Intelligent electric meter multi-element collaborative efficient precision machining and quality control technology and equipment

Abstract

The invention discloses a multi-element cooperative efficient precision machining and quality control technology and equipment for an intelligent electric meter, and the technology equipment is characterized in that a plurality of intelligent machines cooperate to form an automatic assembly line, and a terminal copper bar assembly machine uses a multi-element cooperative flexible clamp to precisely assemble a switch unit and a copper terminal of a mutual inductor to form a terminal box unit; the soldering lug assembly machine efficiently and accurately welds soldering lugs to copper end buttons by means of ultra-thin soldering lug filtering, a three-stage amplification welding head, automatic cutting and intelligent grabbing and a multi-element integrated flexible integrated assembly clamp. And the welding inspection integrated machine and the comprehensive performance testing machine participate in cooperation. High-quality welding inspection integration of the mutual inductor, the relay and the terminal box unit is achieved together, and multi-element cooperative efficient precision production and multi-process cooperative control are achieved. According to the technology, product quality tracing is completed, the production stability and quality in a complex environment are guaranteed, the production efficiency is greatly improved, the labor cost is reduced, and the technology is suitable for multi-element high-precision collaborative flexible welding inspection and automatic blanking, welding and precise machining of ultrathin elements.

Description

Technical Field

[0001] The present invention relates to the technical field of equipment, and particularly to the technology and equipment for multi - collaborative, efficient, precise machining and quality control of smart meters. Background Art

[0002] I. Development and Application Requirements of Smart Meters Smart meters are the basis for carbon, energy efficiency, electricity quantity, and billing metering under the background of the new - type power system's energy dual - carbon. They are large in quantity and wide in application scope. Their reliability and accuracy are crucial for the safe operation of the power grid and users, as well as for economic and property interests.

[0003] Popularization of smart meters: With the advancement of the intellectualization of the power system, traditional meters are gradually replaced by smart meters. Smart meters can monitor the power consumption in real - time, achieve remote meter reading, two - way communication, and support functions such as time - of - use electricity price, bringing great convenience to power management and user use. Globally, countries are vigorously promoting the installation and application of smart meters, and their market scale continues to expand, which puts higher requirements on the production efficiency and quality of smart meters.

[0004] 1. Complicated processing procedures of traditional smart meters: Smart meters include components such as a switch unit (relay or circuit breaker), current transformer, and copper bars of terminal blocks. Most of the components are welded naked, and at least two sets of welding equipment and fixtures are required. The existing processing methods have cumbersome procedures, long turnover cycles, and low efficiency. For example, from the welding of the switch unit and the copper bar of the terminal block to the welding of the current transformer and the copper bar of the terminal block, multiple equipment replacements, workpiece clamping, and positioning are involved in the middle, resulting in a long - time consumption of the entire processing process.

[0005] 2. High degree of manual participation: Currently, the processing of smart meters relies on the cooperation of manual processing and assembly - line operations. Manual operations are not only slow but also prone to human errors, such as welding position deviation and unstable welding quality. At the same time, with the continuous increase of labor costs, the processing mode with a high degree of manual participation makes the production cost remain high, seriously affecting the economic benefits and market competitiveness of enterprises.

[0006] 3. Difficulty in realizing automated processing: To realize the automation of smart meter processing, it is necessary to solve the connection and coordination problems of multiple technical links. This includes how to accurately install the copper terminal buttons of the switch unit and the current transformer to the terminal block body, how to automatically cut, feed, and weld ultra - thin solder pads, and how to effectively detect the performance after welding. In actual operation, the equipment and processes of each processing link need to be closely coordinated. Any problem in any link may lead to the interruption of the automated process. For example, the coordination between the automatic cutting and feeding unit and the ultrasonic welding machine in the solder pad assembly machine, and the linkage of the welding, detection, and control mechanisms in the integrated welding, inspection, and assembly machine, all pose great challenges to automated processing.

[0007] 4. Equipment integration and layout challenges: When constructing the intelligent electricity meter processing equipment system, the integration and reasonable layout of equipment are major difficulties. For example, although the use of a rotary conveyor line for the solder tab assembly machine can reduce the volume, it is necessary to accurately set up stations such as feeding, inspection, welding, and discharging to ensure smooth connection between each station. Otherwise, processing bottlenecks are likely to occur. At the same time, the spatial layout between different equipment should take into account operation convenience, material transfer efficiency, and accessibility for maintenance and repair. It is not easy to achieve efficient equipment integration within a limited production space.

[0008] 5. Complex inspection process: There are many difficulties in comprehensively and accurately inspecting the welded intelligent electricity meters. The welding inspection performance testing machine needs to detect multiple indicators such as welding firmness, welding tensile force, welding resistance, loop conduction, low voltage resistance, coil resistance, coil primary current, DC component, and DC resistance. To achieve such complex inspection functions, not only high-precision multi-performance floating inspection jigs and probes are required, but also parameters such as pressure and stroke during the inspection process need to be precisely controlled to ensure the reliability and consistency of the inspection results. Any error in any inspection link may lead to unqualified products flowing into the market.

[0009] 6. Challenges in fixture design: It is difficult to design fixtures suitable for intelligent electricity meter processing. For example, the assembly fixture of the terminal copper bar assembly machine needs to accurately fix the copper terminals of the switch unit and the current transformer and ensure the installation accuracy with the terminal box body; the first fixture needs to adapt to the fixation and rotation of the switch unit or current transformer to meet the requirements of different welding positions. The fixture should not only ensure the positioning accuracy of parts but also have good versatility and adjustability to adapt to the processing of different models of intelligent electricity meters. At the same time, its durability and maintenance convenience also need to be considered.

[0010] 7. Difficulties in ultra-thin solder tab processing: When dealing with ultra-thin silver-copper-phosphorus solder tabs with a thickness of 0.03 - 0.12 mm, there are various difficulties in cutting, grasping, and welding. During cutting, it is necessary to ensure that the dimensional accuracy is controlled within a very small range to avoid problems such as burrs, tears, and deformations at the edges, while overcoming the influence of material properties and static electricity. In the automatic grasping and feeding link, challenges such as the small size, light and thin characteristics, smooth surface, and high positioning accuracy requirements of the solder tabs need to be addressed. During welding, controlling the welding time and ultrasonic energy output becomes crucial. A slight mistake may result in problems such as overheating, deformation, welding breakage, perforation, or poor welding of the solder tabs, or even failure to achieve welding. The specific technical difficulties are as follows: (1) Difficulties in cutting ultra-thin solder tabs Dimensional accuracy control: Ultra-thin solder tabs with a thickness of 0.03 - 0.12 mm have extremely high requirements for cutting dimensional accuracy. A tiny error may cause the solder tabs to fail to meet the usage requirements. The thickness uniformity of the material itself, the accuracy of the cutting equipment, and the stress changes during the cutting process will all affect the final cutting dimensional accuracy.

[0011] Edge quality control: During the cutting process of ultra-thin solder pads, problems such as edge burrs, tearing, and deformation are likely to occur. This not only affects the appearance quality of the solder pads but may also lead to a decline in electrical performance or even short circuits during subsequent use.

[0012] Influence of material properties: The silver-copper-phosphorus alloy has a certain hardness and toughness. Its mechanical properties will change in the ultra-thin state, increasing the cutting difficulty. The hardness of the material may cause increased tool wear, while the toughness may cause phenomena such as springback of the solder pad during cutting, affecting the cutting quality.

[0013] Electrostatic problems: During the cutting process, due to the friction between the material, the tool, and the equipment, static electricity is easily generated. Static electricity may adsorb impurities such as dust, polluting the surface of the solder pad. At the same time, it may also cause electrostatic discharge, potentially damaging the performance of the solder pad.

[0014] Welding problems and the influence of temperature and humidity on soldering: The existing ultrasonic equipment's welding head has problems such as clutter and harmonics and unstable output energy, making it impossible to achieve the welding of ultra-thin silver-copper-phosphorus solder pads or copper-phosphorus ultra-thin welding. The existing ultrasonic energy cannot be adjusted, and the rough ultrasonic energy cannot achieve welding for ultra-thin solder pads that are welded and broken. Factors such as environmental temperature, humidity, and air quality will all affect the processing quality. For example, if the environmental humidity is too high, the silver-copper-phosphorus solder pads are easily affected by moisture and oxidation, affecting the welding effect; dust and impurities in the workshop may adsorb on the surface of the solder pad, resulting in welding defects and false soldering.

[0015] (2) Difficulties in automatic grasping and feeding Microscopic size and light and thin characteristics: The solder pads are small in size and extremely thin in thickness, which poses extremely high requirements for the accuracy and stability of the grasping mechanism. Conventional grasping methods may not be able to accurately and stably grasp the solder pads, easily resulting in situations such as insecure grasping, dropping, or damaging the solder pads.

[0016] Surface characteristics: The surface of the silver-copper-phosphorus solder pads is usually relatively smooth and may have a certain amount of grease or oxide layer, which will affect the friction and adsorption force during grasping. The grasping mechanism needs to have an appropriate grasping force and contact method to ensure that the solder pads do not slide or fall off during the grasping and feeding process.

[0017] Positioning accuracy: Automatic grasping and feeding require an accurate positioning system to ensure that the solder pads can be accurately placed in the specified position. Due to the microscopic size of the solder pads, the positioning error must be controlled within an extremely small range, otherwise it may lead to deviation in the welding position, affecting the welding quality.

[0018] Speed and efficiency: In actual production, it is necessary to improve the operation speed on the premise of ensuring the accuracy of grasping and feeding, so as to meet the requirements of production efficiency. This requires optimizing the grasping path, improving the response speed of the equipment, etc. At the same time, it is necessary to ensure that there is no shaking or dropping of the solder pads during high-speed movement.

[0019] 8. Stability of multi-device collaborative operation: The processing of smart meters involves the collaborative operation of multiple devices such as terminal copper bar assembly machines, solder pad assembly machines, welding and inspection integrated machines, and welding and inspection performance testing machines. The operating speeds and rhythms of different devices need to be precisely matched. Any malfunction or unstable operation of a single device may affect the continuity and production efficiency of the entire processing flow. For example, if the rotation speed of the turntable of the solder pad assembly machine does not match the working rhythms of the automatic cutting and feeding unit and the ultrasonic welding machine, it will lead to material backlog or idling waiting situations.

[0020] 9. Strict requirements for the production environment: The processing of smart meters has relatively high requirements for the production environment. Factors such as environmental temperature, humidity, and air quality will all affect the processing quality. For example, if the environmental humidity is too high, the silver-copper-phosphorus solder pads are prone to moisture oxidation, affecting the welding effect; dust and impurities in the workshop may adhere to the surface of the solder pads, resulting in welding defects. Maintaining a stable and suitable production environment requires the installation of special environmental control equipment and continuous monitoring and adjustment of environmental parameters, increasing production costs and management difficulties. Summary of the Invention

[0021] Therefore, this invention is mainly applied to the field of smart meter processing equipment, aiming to solve a series of key technical problems in the welding connection and detection between the terminal box unit, switch unit, and mutual inductor during the production process of smart meters. Aiming at problems such as the complicated traditional smart meter processing procedures, high manual participation, difficulty in achieving automation, difficulties in equipment integration and layout, complex detection links, challenges in fixture design, and problems in ultra-thin solder pad processing, a set of multi-element collaborative processing equipment system is innovatively constructed.

[0022] Through the organic collaboration of the terminal copper bar assembly machine, solder pad assembly machine, welding and inspection integrated machine, and welding and inspection performance testing machine, a highly automated assembly line production mode is formed, greatly improving production efficiency and significantly reducing labor costs. Remarkable achievements have been made in key technological innovations. For example, the uniquely designed welding head realizes fine filtering and three-stage amplification of ultrasonic amplitude, solves the problems of clutter, harmonics, and unstable energy in existing equipment, and meets the high-quality welding requirements of ultra-thin solder pads with different thicknesses; the multi-component integrated flexible one-piece assembly fixture and the assembly fixture with precise guiding and limiting greatly improve the assembly accuracy and stability; through measures such as ion extraction fans and copper wire grounding, electrostatic interference is effectively eliminated, reducing the influence of environmental factors on processing quality; the multi-process collaborative control system realizes precise control of each process in terms of time, space, and process parameters; the perfect product quality traceability system can quickly and accurately trace the root cause of quality problems.

[0023] The present invention comprehensively improves the processing quality and production efficiency of smart meters, promotes the technological upgrading of the industry, makes significant breakthroughs in aspects such as high-efficiency production, high-quality manufacturing, environmental adaptability, equipment maintenance, and quality control, and has remarkable economic and social benefits, providing strong technical support and equipment guarantee for the development of the smart meter industry.

