Multi-station coil for electromagnetic pulse welding of aluminum-copper composite busbar connecting piece

Abstract

The invention provides a multi-station coil for electromagnetic pulse welding of an aluminum-copper composite busbar connecting piece, which comprises a C-shaped welding coil module, and the coil is formed by oppositely arranging a left C-shaped coil and a right C-shaped coil; a gap is reserved between the front ends of the left C-shaped coil and the right C-shaped coil, so that the front end of the C-shaped welding coil module is provided with an open opening; at the rear end, the left C-shaped coil and the right C-shaped coil form a plurality of side-by-side frame areas; each frame area is provided with a welding copper bar; the welding copper bar limiting module is used for limiting each welding copper bar; the C-shaped welding coil module and the copper bar connecting limiting module are mounted on the upper surface of the coil mounting module; and a coil pole busbar module is fixed at the through hole on the lower surface of the coil mounting module. By means of the innovative coil design, efficient transmission of energy is achieved, the replacement difficulty is lowered, multi-station welding is supported, and the adaptability and production efficiency of the welding technology are greatly improved.

Description

Technical Field

[0001] The present invention belongs to the field of magnetic pulse welding technology, and specifically relates to a multi-station coil for electromagnetic pulse welding of aluminum-copper composite busbar connectors. This technology is suitable for welding of dissimilar metals such as aluminum-copper composite busbar connectors, and is widely used in industries such as automobile manufacturing, power electronics, and energy storage equipment. Background Art

[0002] Magnetic pulse welding is an efficient solid-state welding technology based on the principle of electromagnetic induction. It uses the electromagnetic force generated by an instantaneous strong magnetic field to drive the metal workpieces to collide at high speed and achieve metallurgical bonding. Since no heating is required during the welding process, no melting and heat-affected zones will be generated, magnetic pulse welding is particularly suitable for the connection of dissimilar metals, such as aluminum and copper, aluminum and steel, etc. Its welding characteristics include high-strength bonding, no heat-affected zone, and high-speed and pollution-free operation. Therefore, it has been widely used in the fields of automobile manufacturing, aerospace, power electronics, and energy storage equipment. In the automotive industry, magnetic pulse welding is used for aluminum-steel connections in lightweight body design and aluminum-copper connecting piece welding in power battery systems. This technology effectively solves the problem of large differences in the melting points of dissimilar metals and the easy formation of brittle compounds at the welding interface in the traditional melting welding method. At the same time, the magnetic pulse welding process is fast and efficient, which can greatly shorten the welding time and improve production efficiency.

[0003] Although magnetic pulse welding technology has many advantages, its development still faces some technical bottlenecks. The design and performance of the core component, the coil, play a decisive role in the realization of the technology. The current coil design has shortcomings in energy utilization, magnetic field distribution uniformity, and flexibility.

[0004] At present, the common types of coils include single coils, split coils and uniform pressure coils. The single coil has a simple structure and is mainly suitable for welding a single workpiece, but the welding efficiency is low and cannot meet the needs of industrial mass production; the split coil provides a certain degree of flexibility, but the magnetic field distribution is uneven, the energy loss is large, and the replacement process is complicated, time-consuming and labor-intensive; the uniform pressure coil achieves uniform distribution of welding pressure by optimizing the magnetic field distribution, which improves the welding quality, but its design and manufacturing costs are high, and there are still deficiencies in energy utilization efficiency. In addition, the current coil design is mostly an integral structure, which needs to be replaced as a whole once damaged. This design not only leads to high maintenance costs and long downtime, but also increases the complexity and inconvenience of equipment use during the production process, especially in high-frequency use scenarios. The impact on production efficiency is particularly obvious. The integral coil lacks a modular design, so even if it is partially damaged, the entire set of coil components needs to be replaced, which greatly increases the maintenance burden of equipment operation. Summary of the invention

[0005] In view of the above technical problems, the present invention provides a multi-station coil for electromagnetic pulse welding of aluminum-copper composite busbar connectors, which adopts a new coil structure with high energy utilization, easy maintenance and modular design, so as to effectively solve the limitations of the integral coil and improve the industrial adaptability and economy of the magnetic pulse welding technology.

