree of automation, the present embodiment is provided with a mounting frame 900 on the outside of the welding clamping module 100, and an adapter plate 910 connected to the three-dimensional mechanical arm 1500 is provided on the mounting frame 900. In this way, the entire welding unit can be installed on the mechanical arm 1500 device through the adapter plate 910, and the welding unit is driven to move by the mechanical arm 1500. The mechanical arm 1500 with multiple degrees of freedom can be accurately moved to the welding position to implement automated welding operations. The accuracy and efficiency of the welding operation are improved through the precise movement and positioning of the mechanical arm.
[0030] like Figure 4 and Figure 5 As shown, in order to facilitate the connection of various control and connection harnesses for welding, this embodiment is provided with a welding cable connector 1000 connected to the welding electrode head 200 through a cable at the upper end of the clamping module 100, which is used to connect the harness before the equipment is operated; the welding cable connector ensures interference-free signal transmission during the welding process, and the control system provides intuitive remote control capabilities through the teach pendant and buttons. This embodiment also provides photoelectric limit modules at both ends of the base 400 corresponding to the sliding direction of the positioning slide 500, which are used to limit the extreme movement position of the positioning slide 500. The photoelectric limit module and the photoelectric detection system are used to prevent the positioning slide from moving incorrectly and ensure the safety of the operation. At the same time, the end of the base 400 is provided with a control line interface 1200 connected to the guide rail module 600 signal, and the control line interface 1200 can be used to connect the signal harness to achieve automatic control. The design of each module of the entire system has high reliability and interchangeability, which can meet the welding requirements of safety capacitor core packages of different specifications, and at the same time provide a good foundation for future upgrades and expansions.
[0031] like Figure 6As shown, this embodiment provides a control system connected to the welding unit and the positioning and conveying system signals, wherein the control system is connected to a teach pendant assembly 1300 and a control button assembly 1400. The control system enables the teach pendant assembly 1300 to display welding parameters, store welding programs, etc. through circuit control, and sends control instructions through the control button assembly 1400.
[0032] When the equipment is actually running, the operation steps are as follows: First, in the automated production workshop, the operator first loads the safety capacitor core package 1600 into the profiling fixture 800, and ensures that the safety capacitor core package 1600 is placed accurately and firmly so that it can be accurately adapted to the subsequent welding operation; then, carefully put the profiling fixture 800 with the safety capacitor core package 1600 into the profiling positioning base plate 700. Then, the experienced operator carefully selects the pre-set welding program through the teaching pendant assembly 1300 on the operating table. During the selection process, the parameters corresponding to the program will be checked again to confirm whether it meets the welding requirements of the current safety capacitor core package 1600, such as welding current, welding time, electrode pressure and other key parameters. After confirmation, the welding is started through the control button assembly 1400. At this time, the positioning and conveying unit receives the start command and starts to run smoothly and at a uniform speed, and transports the positioning slide 500 and the safety capacitor core package 1600 therein into place along the established track.
[0033] After being delivered to the right place, the robot arm 1500 starts to operate flexibly according to the preset motion trajectory, driving the welding electrode head 200 to move accurately to the position above the safety capacitor core package 1600 to be welded, and then the welding electrode head 200 is steadily pressed down by the clamping module 100 to fully contact the surface of the core package. This ensures that the safety capacitor core package 1600 will not become loose during the welding process, thereby ensuring the welding quality.
[0034] During the welding process, the operator needs to stay focused at all times and closely observe the data displayed on the clamping force monitoring table to ensure that the clamping force is always within a reasonable range to avoid problems such as poor welding or damage to the safety capacitor core package 1600 due to excessive or insufficient pressure. At the same time, pay attention to the real-time changes in welding parameters to check whether the welding current, voltage, etc. are stable and whether there are abnormal fluctuations. Once any abnormality in the clamping force or welding parameters is found, the operator must immediately press the emergency stop button to stop the welding operation and investigate and deal with the problem; if it is confirmed that all data are correct after observation, the entire welding system will continue to automatically perform resistance welding on the safety capacitor core package 1600, and the welding electrode head 200 will release energy stably according to the set time, current and other parameters, so that the welding parts of the safety capacitor core package 1600 are gradually welded and fused until all preset welding points are welded and the entire welding process ends smoothly. Finally, the robot arm 1500 will return to the initial standby position in an orderly manner according to the homing procedure, waiting for the next welding task instruction, and preparing for the next round of welding work of the safety capacitor core package 1600.
[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein by equivalents. These modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be included in the scope of the claims and specification of the present invention.
Claims
1. A safety capacitor core resistance welding system, characterized in that: It includes a welding unit and a positioning and conveying unit; The welding unit comprises a clamping module (100), the output end of the lower end of the clamping module (100) is connected to a welding electrode head (200), the welding electrode head (200) is driven by the clamping module (100) to move vertically up and down, and the clamping module (100) is also provided with a pressure monitoring gauge (300), the monitoring end of the pressure monitoring gauge (300) is against the assembly part (210) provided at the upper end of the welding electrode head (200), and is used to monitor the contact pressure between the welding electrode head (200) and the capacitor core package (1600); The positioning and conveying unit comprises a base (400), a positioning slide (500) is provided at the upper end of the base (400), a guide rail module (600) for driving the positioning slide (500) is provided inside the base (400), a detachable contoured positioning base plate (700) is installed at the upper end of the positioning slide (500), and a contoured fixture (800) for accommodating a welding capacitor core package (1600) is provided on the contoured positioning base plate (700).
2. The safety capacitor core package resistance welding system according to claim 1 is characterized in that: A mounting frame (900) is provided on the outside of the pressing module (100), and an adapter plate (910) connected to the three-dimensional mechanical arm (1500) is provided on the mounting frame (900).
3. The safety capacitor core package resistance welding system according to claim 1 is characterized in that: The upper end of the compression module (100) is provided with a welding cable connector (1000) which is connected to the welding electrode head (200) via a cable.
4. The safety capacitor core package resistance welding system according to claim 1 is characterized in that: Photoelectric limit modules (1100) are provided at two ends of the base (400) corresponding to the sliding direction of the positioning slide (500).
5. The safety capacitor core package resistance welding system according to claim 1 is characterized in that: The end of the base (400) is provided with a control line interface (1200) for signal connection with the guide rail module (600).
6. The safety capacitor core package resistance welding system according to claim 1 is characterized in that: It also includes a control system connected to the welding unit and the positioning and conveying system signals, wherein the control system is connected to a teaching pendant assembly (1300) and a control button assembly (1400).
7. A resistance welding process using the safety capacitor core resistance welding system as claimed in any one of claims 1 to 6, characterized in that: The steps include: S1. Capacitor core package placement; the operator first loads the safety capacitor core package (1600) into the profiling fixture (800), and then carefully places the profiling fixture (800) containing the safety capacitor core package (1600) into the profiling positioning base plate (700); S2. Selecting a welding procedure, the operator uses the teaching pendant assembly (1300) to select a pre-set welding procedure, confirms that the welding procedure meets the welding requirements of the current safety capacitor core package (1600), and then starts welding through the control button assembly (1400); S3. Welding starts. After the positioning and conveying unit conveys the safety capacitor core package (1600) to the welding station, the robot arm (1500) drives the welding electrode head (200) to move accurately to the position above the safety capacitor core package (1600) to be welded according to a preset motion trajectory. The welding electrode head (200) maintains an appropriate clamping force through the clamping module (100) and performs automatic welding.