[0024] Therefore, the technologies and equipment for multi-collaborative, high-efficiency, precision machining and quality control of smart meters specifically include: Terminal copper bar assembly machine, which includes a fixed seat for fixing the terminal box body and an assembly fixture for fixing the copper terminals of the switch unit and the current transformer. The terminal copper bar assembly machine installs the copper terminals of the switch unit and the current transformer onto the terminal box body to form a terminal box unit; Welding sheet assembly machine, which includes an automatic cutting and feeding unit, an ultrasonic welding machine, and a first fixture provided with a profiling cavity. The profiling cavity fixes the switch unit or the current transformer; the automatic cutting and feeding unit performs cutting and feeding of the welding sheets; the ultrasonic welding machine welds the welding sheets to the switch unit or the current transformer; Welding and inspection integrated machine, the switch unit is fixed with a second conductive part, the current transformer is fixed with a third conductive part, and the second conductive part and the third conductive part are respectively welded and fixed to the welding sheets; the welding and inspection integrated machine welds and connects the second conductive part to the copper terminal of the switch unit; the welding and inspection integrated machine welds and connects the third conductive part to the copper terminal of the current transformer; Welding, inspection and performance testing machine, which includes a multi-performance floating detection fixture, and the multi-performance floating detection fixture detects the terminal box unit welded with the switch unit and the current transformer.

[0025] The welding sheet assembly machine includes a turntable, and the turntable is provided with a loading station, a detection station, a welding station, and an unloading station. The number of the first fixtures is at least four, and the first fixtures are respectively located at the corresponding stations; the ultrasonic welding machine cooperates with the welding station.

[0026] The first fixture includes an outer sliding sleeve, an inner sliding sleeve, a profiling assembly fixture, a support rod, a lower nut, a floating ball, and a first elastic member. The inner sliding sleeve is located inside the outer sliding sleeve, and the inner sliding sleeve axially slides relative to the outer sliding sleeve. The floating ball and the first elastic member are located between the outer sliding sleeve and the inner sliding sleeve. The first elastic member gives the floating ball an extrusion force to press against the side wall of the inner sliding sleeve. One end of the support rod is linked with one end of the lower nut, and the other end of the lower nut cooperates with the profiling assembly fixture; the profiling cavity is arranged on the profiling assembly fixture.

[0027] The welding sheet assembly machine further includes a lifting and rotating mechanism, and the lifting and rotating mechanism cooperates with the support rod to form the lifting and rotation of the switch unit or the current transformer.

[0028] The solder tab assembling machine further includes a blanking mechanism, the blanking mechanism includes a sliding jaw, the blanking mechanism cooperates with the blanking station, and the sliding jaw cooperates with the switch unit after welding or the current transformer after welding.

[0029] The profiling assembling jig is sleeved with an assembling jig. The assembling jig is composed of a first L-shaped plate. A square groove for assembling the switch unit is provided on the low-end plate of the first L-shaped plate. Multiple arrayed second vacuum suction holes for locking the switch unit are arranged in the square groove. A fifth U-shaped groove for the position communication socket is provided at the rear end of the square groove. A first U-shaped groove for limiting the moving contact piece is provided at the left end of the high-end plate of the first L-shaped plate. Communicating with the first U-shaped groove is an L-shaped platform for positioning and limiting the first copper solder tab and the third copper solder tab. Connected to the limiting L-shaped platform is a lower step platform. Connected to the lower step platform is a second U-shaped groove. The lower step platform and the second U-shaped groove are used for positioning the lead pins on the current transformer. Adjacent to the second U-shaped groove and the limiting L-shaped platform is a positioning and locking groove for the current transformer. The positioning and locking groove is an arc groove provided with multiple arrayed third vacuum suction holes for locking the current transformer. Adjacent to the positioning and locking groove is a third U-shaped groove for limiting the fourth copper solder tab. The bottom plate of the third U-shaped groove is provided with a fourth U-shaped groove for limiting the B soft wire. Adjacent to the right end of the third U-shaped groove is a second L-shaped plate provided with an L-shaped platform for positioning and limiting the first copper solder tab and the fourth copper solder tab. An L-shaped groove plate is arranged on the L-shaped platform, and a vacuum valve is arranged on the L-shaped groove plate.

[0030] The ultrasonic welding machine includes an ultrasonic generator, a first pressing cylinder, a support frame, a housing, a guide post, an ion extractor fan, and a pneumatic valve. The ultrasonic generator is accommodated in the housing. The first pressing cylinder is linked with the ultrasonic generator. The ultrasonic generator is connected to the support frame. The support frame slides relative to the guide post. The extractor fan evacuates the inside of the housing. The pneumatic valve is used to adjust the air pressure.

[0031] The ultrasonic welding machine further includes a horn, a screw rod, and a welding head. The ultrasonic generator is input to the horn through a transducer. The horn is conveyed to the welding head through the screw rod. The amplitude thereof is input from the rear end face of the welding head to the welding teeth, which is a cylinder, and the axis of the cylinder is perpendicular to the rear end face. A fine-threaded screw hole is provided at the center of the rear end face. A coarse-threaded screw hole is provided at the center of the output end of the horn. The rear end conducts energy at a ratio of 1:1 through a first cone and amplifies the amplitude energy at the second stage. The amplified amplitude energy is conveyed to a third cone through a second cylinder. An arc is provided on the third cone. The arc shrinks and concentrates the energy to a flat body. The flat body conducts energy at the third stage to the welding head. The amplitude and energy on the welding head are conveyed to the welding teeth through the energy conducting ribs.

[0032] The automatic cutting and feeding unit includes a stand, on which a friction adjustment unit, a friction gap, and a first guide groove are arranged in sequence from right to left; a cutting cylinder and a cutting knife are arranged on the side at the upper end of the second guide width slide, and the side elevation of the blade is parallel to the welding piece and the outer end surface of the first guide groove plate; a U-shaped suction nozzle is arranged adjacent to the cutting knife gap, and a pair of first vacuum suction holes are arranged on the bottom surfaces of both ends of the U-shaped suction nozzle; the U-shaped suction nozzle is installed on the side of the first guide width slide, and an upper and lower grabbing cylinder is arranged on the upper end of the first guide width slide, the first guide width slide and the upper and lower grabbing cylinders are fixed on the frame, and a driving cylinder is arranged perpendicular to the grabbing cylinder; the friction adjustment unit is arranged at Driven by the motor, the fixed length is automatically set to send the welding piece through the first guide groove to the position below the U-shaped suction nozzle. The upper and lower grabbing cylinders press the U-shaped suction nozzle down on the guide rail table. The cutting cylinder drives the cutter to cut the welding piece and then reset it. The upper and lower grabbing cylinders grab the welding piece sucked by the U-shaped suction nozzle, grab and lift it up. The driving cylinder drives the upper and lower grabbing cylinders to send the welding piece sucked by the U-shaped suction nozzle down to the position of the copper terminal of the switch unit and the copper terminal of the transformer. The welding teeth on the welding head are inserted into the U-shaped suction nozzle to ultrasonically weld the welding piece to the copper terminal of the switch unit and the copper terminal of the transformer. The driving cylinder drives the upper and lower grabbing cylinders to lift and reset the U-shaped suction nozzle.

[0033] The blade angle of the cutter is 28 to 31 degrees; or, the friction gap is less than 0.8-0.9 times the thickness of the welding piece; or, the side elevation of the blade is parallel to the welding piece and the outer end surface of the first guide groove plate, and the gap from the side elevation of the blade to the U-shaped suction nozzle is less than 1.5 to 1 times the thickness of the welding piece; or, the gap from the side bevel of the blade to the U-shaped suction nozzle is 2 to 3 times the thickness of the welding piece; or, the angle of the welding tooth is 90 degrees; or the tooth spacing between the welding teeth is 1mm; or the welding teeth are straight; or the weld tooth tip plane is 0.2mmx0.2mm; or, the weld tooth bottom plane is 0.4mmx0.4mm; or, the weld tooth height is 0.5mm; the weld tooth tips are distributed in a 4x4 array, a 3x3 array, or a 5x5 array.

[0034] The ultrasonic generator is a 40K ultrasonic generator; the screws are M6x1x13 and M8x0.75x15; the total length from the rear end face of the welding head to the welding tooth cylinder is 65±3mm; the finish of the rear end face is less than Ra0.8; a M8x0.75 fine-thread screw hole 17mm is set in the center of the rear end face, and a coarse-thread M6x1 coarse-thread screw hole 15mm is set in the center of the output end of the amplitude transformer; the rear end conducts energy at a ratio of 1:1 through the first cone and amplifies the amplitude energy in the second stage, and the amplified amplitude energy is transmitted to the third cone through the second cylinder, and an arc is set on the third cone, and the arc shrinks and gathers energy to the flat body at a ratio of 1:1, and the flat body conducts energy to the welding head through the third stage amplification; the welding teeth are evenly arranged in multiple 4 or 6 in the circumferential direction of the welding head, and the welding teeth and the welding head are quickly replaced.

[0035] Elastic clamping parts are provided on both sides of the fixing seat, and the elastic clamping parts are pressed against the two sides of the terminal box body; the assembly fixture includes a fixture body, a carrier, and a second elastic part. The carrier slides relative to the fixture body, one end of the second elastic part is pressed against the carrier, and the other end of the second elastic part is pressed against the fixture body. The carrier is provided with a accommodating cavity for fixing the copper terminal of the switch unit and the copper terminal of the transformer; the external driving source first drives the assembly fixture to move toward the fixing seat, and when the assembly fixture is fitted with the fixing seat, the external driving source drives the copper terminal of the switch unit and the copper terminal of the transformer to be installed to the terminal box body.

[0036] One of the carrier and the fixture body is provided with a guide column, and the other of the carrier and the fixture body is provided with a guide groove that cooperates with the guide column; or, one of the carrier and the fixture body is provided with a limiting protrusion, and the other of the carrier and the fixture body is provided with a limiting groove that cooperates with the limiting protrusion.

[0037] The lower end of the accommodating cavity is an arc surface, the upper end is a convex shape, and the upper end and the lower end are connected to form a closed surface. Through this structural setting, the accuracy requirements of the copper terminals of the switch unit and the copper terminals of the mutual inductor can be met.

[0038] The multi-performance floating detection fixture includes: a square plate is provided with a T-shaped slide bar for fixing and connecting diagonally, the T-shaped slide bar and the sliding sleeve fixed on the fixed plate form a sliding pair, the spring in the middle of the T-shaped slide bar is arranged on the back of the fixed plate, a profiling groove of the terminal box unit is arranged in the middle of the square plate, and the first and second recessed grooves protruding from the shape of the terminal box and the sixth U-shaped groove protruding in the middle are arranged on both sides of the profiling groove for clamping the terminal box. A first mounting hole for installing a probe for conducting resistance is arranged between the sixth U-shaped groove and the first recessed groove and the second recessed groove, facing the copper terminal, and a left mounting hole and a right mounting hole are arranged on the front end plane of the profiling groove, facing the welding resistance detection probe for installing the test switch unit and the transformer solder joint.

[0039] The welding inspection performance testing machine includes a second downward pressure cylinder, a multi-performance floating detection fixture, a pressure detection assembly, a mutual inductor on-off probe, a switch unit on-off probe, a welding resistance detection probe, and a resistance detection probe after on-off; the welded terminal box unit, switch unit, and mutual inductor are fixed on the multi-performance floating detection fixture, and the second downward pressure cylinder drives the pressure detection assembly to press against the welded terminal box unit, switch unit, and mutual inductor. The second downward pressure cylinder is a multi-stroke cylinder; the mutual inductor on-off probe is connected to the mutual inductor; the switch unit on-off probe is connected to the switch unit; the welding resistance detection probe and the resistance detection probe after on-off test the corresponding resistance value.

[0040] The welding inspection performance testing machine includes a rotary clamping device, which includes a rotary cylinder and a clamping piece. The rotary cylinder is linked with the clamping piece, and the clamping piece presses against the welded terminal box unit, switch unit, and transformer.

[0041] The intelligent meter multi - collaborative efficient precision machining and quality control technology and equipment provided by the present invention realize the fixation of the terminal box unit, switch unit, and mutual inductor through the pressing member, facilitating performance detection.

[0042] The welding, assembling and inspection integrated machine includes a fixing device, a welding mechanism, a cold - water circulation mechanism, a cold - air mechanism, a first temperature sensor, a CCD detection mechanism, and a control mechanism. The fixing device fixes the terminal box unit, switch unit, and mutual inductor. The welding mechanism includes an upper electrode and a lower electrode. The lower electrode abuts against the lower ends of the copper terminals of the switch unit and the copper terminals of the mutual inductor. The second conductive member and the third conductive member are located on the movement track of the upper electrode. The cold water of the cold - water circulation mechanism flows through the upper electrode and the lower electrode. The cold air of the cold - air mechanism blows towards the upper electrode. The first temperature sensor detects the temperature of the upper electrode and the welding position. The CCD detection mechanism detects the terminal box unit, switch unit, and mutual inductor. The control mechanism detects the welding temperature and adjusts one or two or more combinations of the welding current, welding time, welding pressure, cold - water temperature, cold - water flow rate, cold - air temperature, and cold - air flow rate.

[0043] The cold - water circulation mechanism is provided with a water inlet and a water return port. The water inlet is provided with a second temperature sensor for detecting the cold - water temperature and a first flow sensor for detecting the cold - water flow rate. The water return port is provided with a third temperature sensor for detecting the cold - water temperature.