[0006] The specific technical solution is:

[0007] A multi-station coil for electromagnetic pulse welding of aluminum-copper composite busbar connectors, comprising a C-shaped welding coil module, the C-shaped welding coil module comprising a coil, the coil being composed of a left C-shaped coil and a right C-shaped coil arranged relatively to each other; the left C-shaped coil is symmetrical to the right C-shaped coil; a gap is left between the front ends of the left C-shaped coil and the right C-shaped coil, so that the front end of the C-shaped welding coil module has an open opening; at the rear end of the C-shaped welding coil module, the left C-shaped coil and the right C-shaped coil form a plurality of parallel frame areas; preferably, five frame areas are provided; each frame area is provided with a welding copper strip;

[0008] It also includes a welding copper bar limiting module, which is arranged below the rear end of the C-shaped welding coil module. The welding copper bar limiting module includes a welding copper bar pad, on which a plurality of parallel welding copper bar positioning blocks are arranged, and a limiting groove is formed between adjacent welding copper bar positioning blocks for limiting each welding copper bar;

[0009] The C-shaped welding coil module and the copper bar limit module are installed on the upper surface of the coil installation module;

[0010] A through hole is provided at the front end of the coil mounting module, corresponding to the opening at the front end of the C-shaped welding coil module;

[0011] A coil pole bus module is fixed at the through hole on the lower surface of the coil mounting module;

[0012] The coil pole bus module includes, from top to bottom, a coil positive and negative bus connection seat, a coil positive and negative bus cable connection block, and a coil positive and negative bus cable pressing block; two rows of cable jacks are formed between the coil positive and negative bus connection seat, the coil positive and negative bus cable connection block, and the coil positive and negative bus cable pressing block for installing cables.

[0013] Existing magnetic pulse welding coils generally have problems such as low energy utilization, large heat loss, complex replacement operation, and insufficient welding stations, which limits production efficiency and cannot meet the needs of diversified industrial production. The present invention realizes efficient energy transmission through innovative coil design, reduces the difficulty of replacement, supports multi-station welding, and greatly improves the adaptability and production efficiency of the welding process.

[0014] The technical effects of the present invention are as follows:

[0015] 1. A new coil module configuration is adopted, and the working area is C-shaped, which reduces the overall inductance.: The working area of ​​the coil of the present invention adopts a micro-C-shaped design. Compared with traditional coils, its structure is more compact and the magnetic circuit is significantly optimized. The main advantage of the micro-C-shaped configuration is that it significantly reduces the overall inductance of the coil, which greatly shortens the discharge cycle of the circuit. The shortened discharge cycle means that the coil can release the stored energy more quickly, thereby generating a higher welding current peak with the same energy input. A higher current peak can generate a greater electromagnetic force between the workpieces, accelerate the metal collision in the welding area, and achieve more efficient solid-state welding. In addition, this optimized inductance characteristic also reduces the energy loss in the circuit, improves the conversion efficiency of electrical energy to magnetic energy, and significantly improves energy utilization.

[0016] 2. The multi-station welding design can weld multiple workpieces at the same time, improving production efficiency: its working area is divided into multiple independent welding modules, each module can be used as a separate welding station. Through this multi-station design, the coil can weld multiple workpieces at the same time, realizing the efficient needs of mass production. This design greatly reduces the waiting time during the welding process and improves production efficiency.

[0017] 3. The coil working area adopts an assembled modular design, which can be disassembled and replaced for easy maintenance: The coil working area of ​​the present invention adopts an assembled modular design, and each welding module can be disassembled and replaced independently. When a certain station module fails due to long-term use or accidental damage, there is no need to replace the entire coil structure. Only the damaged module needs to be replaced to restore normal operation. This design greatly reduces maintenance costs and avoids the high cost required for overall replacement of the coil. At the same time, it reduces equipment downtime and improves the operating efficiency of the production line. In addition, the modular design also provides extremely high flexibility. Users can replace welding modules of corresponding shapes according to different production requirements to adapt to a variety of processing scenarios. For example, according to the welding requirements of different workpieces, suitable shape and size modules can be selected to achieve more efficient welding performance. This design further improves the service life and overall reliability of the coil, providing a stable and efficient solution for industrial production.