[0044] The first temperature sensor movably detects the temperature of the upper electrode and the temperature of the welding position.

[0045] The technical solution of the present invention has the following advantages: 1. The intelligent meter multi - collaborative efficient precision machining and quality control technology and equipment provided by the present invention form the welding connection between the terminal box unit, switch unit, and mutual inductor and the performance detection after welding through the cooperation of multiple machines. Compared with the manual processing in the prior art, this processing method can greatly improve the processing efficiency and reduce the production cost.

[0046] 2. The intelligent meter multi - collaborative efficient precision machining and quality control technology and equipment provided by the present invention, with the setting of the turntable, form a turntable - type assembly - line processing, which can reduce the overall volume and meet the requirements of automation.

[0047] 3. For the intelligent electricity meter multi - collaborative high - efficiency precision machining and quality control technology and equipment provided by the present invention, with the first fixture configured in this structure, in order to reduce the volume of the entire equipment, the ultrasonic welding machine can only weld one position at a time. Through the cooperation of the outer sliding sleeve and the inner sliding sleeve, the profiling assembly fixture rotates, enabling the switch unit or the mutual inductor to rotate. Specifically, it rotates 180°, achieving the welding of another welding position. The first elastic member and the floating ball form the locking of the position.

[0048] 4. For the intelligent electricity meter multi - collaborative high - efficiency precision machining and quality control technology and equipment provided by the present invention, the lifting and rotating mechanism realizes the lifting and rotating functions. When the welding of one position point is completed, the switch unit or the mutual inductor is first lifted by the lifting and rotating mechanism, causing the switch unit or the mutual inductor to leave the profiling cavity. Then, it rotates through the lifting and rotating mechanism. After rotating in place, it starts to descend, making the switch unit or the mutual inductor located in the profiling cavity again for the welding operation of another position point.

[0049] 5. For the intelligent electricity meter multi - collaborative high - efficiency precision machining and quality control technology and equipment provided by the present invention, the setting of the blanking mechanism enables the welded switch unit or the welded mutual inductor to be blanked to meet the next processing procedure.

[0050] 6. For the intelligent electricity meter multi - collaborative high - efficiency precision machining and quality control technology and equipment provided by the present invention, the first pressing cylinder drives the ultrasonic generator to move up and down. When welding is required, the ultrasonic generator moves down, and when the welding is completed, the ultrasonic generator moves up.

[0051] 7. For the intelligent electricity meter multi - collaborative high - efficiency precision machining and quality control technology and equipment provided by the present invention, the fixed seat cooperates with the assembly fixture to form the connection and fixation between the copper terminal of the switch unit, the copper terminal of the mutual inductor, and the terminal box body.

[0052] 8. For the intelligent electricity meter multi - collaborative high - efficiency precision machining and quality control technology and equipment provided by the present invention, the guide post and the guide groove cooperate to form a guiding and driving effect. The cooperation between the limit protrusion and the limit groove forms the limit in the direction.

[0053] 9. For the intelligent electricity meter multi - collaborative high - efficiency precision machining and quality control technology and equipment provided by the present invention, the second pressing cylinder is a multi - stroke cylinder. The first stroke is for fixation, and the second stroke is for applying pressure to perform the welding firmness (peel test), welding tensile force, ensuring that no welding detachment occurs under the test pressure. Secondly, through other probes, detections such as welding resistance, loop conduction test, low - voltage resistance test, coil resistance test, coil primary current test, DC component test, DC resistance test, etc. are realized.

[0054] 10. The intelligent meter multi - collaborative high - efficiency precision machining and quality control technology and equipment provided by the present invention adopt such a structural setting. Through the welding mechanism, the connection and fixation between the switch unit, the mutual inductor and the terminal box unit are formed. Compared with the prior art, this machining method is simpler. By adopting automated operation and combining several welding steps, an automated welding effect is formed, improving the machining efficiency. Secondly, by detecting the welding temperature and controlling various parameters, the control of the welding temperature is formed, so that the welding temperature is maintained within the preset threshold, thereby ensuring that phenomena such as false soldering do not occur during the welding process, improving the welding quality. Through multiple modes such as water, cold air, current, or pressure, the effect of controlling the temperature in multiple modes is formed.

[0055] 11. For the intelligent meter multi - collaborative high - efficiency precision machining and quality control technology and equipment provided by the present invention, the temperature sensors are set at different positions of the cold water circulation mechanism, which is convenient for the control mechanism to control at each position. Through the second temperature sensor and the first flow sensor, the water temperature and the flow rate of the outflow can be known. Through the third temperature sensor, it can be known whether the heat is abnormal and whether the heat can be conducted from the upper electrode to the lower electrode.

[0056] 12. For the intelligent meter multi - collaborative high - efficiency precision machining and quality control technology and equipment provided by the present invention, the up - and - down detection of the first temperature sensor makes the detection range larger. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings required for use in the description of the specific embodiments or the prior art. Obviously, the following - described drawings are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0058] Figure 1 It is an exploded view of the terminal box unit, the switch unit, and the mutual inductor provided by the present invention; Figure 2 It is a structural schematic diagram of the intelligent meter multi - collaborative high - efficiency precision machining and quality control technology and equipment provided by the present invention; Figure 3 It is a structural schematic diagram of the solder - tab assembling machine provided by the present invention; Figure 4 It is a partial structural schematic diagram of the solder - tab assembling machine provided by the present invention; Figure 5 It is a structural schematic diagram of the initial state of the first fixture provided by the present invention; Figure 6 It is a structural schematic diagram of the rising state of the first fixture provided by the present invention; Figure 7Schematic diagram of the welding positions of the first fixture, switch unit and current transformer provided by the present invention; Figure 8 Schematic diagram of the structure of the blanking mechanism provided by the present invention; Figure 9 Schematic diagram of the multi-component collaborative flexible fixture structure of the terminal button copper bar assembling machine provided by the present invention; Figure 10 Schematic diagram of the structure of the welding, assembling and inspection integrated machine provided by the present invention; Figure 11 Schematic diagram of the structure of the welding, assembling and inspection integrated machine from another angle provided by the present invention; Figure 12 Schematic diagram of the structure of the welding, assembling and inspection performance testing machine provided by the present invention; Figure 13 Schematic diagram of the structure of the ultrasonic welding head of the solder tab assembling machine provided by the present invention; Figure 14 Schematic diagram of the flexible integrated assembling fixture structure of the solder tab assembling machine provided by the present invention; Figure 15 Schematic diagram of the structure of the multi-performance floating detection fixture of the welding, assembling and inspection performance testing machine provided by the present invention; Figure 16 Schematic diagram of the structure of the automatic cutting and feeding unit provided by the present invention.

[0059] Explanation of reference numerals: 3. Second conveyor belt; 4. Third conveyor belt; 6. Cold water circulation mechanism; 8. Cold air mechanism; 15. Terminal box unit; 16. Switch unit; 17. Current transformer; 19. Upper electrode 19; 21. CCD detection mechanism; 27. Lower electrode; 28. Third temperature sensor; 151. Copper terminal of switch unit; 152. Copper terminal of current transformer; 153. Terminal box body; 161. Second conductive part; 164. First temperature sensor; 171. Third conductive part; 312. Terminal copper bar assembly machine; 313. Welding inspection integration machine; 315. Welding inspection performance testing machine; 321. Automatic cutting and feeding unit; 322. Ultrasonic welding machine; 325. Turntable; 326. First fixture; 328. Solder tab assembly machine; 401. Outer sliding sleeve; 402. Inner sliding sleeve; 403. Profiled assembly fixture; 404. Support rod; 405. Lower hazelnut; 406. Floating ball; 407. First elastic part; 462. Loading station; 465. Detection station; 464. Welding station; 461. Unloading station; 469. Ultrasonic generator; 470. First pressing cylinder; 477. Lifting and rotating mechanism; 471. Support frame; 472. Shell; 473. First guide post; 480. Exhaust fan; 482. Pneumatic valve; 490. Sliding jaw; 492. Unloading mechanism; 500. Assembly fixture; 501. Fixture body; 502. Limit projection; 503. Limit groove; 504. Carrier; 505. Accommodation cavity; 507. Second guide groove; 508. Second guide post; 512. Elastic clamping part; 517. Fixed seat; 519. Fixed plate; 520. Second pressing cylinder; 521. Mounting frame; 523. Linkage; 527. Pressure detection component; 529. Rotating pressing device; 530. Rotating cylinder; 533. Welding resistance detection probe; 534. Multi-performance floating detection fixture; 535. Current transformer on-off probe; 536. Switch unit on-off probe; 537. Resistance detection probe after on-off; 555. Pressing part; 3261. Profiled cavity; 5051. Arc surface; 5052. U-shaped; A461. Threaded connection hole; A462. Second cylinder; A463. Third cone; A464. Flat body; A465. Welding head; A466. Welding tooth; A467. Welding head; A468. First cone; A469. Arc; A470. Energy guiding rib; A471. Rear end; 708. Vertical frame; 709. Friction adjustment unit; 707. Friction gap; 706. First guide groove; 710. Second guide rail amplitude slide plate; 701. Gripping cylinder; 704. Cutting cylinder; 705. Cutting tool; 712. U-shaped suction nozzle; 711. First vacuum suction hole; 711; 702. First guide rail amplitude slide plate; 700. Driving cylinder; A171. First copper solder tab; B161. Third copper solder tab; A161. Fourth copper solder tab; A16. Communication socket; B16. Moving contact; C16. Static contact; A17. Lead pin; B17. B flexible wire; C17. Communication wire; A534. First sink;B534, the second settling tank; C534, the sixth U-shaped groove; D534, the first mounting hole; E534, the first hole; F534, the left mounting hole; G534, the right mounting hole; H534, the sliding column; L534, the T-shaped sliding rod; N534, the profiling groove; M534, the second hole; O534, the front-end plane; X534, the loop resistance detection probe; A500, the first L-shaped plate; A501, the L-shaped groove plate; A502, the fourth U-shaped groove; A503, the square groove; A504, the fifth U-shaped groove; A505, the low-end plate; A506, the L-shaped platform; A507, the third U-shaped groove; A508, the positioning and locking groove; A509, the limiting L-shaped platform; A510, the second U-shaped groove; A511, the lower step platform; A512, the first U-shaped groove; A50, the shifting fixture; A51, the movable fixture.; Detailed implementation manners

[0060] The technical solutions of the present invention will be described clearly and completely below with reference to the accompanying drawings. Obviously, the described embodiments are some but not all of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0061] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation to the present invention. In addition, the terms "first", "second", "third" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance.

[0062] In the description of the present invention, it should be noted that unless otherwise clearly specified and defined, the terms "installation", "connection", "connection" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0063] In addition, the technical features involved in different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0064] Embodiment 1 This embodiment provides technologies and equipment for multi - collaborative, efficient, precise machining and quality control of smart meters, as shown in the appendix Figures 1 - 16 and includes: A terminal copper bar assembly machine 312, which includes a fixed seat 517 for fixing the terminal box body 153 and an assembly fixture 500 for fixing the switch unit copper terminal 151 and the current transformer copper terminal 152. The terminal copper bar assembly machine 312 installs the switch unit copper terminal 151 and the current transformer copper terminal 152 onto the terminal box body 153 to form a terminal box unit 15.

[0065] A solder tab assembly machine 328, which includes an automatic cutting and feeding unit 321, an ultrasonic welding machine 322, and a first fixture 326 with a profiling cavity 3261. The profiling cavity 3261 fixes the switch unit 16 or the current transformer 17. Specifically, it means that the profiling cavity 3261 can fix the switch unit 16 or the current transformer 17. The profiling cavity 3261 is a general setting. Through the setting of the profiling cavity 3261, the number of devices can be reduced and the volume can be reduced. Otherwise, one machine is required for welding the solder tabs corresponding to the switch unit 16, and another machine is required for welding the current transformer 17, resulting in an increase in the number of machines and affecting the floor space. Here, the profiling cavity 3261 can limit and fix according to the common points of the switch unit 16 and the current transformer 17, or can be fixed through different structures. The automatic cutting and feeding unit 321 cuts and feeds the solder tabs. The solder tab strip enters the automatic cutting and feeding unit 321, and through the automatic cutting and feeding unit 321, it is cut and fed to form several solder tabs respectively adapted to the switch unit 16 and the current transformer 17. The ultrasonic welding machine 322 welds the solder tabs to the switch unit 16 or the current transformer 17. Here, the solder tabs are respectively welded and fixed to the second conductive member 161 and the third conductive member 171. For example, if the number of the second conductive members 161 is two and the number of the third conductive members 171 is two, then the number of solder tabs is four, and the four solder tabs are respectively welded and fixed to the two second conductive members 161 and the two third conductive members 171. It should be noted that when welding the switch unit 16 and the solder tabs, the processing of the current transformer 17 cannot be carried out; conversely, when welding the current transformer 17 and the solder tabs, the processing of the switch unit 16 cannot be carried out. The switch unit 16 can be a relay or a load switch or other switching control switches. The solder tabs in this embodiment are ultra - thin solder tabs, specifically ultra - thin silver - copper - phosphorus solder tabs, with a thickness of 0.03 - 0.12 mm.

[0066] The welding inspection integrated machine 313 has a second conductive member 161 fixed to the switch unit 16, and the number of the second conductive members 161 is two here. The mutual inductor 17 has a third conductive member 171 fixed thereto, and the number of the third conductive members 171 is also two. The second conductive member 161 and the third conductive member 171 are respectively fixed to the solder pads by soldering. The welding inspection integrated machine 313 welds and connects the second conductive member 161 to the copper terminal 151 of the switch unit; the welding inspection integrated machine 313 welds and connects the third conductive member 171 to the copper terminal 152 of the mutual inductor. Here, the welding inspection integrated machine 313 is used for welding and fixing, detection, etc. between the switch unit 16, the terminal box unit 15, and the mutual inductor 17.

[0067] The welding inspection performance testing machine 315 includes a multi-performance floating detection fixture 534. The multi-performance floating detection fixture 534 detects the terminal box unit 15 to which the switch unit 16 and the mutual inductor 17 are welded and fixed. The welding inspection performance testing machine 315 detects the welding firmness (adhesion test), welding tensile force, welding resistance, loop conduction test, low-voltage resistance test, coil resistance test, coil primary current test, DC component test, DC resistance test, etc.

[0068] Through the cooperation of multiple machines, the welding connection between the terminal box unit 15, the switch unit 16, and the mutual inductor 17 and the performance detection after welding are formed. Compared with the manual processing in the prior art, this processing method can greatly improve the processing efficiency and reduce the production cost. Adjacent machines can be connected through a conveyor belt or manually transported by workers, and those skilled in the art can adjust according to actual needs. In this embodiment, it is preferably connected through a conveyor belt.

[0069] Specifically, as shown in the appendix Figure 16As shown in the figure, the automatic cutting and feeding unit 321 includes a vertical frame 708. On the vertical frame 708, a friction adjustment unit 709, a friction gap 707 (set to be 0.8 - 0.9 times less than the thickness of the ultra-thin solder sheet), and a first guide groove 706 are arranged in sequence from right to left. At the upper end of the second guide rail amplitude slide plate 710, a cutting cylinder 704 is arranged and a cutting knife 705 is arranged on the side. The blade angle of the cutting knife 705 is 28 degrees to 31 degrees. The side vertical surface of the blade is parallel to the outer end surface of the ultra-thin solder sheet and the first guide groove 706 plate. The gap between the side vertical surface of the blade and the U-shaped suction nozzle 712 is less than 1.5 to 1 times the thickness of the ultra-thin solder sheet. This design limits the problems in the prior art such as difficult cutting of the ultra-thin solder sheet, tool slipping, formation of wrinkles during cutting of the ultra-thin solder sheet, and occurrence of poor "zigzag" shapes. Adjacent to the gap of the cutting knife 705, a U-shaped suction nozzle 712 is arranged. The gap between the side inclined surface of the blade and the U-shaped suction nozzle 712 is 2 to 3 times the thickness of the ultra-thin solder sheet. On the bottom surfaces at both ends of the U-shaped suction nozzle 712, a pair of first vacuum suction holes 711 are respectively arranged (the suction force of the vacuum valve is adaptively adjusted according to the weight of the ultra-thin solder sheet). This design solves the problems such as difficult grasping of the ultra-thin solder sheet, easy suction of the ultra-thin solder sheet during the grasping process, skew and loss during the suction and movement process, and burrs, tears, deformation, etc. at the edges. The U-shaped suction nozzle 712 is installed on the side of the first guide rail amplitude slide plate 702. At the upper end of the first guide rail amplitude slide plate 702, an up and down grasping cylinder 701 is arranged. The first guide rail amplitude slide plate 702 and the up and down grasping cylinder 701 are fixed on the machine frame, and a driving cylinder 700 is arranged perpendicular to the grasping cylinder 701.

[0070] The friction adjustment unit 709 automatically sets a fixed length under the drive of the motor to pass the ultra-thin solder sheet through the first guide groove 706 to the position below the U-shaped suction nozzle 712. The up and down grasping cylinder 701 presses the U-shaped suction nozzle 712 onto the guide rail table. The cutting cylinder 704 drives the cutting knife 705 to cut the ultra-thin solder sheet and then reset. The up and down grasping cylinder 701 sucks and grabs and lifts the ultra-thin solder sheet sucked by the U-shaped suction nozzle 712. The driving cylinder 700 drives the up and down grasping cylinder 701 to send the ultra-thin solder sheet sucked by the U-shaped suction nozzle 712 to the positions of the switch unit copper terminal 151 and the current transformer copper terminal 152 pressed down to the welding station 464. The welding teeth A466 on the welding head A467 are inserted into the U-shaped suction nozzle 712 to ultrasonically weld the ultra-thin solder sheet to the switch unit copper terminal 151 and the current transformer copper terminal 152. The driving cylinder 700 drives the up and down grasping cylinder 701 to lift and reset the U-shaped suction nozzle 712 to form a complete unit.

[0071] Specifically, as shown in the appendix Figures 2 - 8As shown in the figure, the solder tab assembly machine 328 includes a turntable 325, and the turntable 325 is provided with a feeding station 462, an inspection station 465, a welding station 464, and a discharging station 461. The four stations can be distributed in a circumferential array, or can be adjusted according to actual needs. The number of the first jigs 326 is at least four. When the number of the first jigs 326 is four, the four first jigs 326 rotate corresponding to the four stations during the rotation. When the number of the first jigs 326 exceeds four, the extra first jigs 326 are vacant positions, and the speed of the turntable 325 can be controlled, and those skilled in the art can adjust it according to actual needs. The ultrasonic welding machine 322 cooperates with the welding station 464. For example, the first jig 326 fixed with the switch unit 16 moves to the welding station 464. At this time, the automatic cutting and feeding unit 321 matches the cut solder tab with the switch unit 16, and a welding effect is formed through the ultrasonic welding machine 322. A turntable 325 type assembly line processing can be formed, which can reduce the overall volume and meet the requirements of automation. In addition, welding can also be performed through an assembly line structure, but the defect of this structure is that it will occupy a large space.

[0072] Specifically, as shown in the appendix Figures 2 - 8As shown in the figure, the first fixture 326 includes an outer sliding sleeve 401, an inner sliding sleeve 402, a profiling assembly fixture 403, a support rod 404, a lower hazelnut 405, a floating ball 406, and a first elastic member 407. The inner sliding sleeve 402 is located inside the outer sliding sleeve 401 and axially slides relative to the outer sliding sleeve 401. The profiling assembly fixture 403 is located on the top surface of the inner sliding sleeve 402. The profiling assembly fixture 403 is linked with the inner sheath, and a profiling cavity 3261 is provided in the profiling assembly fixture 403. The lower end of the lower hazelnut 405 is linked with the support rod 404, and the upper end of the lower hazelnut 405 extends into the profiling cavity 3261 for cooperation, that is, the lower hazelnut 405 can move vertically upward and drive the profiling assembly fixture 403 and the inner sliding sleeve 402 to move vertically upward. Since the switch unit 16 or the current transformer 17 is fixed on the profiling assembly fixture 403, the switch unit 16 and the current transformer 17 also move accordingly at this time. Here, the lower hazelnut 405 specifically cooperates with the profiling assembly fixture 403 to drive the profiling assembly fixture 403 to move, realizing the rotation and lifting of the profiling assembly fixture 403. The floating ball 406 and the first elastic member 407 are located between the outer sliding sleeve 401 and the inner sliding sleeve 402. The first elastic member 407 gives the floating ball 406 a squeezing force to press against the side wall of the inner sliding sleeve 402, and the floating ball 406 forms a limiting and fixing effect. Here, small grooves are provided on the outer side wall of the inner sliding sleeve 402, which just abut against the floating ball 406 to form a limit. However, when the inner sliding sleeve 402 is driven by a vertically upward force to move, the floating ball 406 can be separated from the small groove to release the limit. The first fixture 326 is arranged in such a structure. Since the volume of the whole device is reduced, the ultrasonic welding machine 322 can only weld one position at a time (the numbers of the second conductive member 161 and the third conductive member 171 are both two, so two positions need to be welded). Through the cooperation of the outer sliding sleeve 401 and the inner sliding sleeve 402, the profiling assembly fixture 403 can move upward and rotate, realizing that the switch unit 16 or the current transformer 17 can rotate, specifically rotate 180°, to realize the welding of another welding position. The first elastic member 407 and the floating ball 406 form a position lock. In the attached figure, point A is the welding point of the current transformer 17; point B is the welding point of the switch unit 16.

[0073] Specifically, as shown in the attached Figures 2 - 8As shown, the solder tab assembling machine 328 further includes a lifting and rotating mechanism 477. The lifting and rotating mechanism 477 cooperates with the support rod 404 to form the lifting and rotation of the switch unit 16 or the mutual inductor 17. Here, the lifting and rotating mechanism 477 has the functions of lifting and rotating. The lifting and rotating mechanism 477 realizes the lifting and rotating functions. When the welding at one position point is completed, the switch unit 16 or the mutual inductor 17 is first lifted by the lifting and rotating mechanism 477, so that the switch unit 16 or the mutual inductor 17 leaves the profiling cavity 3261, and then rotates through the lifting and rotating mechanism 477. After rotating to the in-place position, it starts to descend, so that the switch unit 16 or the mutual inductor 17 is re-located in the profiling cavity 3261 to perform the welding operation at another position point.

[0074] Specifically, as shown in the appendix Figures 2 - 8 As shown, the solder tab assembling machine 328 further includes a blanking mechanism 492. The blanking mechanism 492 includes a sliding jaw 490. The blanking mechanism 492 cooperates with the blanking station 461, and the sliding jaw 490 cooperates with the welded switch unit 16 or the welded mutual inductor 17. The setting of the blanking mechanism 492 enables the welded switch unit 16 or the welded mutual inductor 17 to be blanked to meet the next processing procedure. The blanking mechanism 492 drives the sliding jaw 490 to perform horizontal sliding and vertical up-and-down sliding.

[0075] Specifically, as shown in the appendix Figures 2 - 8 and Figure 13As shown in the figure, the multi-component flexible ultrasonic welding machine 322 includes an ultrasonic generator 469, a first pressing cylinder 470, a support frame 471, a housing 472, a first guiding column 473, an ion extractor 480, and a pneumatic valve 482. The ultrasonic generator 469 is housed in the housing 472. A part of the ultrasonic generator 469 is located in the internal chamber of the housing 472, and a part of the ultrasonic generator 469 and the welding head A467 extend to the outside for cooperation with the welding station 464 to form ultrasonic welding. The first pressing cylinder 470 is linked with the ultrasonic generator 469, and the first pressing cylinder 470 drives the ultrasonic generator 469 to move vertically up and down. The ultrasonic generator 469 is connected to the support frame 471, and the support frame 471 slides relative to the first guiding column 473, and the first guiding column 473 forms a guiding effect. The extractor 480 evacuates the inside of the housing 472. The pneumatic valve 482 is used to adjust the air pressure. The first pressing cylinder 470 is connected to the transducer, the transducer is connected to the ultrasonic generator 469, the output end of the transducer is connected to the horn, and the output end of the horn has a fixed flange. The fixed flange fixedly connects the end of the horn and the welding head A467 with a screw; the fixed flange fixes the end of the horn and the welding head A467 on the outer end of the housing 472; the first pressing cylinder 470 drives the ultrasonic generator 469 to move up and down. When welding is required, the ultrasonic generator 469 drives the welding head A467 to move down, and when welding is completed, the ultrasonic generator 469 moves up to drive the welding head A467 to reset.

[0076] Furthermore, the inventive features of the welding head A467 are as follows: the rear end A471 is a cylinder with a diameter of ϕ22x5mm and is connected to a 45-degree first cone A468 with a size of 5x5. The 45-degree first cone A468 is connected to a second cylinder A462 with a size of ϕ32x22mm. The ϕ32x22mm second cylinder A462 is connected to a third cone A463 with a length of 10. The third cone A463 is connected to a flat body A464 with a size of ϕ22x22mm and a length of 7mm. The flat body A464mm is connected to a welding head A465 with a size of ϕ22x6mm. Welding teeth A466 with a size of 4x5x5 are evenly arranged in a cross pattern around the welding head A465. A energy guiding rib A470 is arranged between the welding head A465 and the welding teeth A466.

[0077] The purpose of arranging the welding teeth A466 in a cross pattern with a size of 4x5x5 is to solve the problem of quick replacement of multiple welding teeth, greatly saving costs, and solving the problems of high cost waste and time-consuming replacement of the existing single-head welding head.