[0018] 4. The open coil design has better heat dissipation, ensuring welding efficiency and longer service life: Due to the working principle of magnetic pulse welding, the coil is prone to heat up after a long period of high-frequency current, resulting in increased coil resistance and weakened welding current. This coil adopts an open design to ensure that heat can be dissipated quickly, improving welding energy utilization and coil service life. At the same time, it is convenient for clamping and placing workpieces, improving operational convenience. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1It is one of the overall structural schematic diagrams of the present invention;

[0020] Figure 2 This is the second schematic diagram of the overall structure of the present invention;

[0021] Figure 3 It is a schematic diagram of the structure of each component of the present invention;

[0022] Figure 4 is an exploded view of the present invention;

[0023] Figure 5 It is a schematic diagram of the use of the present invention. DETAILED DESCRIPTION

[0024] The specific technical solution of the present invention is described in conjunction with the accompanying drawings.

[0025] like Figures 1 to 4 As shown, a multi-station coil for electromagnetic pulse welding of aluminum-copper composite busbar connectors includes a C-shaped welding coil module 100, and the C-shaped welding coil module 100 includes a coil, wherein the coil is composed of a left C-shaped coil 102 and a right C-shaped coil 103 arranged relatively to each other; the left C-shaped coil 102 is symmetrical to the right C-shaped coil 103; a gap is left between the front ends of the left C-shaped coil 102 and the right C-shaped coil 103, so that the front end of the C-shaped welding coil module 100 has an open opening; at the rear end of the C-shaped welding coil module 100, the left C-shaped coil 102 and the right C-shaped coil 103 form a plurality of parallel frame areas; each frame area is provided with a welding copper strip 101; this embodiment has five frame areas.

[0026] It also includes a welding copper bar limiting module 200, which is arranged below the rear end of the C-shaped welding coil module 100. The welding copper bar limiting module 200 includes a welding copper bar pad 202, on which a plurality of parallel welding copper bar positioning blocks 201 are arranged, and limiting grooves are formed between adjacent welding copper bar positioning blocks 201 for limiting each welding copper bar 101;

[0027] The C-shaped welding coil module 100 and the copper bar limiting module 200 are installed on the upper surface of the coil installation module 300;

[0028] The front end of the coil mounting module 300 is provided with a through hole, corresponding to the opening at the front end of the C-shaped welding coil module 100;

[0029] On the lower surface of the coil mounting module 300, a coil pole busbar module 400 is fixed at the through hole;

[0030] like Figure 4The coil pole bus module 400 includes, from top to bottom, a coil positive and negative bus connection seat 401, a coil positive and negative bus cable connection block 401, and a coil positive and negative bus cable pressing block 401; two rows of cable jacks are formed between the coil positive and negative bus connection seat 401, the coil positive and negative bus cable connection block 401, and the coil positive and negative bus cable pressing block 401 for installing cables 404.

[0031] Each frame composed of the welding copper strip 101, the left C-shaped coil 102, and the right C-shaped coil 103 is an independent module, which can be used for individual replacement or independent operation. The overall structure consists of a modularly designed welding coil module 100 and an open welding copper strip limit module 200. The coil mounting module 300 provides a stable mounting base, and the open welding coil module 100 is designed to concentrate the magnetic field on the rear end frame area for welding operations. The left C-shaped coil 102 and the right C-shaped coil 103 are made of highly conductive materials, such as copper or copper alloys, to reduce resistance and efficiently generate a strong magnetic field.

[0032] like Figure 5 When the coil is working, a strong magnetic field is generated by passing a high-frequency current into the inside of the coil. The magnetic field is concentrated in the upper welding copper strip 101 area of ​​the C-shaped welding coil module 100. The welding part of the welding workpiece 500 to be welded is located on the welding copper strip 101. The strong magnetic field acts on the surface of the welding workpiece 500, driving the welding workpiece 500 to collide with each other at a very high speed to achieve solid-state welding. The concentration of the magnetic field ensures high energy utilization efficiency in the welding area, and there is no heat-affected zone during the welding process, which ensures the strength and quality of the welded joint. Each narrow frame is an independent welding station, which supports the simultaneous welding of multiple workpieces and greatly improves production efficiency. In addition, the modular design allows each frame to be replaced separately. When a certain area is damaged, there is no need to replace the coil as a whole, which greatly reduces maintenance costs and downtime. Its open structure also enhances the adaptability to workpieces of different sizes and shapes, providing an efficient and reliable solution for mass production.