[0078] The further invention of the welding teeth A466 has four major characteristics: 1. The angle of the teeth is 90 degrees; 2. The tooth pitch is 1 mm; 3. Straight lines; 4. The tooth tip plane is 0.2 mm x 0.2 mm; 5. The tooth bottom plane is 0.4 mm x 0.4 mm; the tooth height is 0.5 mm; 6. The tooth tips are arranged in a 4x4 array (suitable for copper welding sheets with a thickness of 0.3 - 0.5 mm); 7. The tooth tips are arranged in a 3x3 array (suitable for copper welding sheets with a thickness of 0.6 mm - 1.2 mm); 8. The tooth tips are arranged in a 5x5 array (suitable for copper welding sheets with a thickness of 0.2 - 0.1 mm).

[0079] Furthermore, the invention characteristics of the welding head A467 are as follows: A 40K ultrasonic generator 469 is adopted and input to the horn through a transducer. The horn is transported to the welding head A467 through screws of M6x1x13 and M8x0.75x15 mm. The total length of the amplitude input from the rear end A471 end face of the welding head A467 to the column body of the welding teeth A466 is 65 ± 3 mm, and the axis of the 65 ± 3 mm column body is perpendicular to the rear end A471 end face. The surface finish of the rear end A471 end face is less than Ra0.8; a fine thread M8x0.75 screw hole of 17 mm is arranged at the center of the rear end A471 end face, and a coarse thread M6x1 screw hole of 15 mm is arranged at the center of the output end of the horn; in the middle, it is connected by screws of M6x1x13 and M8x0.75x15 mm; this setting finely filters the clutter of the existing ultrasonic amplitude wave and amplifies the first-stage amplified amplitude. The rear end A471 conducts energy according to 1:1 through the first cone A468 and amplifies the amplitude energy at the second stage. The amplified amplitude energy is transported to the third cone A463 through the second column A462. An arc A469 is arranged on the third cone A463 to contract and concentrate energy to the flat body A464 according to a 1:1 ratio. The flat body A464 conducts energy to the welding head A465 at the third stage. The amplitude and energy on the welding head A465 are transported to the 4x4 array welding teeth A466 through the energy conduction rib A470. According to different arrays, different thicknesses of ultra-thin silver copper phosphorus welding sheets are welded to the different array tooth tips on the welding teeth A466 of the welding head A467. This technical invention solves the problems of clutter, harmonic waves, and unstable output energy in the existing ultrasonic equipment's welding head A467, and it is impossible to realize the welding of ultra-thin silver copper phosphorus and copper phosphorus ultra-thin welding sheets. The existing ultrasonic energy cannot be adjusted, and the rough ultrasonic energy causes problems such as welding through of ultra-thin welding sheets. The welding teeth A466 are evenly arranged in a plurality in the circumferential direction of the welding head A467, which can be 4 or 6. If one fails, the other can be quickly replaced. With this setting, the welding head A467 and the welding teeth have high precision, good consistency, and low cost. This invention is applicable to ultrasonic welding of ultra-thin welding sheets with different specifications and materials (0.03 - 0.12 mm) in thickness.

[0080] Working principle: The ultra-thin solder ultrasonic unit includes an intelligent numerical control ultrasonic generator 469 + a transducer (not shown in the figure) + a horn (fixed flange) (not shown in the figure) + a welding head A467 + (solder + switch unit 16 (circuit breaker or current transformer 17)) workpiece + a bottom die (lower hazelnut 405).

[0081] The ultrasonic generator 469 is an intelligent numerical control ultrasonic generator 469. The ultrasonic generator 469 is connected to an alternating current of 220V industrial frequency 50 / 60Hz and takes it as the electrical energy input. Through internal circuits such as rectification, transformation, and special power tubes, the 220V electricity is converted into a high-voltage high-frequency electricity output of a specific frequency such as 20kHz or 40kHz for resonance, providing the required electrical energy source for the transducer; the transducer receives the high-frequency high-voltage electrical signal output by the ultrasonic generator 469, and uses the inverse piezoelectric effect of piezoelectric ceramics to convert the input high-frequency electrical signal into a mechanical vibration signal of the same frequency for output. Usually, the output amplitude is relatively small, generally about 10μm; the mechanical vibration output by the transducer is input to the horn (fixed flange). According to its own shape and structure, the horn amplifies or reduces the input mechanical vibration and transmits the adjusted mechanical vibration to the welding head A467 (in this invention, it is to amplify the mechanical vibration amplitude). The welding head A467 receives the mechanical vibration transmitted by the horn. The welding head A467 transmits the mechanically vibrated energy and pressure that has been further filtered and three-stage amplified (the core invention that does not exist in the prior art) to the surface of the copper workpiece to be welded. The mechanical vibration energy and pressure from the welding head A467 are input to the array of welding teeth on the welding head A467. The array of welding teeth presses the ultra-thin solder and the switch unit 16 (relay or circuit breaker) or the current transformer 17 between the bottom die. Under the combined action of the mechanical vibration energy and pressure output by the array of welding teeth (the bottom die provides stable support), the copper material on the surface of the workpiece where the array of welding teeth is located generates high-frequency vibration, causing the tiny protruding parts on the surface of the workpiece to rub against each other, converting the vibration energy into physical phenomena such as heat energy and plastic deformation. With continuous vibration, the oxide film on the surface of the copper is broken and removed, plastic deformation and atomic diffusion occur, and the atomic bonding within the diffusion range on the contact surface continuously increases, forming a firm welded joint. Finally, welding is achieved, and the welded copper product is output. The main function of the bottom die is to bear the pressure transmitted by the workpiece and the vibration reaction force, etc. It provides support and positioning for the workpiece to ensure the stable position of the workpiece during the welding process, enabling the welding to be carried out accurately and outputting stable welding quality and precision.

[0082] Furthermore, an ion extraction fan 480, a welding head A467, a lower hazelnut 405, an ultra-thin solder slice cutter, and a U-shaped suction nozzle are provided in the ultrasonic welding machine 322, and the close-range copper wire is grounded to solve the static electricity generated by the friction between the material and the tool and the equipment during the cutting process of the ultra-thin solder slice, the friction between the solder teeth and the ultra-thin solder slice and the lower hazelnut 405, and the static electricity may adsorb dust and other impurities, polluting the surface of the solder slice. At the same time, it may also cause electrostatic discharge, potentially damaging the performance of the solder slice. Factors such as environmental temperature, humidity, and air quality will all affect the processing quality. For example, if the environmental humidity is too high, the silver-copper-phosphorus solder slice is prone to moisture oxidation, affecting the welding effect; dust and impurities in the workshop may be adsorbed on the surface of the solder slice, resulting in welding defects and false soldering.

[0083] The invention of the multi-component flexible ultrasonic welding machine 322 has achieved outstanding technical effects in many aspects in the related field of power equipment manufacturing through multiple innovative designs and components working together: Efficient and automated production: Multiple machines operate in coordination. From the automatic cutting and feeding of the solder slice assembly machine 328, the ultrasonic welding with the turntable 325 type workstations, to the welding and fixing of the welding and inspection integration machine 313 and the comprehensive inspection of the welding and inspection performance testing machine 315, an automated production line is formed. Compared with manual processing, it greatly improves the welding connection and inspection efficiency between the terminal box unit 15, the switch unit 16, and the mutual inductor 17, reduces the labor cost, and shortens the production cycle.

[0084] The turntable 325 of the solder slice assembly machine 328 is provided with multiple workstations, which cooperate with multiple first jigs 326 to realize continuous cyclic operations of loading, inspection, welding, and unloading, reducing the idle time of the equipment, increasing the output per unit time, and meeting the large-scale production requirements.

[0085] Flexible and universal design: The profiling cavity 3261 of the first jig 326 is a general setting, which can fix both the switch unit 16 and the mutual inductor 17. This reduces the number of special jigs and equipment, reduces the overall equipment volume, lowers the equipment procurement and maintenance costs, and at the same time improves the versatility and adaptability of the equipment, facilitating flexible switching of different products according to production needs.

[0086] The lifting and rotating mechanism 477 cooperates with the special structure of the first jig 326 to be able to lift and rotate the switch unit 16 or the mutual inductor 17, meeting the welding requirements of different positions of the ultrasonic welding machine 322, and further enhancing the adaptability of the equipment to complex welding tasks.

[0087] High-quality welding quality: The welding inspection integrated machine 313 adjusts parameters such as welding current, time, and pressure through a control mechanism. At the same time, it uses a cold water circulation mechanism 6 and a cold air mechanism 8 to control the welding temperature, ensuring that the welding temperature is maintained within a preset threshold, effectively avoiding problems such as false soldering, and improving the firmness and reliability of the welded joint.

[0088] The welding head A467 of the ultrasonic welding machine 322 is specially designed. Through a unique structure, it realizes fine filtering and three-stage amplification of the ultrasonic amplitude, solves the problems of clutter, harmonics, and unstable energy in existing equipment, and can achieve high-quality welding of ultra-thin silver copper phosphorus solder sheets and copper phosphorus. It meets the welding requirements for ultra-thin solder sheets of different thicknesses (0.03 - 0.12 mm), ensuring the stability and consistency of welding quality.

[0089] Convenient maintenance and cost control: The 4x5x5 welding teeth A466 arranged in a cross on the welding head A467 solve the problem of quick replacement of multi-head welding teeth. Compared with the existing single-head welding head A467, it greatly saves costs, reduces replacement time, improves the maintenance efficiency of the equipment, and reduces the production downtime caused by equipment maintenance.

[0090] The welding teeth A466 have various array cusp layouts (4x4, 3x3, 5x5), which can be selected according to different thicknesses of purple copper solder sheets, improving the applicability of the welding head A467 to different specifications of solder sheets and reducing the cost and time consumption caused by replacing the welding head A467.

[0091] Precise detection and quality assurance: The multi-performance floating detection fixture 534 of the welding inspection performance testing machine 315 can comprehensively detect the terminal box unit 15 with the switch unit 16 and the mutual inductor 17 welded and fixed, including various performance detections such as welding firmness, welding tensile force, and welding resistance. This ensures the quality reliability of the product before leaving the factory, timely discovers and eliminates unqualified products, improves the overall quality of the product, and reduces the cost caused by after-sales quality problems.

[0092] Eliminating static electricity and environmental adaptation: The ultrasonic welding machine 322 is equipped with an ion extraction fan 480, and the welding head A467, the lower hazelnut 405(405), the ultra-thin solder sheet cutter, and the U-shaped suction head are grounded by a short-distance copper wire, effectively solving the static electricity problem generated by friction during the cutting and welding of ultra-thin solder sheets. It avoids electrostatic adsorption of dust and impurities to contaminate the surface of the solder sheet, prevents damage to the performance of the solder sheet caused by electrostatic discharge, and improves the stability and quality of product production in a complex environment. At the same time, to a certain extent, it reduces the influence of environmental factors (such as humidity, air quality) on the welding effect and ensures the adaptability of the production environment.

[0093] Specifically, as shown in the appendix Figure 9As shown in the figure, the terminal copper bar assembling machine uses a multi-component collaborative flexible fixture for operation. The multi-component collaborative flexible fixture includes a shifting fixture A50 that changes positions with a multi-station turntable and a movable fixture A51 for assembling the shifting fixture A50. The shifting fixture A50 is used for the automatic assembly of the terminal box body 153, and the movable fixture A51 is used for the automatic assembly of a plurality of switch unit copper terminals 151 and a plurality of current transformer copper terminals 152. The movable fixture A51 automatically presses a plurality of switch unit copper terminals 151 and a plurality of current transformer copper terminals 152 into the terminal box body 153 to form a terminal box unit 15. Specifically, the movable fixture A51 includes an assembly fixture 500, and the shifting fixture A50 includes a fixed seat 517. Elastic clamping members 512 are provided on both sides of the fixed seat 517, and the elastic clamping members 512 press against both sides of the terminal box body 153. The assembly fixture 500 includes a fixture body 501, a carrier 504, and a second elastic member. The carrier 504 slides relative to the fixture body 501. One end of the second elastic member abuts against the carrier 504, and the other end of the second elastic member abuts against the fixture body 501. The carrier 504 is provided with receiving cavities 505 for fixing the switch unit copper terminals 151 and the current transformer copper terminals 152. Here, the number of the receiving cavities 505 is four, and the four receiving cavities 505 respectively fix two switch unit copper terminals 151 and two current transformer copper terminals 152. An external drive source first drives the assembly fixture 500 to move towards the fixed seat 517. When the assembly fixture 500 is in contact with the fixed seat 517, the external drive source drives the switch unit copper terminals 151 and the current transformer copper terminals 152 to be installed into the terminal box body 153. The fixed seat 517 cooperates with the assembly fixture 500 to form the connection and fixation between the switch unit copper terminals 151, the current transformer copper terminals 152 and the terminal box body 153.

[0094] Specifically, as shown in the appendix Figure 9 As shown in the figure, one of the carrier 504 and the fixture body 501 is provided with a second guide post 508, and the other of the carrier 504 and the fixture body 501 is provided with a second guide groove 507 that cooperates with the second guide post 508. The cooperation between the second guide post 508 and the second guide groove 507 forms an effect of guiding and driving. Alternatively, one of the carrier 504 and the fixture body 501 is provided with a limit protrusion 502, and the other of the carrier 504 and the fixture body 501 is provided with a limit groove 503 that cooperates with the limit protrusion 502. The cooperation between the limit protrusion 502 and the limit groove 503 forms a limit in the direction.

[0095] Specifically, as shown in the appendix Figure 9 As shown in the figure, the lower end of the receiving cavity 505 is an arc surface 5051, and the upper end is a U-shaped surface 5052. The upper end and the lower end are connected to form a closed surface. Through this kind of structural setting, the precision requirements of the switch unit copper terminals 151 and the current transformer copper terminals 152 can be met.

[0096] The invention technical effects of the assembly fixture 500 for the copper terminal 151 of the switch unit and the copper terminal 152 of the mutual inductor: 1. High-efficiency and precise assembly Automatic guiding assembly: Through the cooperation of the second guiding column 508 and the second guiding groove 507, precise guidance is provided for the sliding of the carrier 504 relative to the fixture body 501, enabling the assembly fixture 500 to accurately move towards the fixed seat 517 under the action of an external driving source. This ensures that during the installation of the copper terminal 151 of the switch unit and the copper terminal 152 of the mutual inductor, they can accurately align with the corresponding installation positions on the terminal box body 153, effectively improving the accuracy and efficiency of assembly and reducing installation failures or product quality problems caused by assembly deviations.

[0097] 2. Ensure accuracy: The cooperation between the limiting protrusion 502 and the limiting groove 503 further limits the movement of the carrier 504 in a specific direction. This not only helps to maintain the stability during the assembly process, preventing unnecessary displacement of the carrier 504 during sliding, but also ensures the position consistency of the copper terminal 151 of the switch unit and the copper terminal 152 of the mutual inductor during each installation, greatly meeting the strict requirements of automatic assembly accuracy and improving the stability of product quality.

[0098] 3. Reliable connection and fixation Elastic clamping for stability: The elastic clamping members 512 on both sides of the fixed seat 517 press against both sides of the terminal box body 153, providing stable fixed support for the terminal box body 153. During the installation of the copper terminal 151 of the switch unit and the copper terminal 152 of the mutual inductor onto the terminal box body 153, the elastic clamping members 512 can adapt to the shape change of the terminal box body 153, always maintaining a stable clamping force, preventing the terminal box body 153 from shifting or shaking, ensuring the reliability of the connection and fixation process, and contributing to the formation of a firm and stable connection.

[0099] Cooperation of the assembly fixture 500: The carrier 504 of the assembly fixture 500 is provided with a receiving cavity 505, which can firmly fix the copper terminal 151 of the switch unit and the copper terminal 152 of the mutual inductor. Under the action of an external driving source, the carrier 504 and the fixed seat 517 work together to achieve precise docking and firm connection between the copper terminal and the terminal box body 153. This cooperative assembly method greatly improves the reliability and consistency of the connection compared to traditional manual assembly, reducing the influence of human factors on the connection quality.

[0100] 4. Adapt to different copper terminals Unique design of the accommodating cavity 505: The lower end of the accommodating cavity 505 is an arc surface 5051, and the upper end is a U-shaped 5052. The upper and lower ends are connected to form a closed surface. This unique structural design can better adapt to the shape characteristics of the copper terminal 151 of the switch unit and the copper terminal 152 of the mutual inductor, providing a more fitting and stable fixing method. The arc surface 5051 can play a guiding and buffering role when the copper terminal is placed into the accommodating cavity 505, while the U-shaped 5052 limits the copper terminal from above, ensuring that the copper terminal will not rotate or displace during the assembly process, thus meeting the automatic assembly accuracy requirements of the copper terminals 151 of the switch unit and the copper terminals 152 of the mutual inductor with different shapes and specifications, and enhancing the versatility of the assembly fixture 500.

[0101] 5. Buffering and Adaptability Elastic element buffering and adjustment: The second elastic element provided between the carrier 504 and the fixture body 501 plays a role of buffering and adaptive adjustment during the assembly process. When the external driving source pushes the assembly fixture 500 towards the fixed seat 517, the second elastic element can automatically adjust the position of the carrier 504 according to the change of the assembly resistance, avoiding damage to the copper terminal or the terminal box body 153 caused by excessive external force. At the same time, after the assembly is completed, the second elastic element can also provide a certain pre-tightening force to further enhance the connection stability between the copper terminal and the terminal box body 153.

[0102] Specifically, as shown in the attached Figure 1 and the attached Figure 12As shown in the figure, the welding inspection performance testing machine 315 includes testing instruments installed under the frame (not shown in the figure). A fixed plate 519 is installed on the frame, and a Z-shaped mounting bracket 521 is installed on the fixed plate 519. A double-station multi-stage second pressing cylinder 520 is provided on the mounting bracket 521. A linkage 523 is connected under the rod of the second pressing cylinder 520. A pressure sensor is provided under the linkage 523. The pressure sensor is installed on an L-shaped fixed plate. The L-shaped fixed plate is fixedly connected to a linear guide rail. The linear guide rail and the slide rail form a sliding pair. The slide rail is fixed on the vertical plate of the Z-shaped mounting bracket 521. An instrument transformer test fixture and a switch unit test fixture are provided under the L-shaped fixed plate. The instrument transformer test fixture and the switch unit test fixture are respectively fixed to the test rod of the pressure sensor. The instrument transformer test fixture consists of an L-shaped plate provided under a square plate. An arc-shaped plate for pressing the instrument transformer 17 is provided under the L-shaped plate. The arc-shaped plate of the instrument transformer 17 presses on two copper solder joints A171 of the instrument transformer 17. The switch unit test fixture consists of a double L-shaped pressing plate provided under a square plate, which presses on the extended end where the third copper solder joint B161, the fourth copper solder joint A161 are lapped with the copper terminal 151 of the switch unit. The copper terminal 152 of the instrument transformer and the copper terminal 151 of the switch unit are installed in a terminal box to form a terminal box unit 15. The terminal box unit 15 is installed in a multi-performance floating detection fixture 534. The sliding column H534 on the multi-performance floating detection fixture 534 slides along the sliding sleeve on the fixed plate 519. A switch unit on-off probe 536, an instrument transformer on-off probe 535, a post-on-off resistance detection probe 537, and a loop resistance detection probe X534 are respectively provided under the fixed plate 519. The post-on-off resistance detection probe 537 and the welding resistance detection probe 533 are respectively aligned with the communication line pins on the switch unit 16 and the instrument transformer 17, the copper terminal 151 of the switch unit and the copper terminal 152 of the instrument transformer (at the middle position of the locking screw), the welding joint where the third copper solder joint B161, the fourth copper solder joint A161 are lapped with the copper terminal 151 of the switch unit, the welding joint where the first copper solder joint A171 and the second copper solder joint A171 of the instrument transformer 17 are lapped with the copper terminal 152 of the instrument transformer, and are arranged through the through holes on the multi-performance floating detection fixture 534. Rotating pressing devices 529 are arranged on the left and right sides of the fixed plate 519 and the multi-performance floating detection fixture 534 to press the terminal box unit 15 on the multi-performance floating detection fixture 534. Under the drive of the second pressing cylinder 520, the instrument transformer test fixture and the switch unit test fixture on the multi-performance floating detection fixture 534 are pressed at the test position, and the pressure sensor and the corresponding probes test the pressure value, welding resistance value, resistance value, on-off resistance value, and on-off function on the line of the switch unit 16 (relay or circuit breaker) and the instrument transformer 17. Whether the welding is qualified, whether there is false soldering and peeling, and whether the resistance value performance and function are qualified and good are judged in turn according to the upper and lower limits.

[0103] Specifically, the welding inspection performance testing machine 315 includes a rotary pressing device 529. The rotary pressing device 529 includes a rotary cylinder 530 and a pressing member 555. The rotary cylinder 530 is linked with the pressing member 555, and the pressing member 555 presses against the welded terminal box unit 15, switch unit 16, and current transformer 17.

[0104] As shown in the appendix Figure 15 The inventive features of the multi-performance floating detection fixture 534 include that T-shaped sliding rods L534 are provided diagonally on the square plate for fixed connection. The T-shaped sliding rods L534 and the sliding sleeves H534 fixed on the fixed plate 519 form a sliding pair. The springs in the middle of the T-shaped sliding rods L534 are arranged on the back of the fixed plate 519. A profiling groove N534 for the terminal box unit 15 is provided in the middle of the square plate. First sinking grooves A534 and second sinking grooves B534 for positioning the protruding shape of the terminal box unit 15 and a sixth U-shaped groove C534 for positioning in the middle are provided on both sides of the profiling groove N534. A first mounting hole D534 for installing a probe 537 for conducting resistance is provided between the sixth U-shaped groove C534, the first sinking groove A534, and the second sinking groove B534 opposite the copper terminal. On the front plane O534 of the profiling groove N534, a left mounting hole F534 and a right mounting hole G534 for welding resistance detection probes 533 for installing the solder joints of the test switch unit 16 and the current transformer 17 are provided. A first hole E534 is provided in the second sinking groove B534. The multi-performance floating detection fixture 534 also has a second hole M534.

[0105] The inventive effects of the multi-performance floating detection fixture 534 are specifically the effects related to the floating function: 1. Different heights or position deviations: The T-shaped sliding rods L534 on the diagonal of the square plate and the sliding sleeves H534 fixed on the fixed plate 519 form a sliding pair, and the springs in the middle of the T-shaped sliding rods L534 are arranged on the back of the fixed plate 519. This design endows the fixture with floating performance. When there are certain deviations in the height or position of the terminal box unit 15 to be detected, the springs can play a buffering and adjusting role, enabling the square plate to adaptively adjust its position and ensuring the smooth progress of the detection. It avoids the situation of detection failure or inaccurate detection caused by the small position error of the object to be detected, and improves the compatibility of the fixture with workpieces in different states.

[0106] 2. Reducing damage during the detection process: The floating function can reduce the hard collision and extrusion between the fixture and the object to be detected during the detection process. The buffering effect of the spring makes the fixture softer when contacting the workpiece, reducing the risk of damage such as scratches and indentations on the surface of the terminal box unit 15, and helping to protect the appearance and performance of the product to be detected.

[0107] 3. Effects related to the profiling groove and the positioning structure 1. Precision positioning terminal box: There is a profiling groove N534 for the terminal box unit 15 in the middle of the square plate. On both sides of the profiling groove N534, there are the first sunk groove A534 and the second sunk groove B534 for positioning the convex shape of the terminal box and the sixth U-shaped groove C534 for positioning in the middle. These profiling and positioning structures can precisely match the shape of the terminal box unit 15, achieving precise positioning of the terminal box. Ensure that the position of the terminal box is fixed during the detection process, avoid inaccurate detection results caused by shaking or displacement, and improve the accuracy and reliability of detection.

[0108] 2. Improve detection stability: Through the positioning function of the sunk groove and the U-shaped groove, the terminal box is firmly fixed in the profiling groove, so that the terminal box will not move or shift during various detection operations. This is particularly important for detection items such as conduction resistance and welding resistance that require precise measurement, which can ensure the stability of the detection process and reduce measurement errors.

[0109] 4. Related effects of probe mounting holes 1. Accurately detect conduction resistance: There is a first mounting hole D534 for installing a probe 537 for detecting conduction resistance between the sixth U-shaped groove C534, the first sunk groove A534 and the second sunk groove B534, facing the copper terminal. This design enables the probe 537 to accurately contact the copper terminal, thereby achieving precise detection of the conduction resistance. The position of the mounting hole corresponds precisely to the copper terminal, ensuring good electrical contact between the probe and the copper terminal, and improving the accuracy and reliability of conduction resistance detection.

[0110] 2. Effectively detect welding resistance: On the front-end plane O534 of the profiling groove N534, there are a left mounting hole F534 and a right mounting hole G534 for a welding resistance detection probe 533 facing the solder joints for installing the test switch unit 16 and the mutual inductor 17. By accurately installing the probe 533 through these two mounting holes, it can ensure precise contact between the probe and the solder joints, thereby effectively detecting the welding resistance of the solder joints of the test switch unit 16 and the mutual inductor 17. Accurate detection of welding resistance helps to timely discover welding quality problems and ensure the electrical performance and stability of the product.

[0111] Specifically, as shown in the appendix Figures 10 - 11 The welding, inspection and integration machine 313 includes a fixing device, a welding mechanism, a cold water circulation mechanism 6, a cold air mechanism 8, a first temperature sensor 164, a CCD detection mechanism 21, and a control mechanism. The fixing device fixes the terminal box unit 15, the switch unit 16, and the mutual inductor 17.

[0112] In this embodiment, the number of welding, inspection and integration machines 313 is two. The second conveyor belt 3 is connected to a first conveyor belt (not shown in the drawing) and a third conveyor belt 4. The first conveyor belt is connected in parallel with the welding, inspection and integration machine 313, and the third conveyor belt 4 is connected in parallel with another welding, inspection and integration machine 313.