[0033] Dynamic working process of the present invention:

[0034] After the coil is installed and fixed on the welding equipment, the workpiece is first clamped into the welding area of ​​the narrower welding copper strip 101 at the rear end to ensure accurate positioning of the workpiece. The narrow frame design of the welding copper strip 101 combined with the hole structure provides precise physical positioning support for the workpiece and facilitates the concentration of the magnetic field. Before welding begins, a high-frequency and high-current is passed through the coil through the equipment. Due to the uniqueness of the structural design of the C-shaped welding coil module 100, the coil generates a high-intensity instantaneous magnetic field in its opening area, and the magnetic field is highly concentrated in the workpiece area inside the right frame, acting on the workpiece surface.

[0035] When the magnetic field acts on the workpiece, induced currents are generated in the workpiece, and these induced currents generate strong electromagnetic forces between the workpieces through interaction. This electromagnetic force drives the surfaces of the workpieces to collide with each other at extremely high speeds, causing the materials in the collision area to undergo severe plastic deformation, removing the oxide film and contamination layer on the surface of the workpiece, forming a clean metal contact interface, and thus achieving metallurgical bonding. The entire welding process is completed within microseconds, and since welding is a solid-state process, no heating is required, avoiding the heat-affected zone in traditional welding, and ensuring the strength and toughness of the welded joint.

[0036] The multi-station design of the coil allows each narrower welding copper strip 101 to be welded at the same time. The workpieces on the first, second, third to fifth stations can be clamped at the same time, and the welding task of multiple workpieces can be completed at the same time, thereby significantly improving production efficiency. At the same time, the modular design of the welding coil module allows the module to be directly disassembled and replaced when the frame module of a station is damaged, without having to replace the entire coil equipment as a whole, reducing equipment downtime and maintenance costs.

[0037] During the whole process, considering that a lot of heat is generated during the long-term welding of the coil, in order to improve the life of the coil, the open design of the coil ensures that the heat can be dissipated quickly, while facilitating the clamping and placement of the workpiece, improving the convenience of operation. In addition, the advantages of the C-shaped coil module in magnetic field concentration and energy utilization efficiency enable it to perform excellent performance in welding different workpiece materials (such as aluminum-copper connections) and shapes (such as special-shaped parts). In short, the coil achieves high-quality welding process and flexible industrial adaptability through modular, open and efficient magnetic field utilization design.

Claims

1. A multi-station coil for electromagnetic pulse welding of aluminum-copper composite busbar connectors, characterized in that: The invention comprises a C-shaped welding coil module (100), wherein the C-shaped welding coil module (100) comprises a coil, wherein the coil is composed of a left C-shaped coil (102) and a right C-shaped coil (103) arranged opposite to each other; the left C-shaped coil (102) and the right C-shaped coil (103) are symmetrical; a gap is left between the front ends of the left C-shaped coil (102) and the right C-shaped coil (103), so that the front end of the C-shaped welding coil module (100) has an open opening; at the rear end of the C-shaped welding coil module (100), the left C-shaped coil (102) and the right C-shaped coil (103) form a plurality of parallel frame areas; each frame area is provided with a welding copper strip (101); It also includes a welding copper bar limiting module (200), which is arranged below the rear end of the C-shaped welding coil module (100) and is used to limit the position of each welding copper bar (101); The C-shaped welding coil module (100) and the copper bar limiting module (200) are installed on the upper surface of the coil installation module (300); A through hole is provided at the front end of the coil mounting module (300), corresponding to the opening at the front end of the C-shaped welding coil module (100); A coil pole bus module (400) is fixed at a through hole on the lower surface of the coil mounting module (300).

2. The multi-station coil for electromagnetic pulse welding of aluminum-copper composite busbar connector according to claim 1, characterized in that: The welding copper bar limiting module (200) comprises a welding copper bar pad (202), on which a plurality of parallel welding copper bar positioning blocks (201) are arranged, and between adjacent welding copper bar positioning blocks (201) a limiting groove is formed for limiting each welding copper bar (101).

3. The multi-station coil for electromagnetic pulse welding of aluminum-copper composite busbar connector according to claim 1, characterized in that: The coil pole bus module (400) comprises, from top to bottom, a coil positive and negative bus connection seat (401), a coil positive and negative bus cable connection block (401), and a coil positive and negative bus cable pressing block (401); two rows of cable jacks are formed between the coil positive and negative bus connection seat (401), the coil positive and negative bus cable connection block (401), and the coil positive and negative bus cable pressing block (401) for installing cables (404).

4. The multi-station coil for electromagnetic pulse welding of aluminum-copper composite busbar connector according to claim 1, characterized in that: There are five border areas.

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