[0113] The welding mechanism includes an upper electrode 19 and a lower electrode 27. The lower electrode 27 abuts against the lower ends of the copper terminal of the switch unit 151 and the copper terminal of the mutual inductor 152. The second conductive member 161 and the third conductive member 171 are located on the movement track of the upper electrode 19. Here, the welding method between the upper electrode 19 and the lower electrode 27 can be that the upper electrode 19 and the lower electrode 27 move relatively at the same time, and finally form upper and lower clamping to form resistance brazing. It can also be that the upper electrode 19 moves and the lower electrode 27 is in a static state; it can also be that the lower electrode 27 moves and the upper electrode 19 is in a static state. The upper electrode 19 and the lower electrode 27 are respectively connected to corresponding electrode arms.

[0114] The cold water of the cold water circulation mechanism 6 flows through the upper electrode 19 and the lower electrode 27.

[0115] The cold air of the cold air mechanism 8 blows towards the upper electrode 19.

[0116] The first temperature sensor 164 detects the temperature of the upper electrode 19 and the welding position.

[0117] The CCD detection mechanism 21 detects the terminal box unit 15, the switch unit 16, and the mutual inductor 17.

[0118] The control mechanism detects the welding temperature, and the control mechanism adjusts one or two or more combinations of the welding current, welding time, welding pressure, cold water temperature, cold water flow rate, cold air temperature, and cold air flow rate. With this structural arrangement, the connection and fixation between the switch unit 16, the mutual inductor 17, and the terminal box unit 15 are formed through the welding mechanism. Compared with the prior art, this processing method is simpler. By adopting automated operation, several welding steps are combined to form an automated welding effect, improving the processing efficiency. Secondly, by detecting the welding temperature and controlling various parameters, the control of the welding temperature is formed, so that the welding temperature is maintained within a preset threshold, thereby ensuring that no phenomena such as false soldering occur during the welding process, improving the welding quality, and forming the effect of controlling the temperature in multiple modes through multiple modes such as water or cold air or current or pressure.

[0119] The welding, assembling and detecting integrated machine 313 invention has remarkable technical effects in many aspects: 1. Improve processing efficiency: The welding, installation and inspection integrated machine 313 integrates multiple steps such as welding, installation and inspection. Through automated operations, several welding steps are combined to form an automated welding effect. Compared with the prior art, it reduces manual intervention and process conversion time, avoids operations such as handling and repositioning between different devices, and greatly improves the processing efficiency of the connection and fixation between the terminal box unit 15, the switch unit 16, and the mutual inductor 17. At the same time, the setting method in which two welding, installation and inspection integrated machines 313 are respectively connected in parallel with the first conveyor belt and the third conveyor belt 4 can realize continuous operation in a production line, further improving the overall production efficiency.

[0120] 2. Ensure welding quality: The control mechanism can detect the welding temperature and adjust one or more parameters among the welding current, welding time, welding pressure, cold water temperature, cold water flow rate, cold air temperature, and cold air flow rate to maintain the welding temperature within the preset threshold. This effectively avoids phenomena such as false soldering caused by improper temperature, ensures the firmness and reliability of the welding points, and improves the welding quality. By comprehensively controlling multiple modalities (water, cold air, current, pressure, etc.) to adjust the temperature, the welding process becomes more stable and controllable.

[0121] 3. Good electrode cooling effect: The cold water of the cold water circulation mechanism 6 flows through the upper electrode 19 and the lower electrode 27, and the cold air of the cold air mechanism 8 blows towards the upper electrode 19. This dual cooling method can effectively reduce the temperature of the electrode. On the one hand, it prevents the electrode from being damaged or its performance from deteriorating due to long-term high-temperature operation, extending the service life of the electrode; on the other hand, the stable electrode temperature helps to maintain the consistency of welding parameters, thus ensuring the stability of welding quality.

[0122] 4. Precise temperature monitoring: The first temperature sensor 164 can detect the temperature of the upper electrode 19 and the welding position in real time, providing accurate temperature feedback information for the control mechanism. Based on these real-time temperature data, the control mechanism adjusts relevant parameters in a timely manner to achieve precise control of the welding temperature, further improving the reliability and quality of the welding process.

[0123] 5. Comprehensive product inspection: The CCD inspection mechanism 21 can inspect the terminal box unit 15, the switch unit 16, and the mutual inductor 17, and can timely detect defects or abnormalities in the size, shape, appearance, etc. of the products. By conducting real-time inspection during the production process, it avoids unqualified products from flowing into the next process, reduces the scrap rate, and improves the overall quality and production efficiency of the products.

[0124] 6. Flexible welding methods: There are multiple options for the welding method between the upper electrode 19 and the lower electrode 27 of the welding mechanism, including the relative movement of the upper and lower electrodes 27 at the same time, the movement of the upper electrode 19 while the lower electrode 27 remains stationary, the movement of the lower electrode 27 while the upper electrode 19 remains stationary, etc. This flexible welding method can be selected according to different product requirements and process requirements, improving the adaptability and versatility of the equipment and enabling it to meet different types of welding tasks.

[0125] 7. High degree of automation: The operation of the entire welding and inspection integrated machine 313 is automatically controlled by the control mechanism, reducing the errors and instability of manual operation. The automated control method not only improves production efficiency but also reduces the technical requirements for operators, making the production process more standardized and regularized.

[0126] Such as attached Figure 14As shown in the figure, the flexible integrated assembly fixture includes a profiling assembly fixture 403. Multiple components (including relays, circuit breakers, and instrument transformers) are sleeved on the profiling assembly fixture 403. The profiling assembly fixture 403 includes a first L-shaped plate A500. A square groove A503 for assembling the switch unit 16 is provided on the low-end plate A505 of the first L-shaped plate A500. A plurality of second array vacuum suction holes (not shown in the figure) for locking the switch unit 16 are arranged in the square groove A503. A fifth U-shaped groove A504 for positioning the communication socket A16 is provided at the rear end of the square groove A503. At the left end of the high-end plate of the first L-shaped plate A500, a first U-shaped groove A512 for limiting the moving contact piece B16 is provided. Communicating with the first U-shaped groove A512 is an L-shaped platform A509 for positioning and limiting the first copper solder piece A171 and the third copper solder piece B161. Connected to the limiting L-shaped platform A509 is a lower step platform A511. Connected to the lower step platform A511 is a second U-shaped groove A510. The lower step platform A511 and the second U-shaped groove A510 are used for positioning the lead pin A17 on the instrument transformer 17. Adjacent to the second U-shaped groove A510 and the limiting L-shaped platform A509, a positioning and locking groove A508 for the instrument transformer 17 is provided. The arc groove of the positioning and locking groove A508 is provided with a plurality of array third vacuum suction holes (not shown in the figure) for locking the instrument transformer 17. Adjacent to the positioning and locking groove A508, a third U-shaped groove A507 for limiting the fourth copper solder piece A161 is provided. On the bottom plate of the third U-shaped groove A507, a fourth U-shaped groove A502 for limiting the B flexible wire B17 is provided. Adjacent to the right end of the third U-shaped groove A507, a second L-shaped plate is provided with an L-shaped platform A506 for positioning and limiting the first copper solder piece A171 and the fourth copper solder piece A161. An L-shaped groove plate A501 is provided on the L-shaped platform A506, and a vacuum valve (not shown in the figure) is provided on the L-shaped groove plate A501, forming an integrated flexible assembly fixture for multiple components such as the instrument transformer 17 and the switch unit 16 (relay, circuit breaker). This realizes the primary positioning of multiple component switch units 16 (relays or circuit breakers) and instrument transformers 17, reduces the error of multiple positionings in the prior art, eliminates the problem of assembly deformation in the sampling components in the prior art, improves the accuracy at the same time, and realizes the locking and limiting of multiple components.

[0127] The advantages and effects achieved by the present invention in terms of technology are as follows; 1. Assembly efficiency: Integrating multiple components on one fixture enables multiple assembly processes to be carried out simultaneously, reducing the number of loading and unloading times and transfer time of workpieces between different fixtures, thus greatly improving the assembly efficiency.

[0128] 2. Enhanced assembly accuracy: Through the integrated design and precise positioning device, the relative position accuracy of each component during the assembly process can be guaranteed, effectively reducing the cumulative error and improving the assembly quality and consistency of the product.

[0129] 3. Adapt to multiple products: It has the characteristics of flexibility. By adjusting certain components or parameters of the fixture, it can adapt to the assembly requirements of products with different models and specifications, improving the versatility and utilization rate of the fixture, and reducing the cost for enterprises to equip special fixtures for different products.

[0130] 4. Save space: Compared with traditional multiple scattered fixtures, the multi-component integrated flexible one-piece assembly fixture integrates multiple functions into one, occupying less production space, which helps to optimize the layout of the production workshop and improve space utilization rate.

[0131] 5. Facilitate management: Since the number of fixtures is reduced, the management and maintenance work is more centralized and simple, reducing the difficulty and cost of fixture management. At the same time, it is also convenient to track and monitor the usage of fixtures.

[0132] The invention of the multi-component integrated flexible one-piece assembly fixture solves the following problems: 1. The problem of poor versatility of traditional fixtures: Traditional fixtures are usually designed for specific products or parts. Once the product model or specification changes, the fixture often cannot be used continuously and needs to be redesigned and manufactured. The multi-component integrated flexible one-piece assembly fixture can adapt to the assembly of multiple products through its flexible design, effectively solving this problem and improving the usage efficiency and economy of the fixture.

[0133] 2. The problem of unstable assembly accuracy: In the traditional assembly process, using multiple fixtures for assembly of different processes is prone to errors in positioning between fixtures and error accumulation caused by multiple clamping, resulting in unstable assembly accuracy. The multi-component integrated flexible one-piece assembly fixture can precisely control the assembly positions of each component through integrated design and a high-precision positioning system, ensuring the stability and consistency of assembly accuracy.

[0134] 3. The problem of low production efficiency: Traditional fixtures need to be frequently replaced and adjusted, resulting in long workpiece loading and unloading time and more downtime during the production process, affecting production efficiency. The multi-component integrated flexible one-piece assembly fixture can realize simultaneous assembly of multiple processes, reducing the number of fixture replacements and downtime, improving production efficiency, and shortening the production cycle of products.

[0135] 4. The problem of tight production space: Multiple traditional fixtures occupy a large amount of space in the workshop, not only making the workshop layout appear messy, but also increasing the difficulty of material transportation and personnel operation. The integrated design of the multi-component integrated flexible one-piece assembly fixture greatly reduces the number and floor area of fixtures, making the production space more compact and tidy, which is conducive to improving the management level and logistics efficiency of the production site.

[0136] Specifically, as shown in the appendix Figures 10 - 11As shown, the cold water circulation mechanism 6 is provided with a water inlet and a water return port. The water inlet is provided with a second temperature sensor for detecting the temperature of the cold water and a first flow sensor for detecting the cold water flow rate; the water return port is provided with a third temperature sensor 28 for detecting the temperature of the cold water. The setting of the temperature sensors at different positions of the cold water circulation mechanism 6 facilitates the control of the control mechanism at each position. Through the second temperature sensor and the first flow sensor, the water temperature and the flow rate of the outflow can be known. Through the third temperature sensor 28, it can be known whether the heat is abnormal and whether the heat can be conducted from the upper electrode 19 to the lower electrode 27.

[0137] Specifically, as shown in the appendix Figures 10 - 11 As shown, the first temperature sensor 164 movably detects the temperature of the upper electrode 19 and the temperature of the welding position. The up and down detection of the first temperature sensor 164 makes the detection range larger.

[0138] Specifically, as shown in the appendix Figures 10 - 11 As shown, the cold air mechanism 8 is provided with a fourth temperature sensor and a first flow velocity sensor. The fourth temperature sensor detects the cold air temperature, and the first flow velocity sensor detects the cold air flow velocity. Through the fourth temperature sensor and the first flow velocity sensor, the cold air temperature and the cold air flow velocity can be controlled. The cold air mechanism 8 can generate cold air and control the temperature of the cold air, etc.

[0139] Specifically, the first temperature sensor 164 movably detects the upper electrode 19 and the welding position. The up and down detection of the first temperature sensor 164 makes the detection range larger.

[0140] Specifically, as shown in the appendix Figures 10 - 11 As shown, it further includes a CCD detection mechanism 21. The CCD detection mechanism 21 detects whether there are solder pads fixed on the second conductive member 161 and the third conductive member 171. The setting of the CCD detection can ensure that before welding, the second conductive member 161 and the third conductive member 171 are fixed with solder pads, improving the welding quality. In this embodiment, the CCD detection mechanism 21 has two sets, the upper CCD detection mechanism 21 consists of a pair of condensers and a CCD (detecting whether the dimensions before and after assembly and welding are qualified, whether the sampling pins and signal pins of the switch unit 16 and the mutual inductor 17 are missing, deformed, whether the welding surface changes color, whether the solder overflows and is qualified, and whether the appearance is qualified), and the lower CCD detection mechanism 21 consists of a pair of lights and a CCD (detecting whether there are solder pads before the assembly of the switch unit 16 and the mutual inductor 17 and whether the dimensions and positions are qualified, detecting the position dimensions and appearance of the copper bar assembly and the terminal box unit 15).

[0141] Specifically, it further includes an alarm mechanism. When a fault occurs, the control mechanism controls the alarm mechanism to act to achieve an alarm. Here, the alarm method can be a sound alarm, a visual alarm, or a combination of a sound alarm and a visual alarm. Here, the visual alarm can be a warning light.

[0142] Specifically, for example, when the return water temperature is abnormal, heat cannot be conducted to the product and then to the lower electrode 27. At this time, the return water temperature will be lower than the preset value. When the temperature of the lower electrode 27 is abnormal, the temperatures of the upper and lower electrodes 27 will be inconsistent, and poor welding is likely to occur. Therefore, at this time, the control mechanism automatically adjusts the welding parameters, adjusting one or two combinations or three combinations of the welding current, welding time, and welding pressure, and then determines whether the return water temperature has been adjusted to the preset value. When multiple adjustments are ineffective, an alarm can be controlled to avoid the phenomenon of poor welding of too many products.

[0143] For another example, when the temperature of the upper electrode 19 is too high or overheated, the control mechanism controls the electric valve of the cold air mechanism to adjust the temperature and flow rate of the cold air, so that the temperature of the upper electrode 19 returns to the preset threshold value. Here, the cold water temperature and flow rate of the cold water circulation mechanism 6 can also be adjusted.

[0144] For another example, when the temperature of the upper electrode 19 is insufficient, the temperature of the lower electrode 27 is insufficient, or the temperature of the welding position is insufficient, the control mechanism controls the adjustment of the cold water temperature and flow rate of the cold water circulation mechanism 6 to compensate for the insufficient welding temperature.

[0145] For example, when the residual temperature at the welding position has not reached the preset value, the control mechanism adjusts the welding parameters, adjusting one or two combinations or three combinations of the welding current, welding time, and welding pressure, to compensate for the welding heat, so that the residual temperature at the welding position reaches the preset value. Here, the detection of the residual temperature at the welding position is extremely important. If the residual temperature at the welding position does not meet the standard, it is also easy to cause problems such as false soldering at the welding position and low welding quality.

[0146] Further detailed description of the problems solved by the present invention and supplementary description of the inventive points: Technical problems to be solved Low production efficiency: The existing intelligent electricity meter processing uses manual processing, with cumbersome processes and low efficiency, and the cooperation between equipment is unreasonable, resulting in a long production cycle.

[0147] Poor equipment versatility: Traditional jigs and equipment are usually designed for specific products or parts. When the product model or specification changes, they often cannot be used continuously and need to be redesigned and manufactured.

[0148] Unstable welding quality: During the welding process, improper control of parameters such as temperature and current is likely to cause problems such as false soldering, affecting the welding quality. At the same time, existing ultrasonic equipment has problems such as clutter, harmonics, and unstable energy, and cannot achieve high-quality welding of ultra-thin solder joints.

[0149] Insufficient detection accuracy: There are problems of low accuracy and incomplete detection items in the product detection link, which is difficult to ensure the stability and consistency of product quality, and cannot detect and eliminate unqualified products in time.

[0150] High equipment maintenance cost: Equipment maintenance and management are relatively complicated. For example, the replacement of welding head A467 is time-consuming and costly, which affects production efficiency and enterprise benefits. Static electricity interference: During the cutting and welding process of ultra-thin solder sheets, static electricity is easily generated due to the friction between the material and the tool, equipment, and between the soldering teeth and the ultra-thin solder sheet and the lower hazelnut 405. Static electricity may not only absorb dust and other impurities to pollute the surface of the solder sheet, but also cause electrostatic discharge, causing potential damage to the performance of the solder sheet. At the same time, environmental factors such as temperature, humidity, and air quality will also affect the processing quality. For example, if the ambient humidity is too high, the silver-copper-phosphorus solder sheet is easily affected by moisture and oxidation, and the dust and impurities in the workshop may be adsorbed on the surface of the solder sheet, resulting in welding defects and cold solder joints.

[0151] Assembly accuracy and stability: In the traditional assembly process, multiple fixtures are used for assembly of different processes, which is prone to unstable assembly accuracy due to positioning errors between fixtures and accumulation of errors caused by multiple clamping. In addition, in the process of assembling the switch unit copper terminal 151, the transformer copper terminal 152 to the terminal box body 153, if accurate positioning and stable connection cannot be guaranteed, the overall performance of the smart meter will be affected.

[0152] Equipment takes up a large space: In the traditional production model, equipment and fixtures with different functions are relatively scattered, occupying a large amount of production space, making the workshop layout messy, increasing the difficulty of material transportation and personnel operation, and is not conducive to improving the management level and logistics efficiency of the production site.

[0153] Low degree of equipment automation: The existing technology involves a lot of manual intervention, which is not only inefficient, but also the errors and instability of manual operation will affect the consistency of product quality. At the same time, it places high technical requirements on operators, increasing labor costs.

[0154] Difficulties in adaptability and maintenance of welding head A467: In the welding of smart meter parts, welding pieces of different thicknesses and materials require welding head A467 to have good adaptability. The traditional single-head welding head A467 is difficult to meet the welding needs of welding pieces of various specifications, and the replacement process is time-consuming, labor-intensive and costly. At the same time, during long-term use, welding head A467 is prone to wear and damage due to frequent contact with harsh working conditions such as high temperature, high pressure and friction. How to extend the service life of welding head A467 and reduce maintenance frequency is also a technical problem that needs to be solved urgently.

[0155] Precise control of multi-process collaborative operations: Smart meter processing involves multiple processes such as terminal copper strip assembly, welding of welding pieces, overall welding fixation, and performance testing, and each process requires close coordination and cooperation. In actual production, how to ensure precise control of each process in terms of time, space, and process parameters, and avoid problems such as production stagnation and quality fluctuations due to improper process connection, is a key technical problem to ensure efficient and stable production.

[0156] Difficulty in product quality traceability: During the production process of smart meters, due to the involvement of numerous components, complex processing procedures, and a large amount of production data, when quality problems occur in the products, it is difficult to quickly and accurately trace the root causes of the problems, such as specific processing links, equipment parameters, raw material batches, etc. This not only affects the efficiency of solving product quality problems but also may lead to a large number of potential problem products flowing into the market, damaging the enterprise's reputation.

[0157] The invention supplement points for solving the above technical problems Automated assembly line production: Through the coordinated operation of multiple machines such as the terminal copper bar assembly machine 312, the solder tab assembly machine 328, the welding and inspection integration machine 313, and the welding and inspection performance testing machine 315, an automated assembly line production is formed, greatly improving the production efficiency and reducing the labor cost.

[0158] General and flexible design: The profiling cavity 3261 of the first fixture 326 is a general setting, which can fix the switch unit 16 and the mutual inductor 17, reducing the number of special fixtures and equipment. The lifting and rotating mechanism 477 cooperates with the special structure of the first fixture 326 to meet the welding requirements at different positions, enhancing the versatility and adaptability of the equipment.

[0159] High-quality welding technology: The welding and inspection integration machine 313 adjusts the welding parameters through the control mechanism, and uses the cold water circulation mechanism 6 and the cold air mechanism 8 to control the welding temperature to avoid problems such as false soldering. The welding head A467 of the ultrasonic welding machine 322 has a special design, realizing fine filtering and three-stage amplification of the ultrasonic amplitude, and can achieve high-quality welding of ultra-thin solder tabs with different thicknesses.

[0160] Precision detection technology: The multi-performance floating detection fixture 534 of the welding and inspection performance testing machine 315 can comprehensively detect the products, including various performance detections such as welding firmness, welding tensile force, and welding resistance, ensuring the reliability of product quality. The design of the multi-performance floating detection fixture 534 enables the fixture to have a floating performance, which can adapt to workpieces in different states and improve the detection accuracy.

[0161] Convenient maintenance design: The welding teeth of the welding head A467 adopt a cross-shaped design, solving the problem of quick replacement of multiple welding teeth, saving costs and reducing replacement time. The design of various arrayed tooth tips of the welding teeth improves the applicability of the welding head A467 to different specifications of solder tabs and reduces the equipment maintenance cost.

[0162] Electrostatic elimination and environmental adaptation design: The ultrasonic welding machine 322 is equipped with an ion extraction fan 480, and the welding head A467, lower hazelnut 405, ultra-thin solder slice cutter, and U-shaped suction head are grounded with copper wires at close range, effectively solving the electrostatic problem. Through these measures, the contamination and performance damage of the solder slices caused by static electricity are avoided, the influence of environmental factors on the welding effect is reduced to a certain extent, and the stability and quality of product production in a complex environment are ensured.

[0163] Efficient and precise assembly design: The assembly fixture 500 provides precise guidance and limitation for the sliding of the carrier 504 relative to the fixture body 501 through the cooperation of the guiding structure or limiting structure, ensuring that the copper terminal buttons 151 of the switch unit and the copper terminal buttons 152 of the current transformer can accurately align with the corresponding positions on the terminal box body 153 during the installation process, improving the accuracy and efficiency of assembly. At the same time, the elastic clamping members 512 on both sides of the fixed seat 517 provide stable fixed support for the terminal box body 153, and the accommodation cavity 505 design of the carrier 504 can better adapt to the shape of the copper terminal buttons, ensuring the reliability of the connection and fixing process.

[0164] Space optimization design: The multi-component integrated flexible one-piece assembly fixture integrates the assembly functions of multiple components, reducing the number of fixtures and the floor area. The solder slice assembly machine 328 adopts a turntable 325 design, reducing the overall volume. These designs optimize the layout of the production workshop, improve the space utilization rate, and are conducive to enhancing the management level and logistics efficiency of the production site.

[0165] Highly automated control: The operation of the entire intelligent electricity meter processing equipment is automatically controlled by the control mechanism. For example, the control mechanism of the welding, assembly, and inspection integrated machine 313 can automatically adjust parameters such as welding current, time, and pressure, as well as control the cold water circulation mechanism 6 and the cold air mechanism 8. Automated control reduces the errors and instabilities of manual operations, lowers the technical requirements for operators, makes the production process more standardized and normalized, and improves the consistency of production efficiency and product quality.

[0166] Innovative design of the welding head A467: The welding head A467 adopts a unique structural design. The rear end A471 is connected to a series of components with different shapes, realizing fine filtering and three-stage amplification of the ultrasonic amplitude, effectively solving the problems of clutter, harmonics, and energy instability in existing ultrasonic equipment, and being able to meet the high-quality welding requirements of ultra-thin silver-copper-phosphorus solder slices with different thicknesses (0.03 - 0.12 mm) and copper phosphorus.

[0167] On the welding head A467, there are solder teeth A466 arranged in a cross pattern with a size of 4x5x5, which solves the problem of quick replacement of multiple solder teeth A466, greatly saves costs, and reduces the replacement time. At the same time, the solder teeth A466 have various array cusp layout designs (4x4, 3x3, 5x5), which can be selected according to the thickness of different copper solder sheets, significantly improving the applicability of the welding head A467 to different specifications of solder sheets, and reducing the welding quality problems and maintenance costs caused by the mismatch of the welding head A467.

[0168] Multi-process collaborative control system: Through the layout of the automated production line, the terminal copper bar assembly machine 312, the solder sheet assembly machine 328, the welding and inspection integrated machine 313, and the welding and inspection performance testing machine 315 are organically combined, and the conveyor belt is used to realize the material transfer between adjacent machines, ensuring the close connection of each process in space.

[0169] Each device is equipped with a corresponding control mechanism. For example, the control mechanism of the welding and inspection integrated machine 313 can detect the welding temperature and precisely adjust multiple parameters such as welding current, welding time, welding pressure, cold water temperature, cold water flow rate, cold air temperature, and cold air flow rate to maintain the welding temperature within the preset threshold. At the same time, the control mechanisms of each device can perform data interaction and collaborative work to achieve precise control of multiple processes in terms of time and process parameters, ensuring the efficient and stable operation of the entire production process.

[0170] Perfect product quality traceability system: During the production process, each processing device collects and records a large amount of data, including but not limited to welding parameters (current, time, pressure, etc.), assembly data (component position, fixing method, etc.), and inspection results (welding firmness, resistance value, etc.).

[0171] A unified data management platform is established to integrate and store these data, and a unique identification code is assigned to each product. When a quality problem occurs in the product, relevant data can be quickly queried through this identification code, traced back to each link in the product production process, accurately locate the root cause of the problem, and take measures for improvement in a timely manner, effectively improving the efficiency and accuracy of product quality traceability, and ensuring product quality and corporate reputation.

[0172] Obviously, the above embodiments are only examples given for clear illustration and are not limitations on the implementation manners. For those of ordinary skill in the art, other different forms of changes or variations can be made based on the above description. It is not necessary and impossible to enumerate all the implementation manners here. And the obvious changes or variations derived therefrom are still within the protection scope of the present invention.

Claims

1. Smart meter multi-functional collaborative high-efficiency precision processing and quality control technology and equipment, characterized by: include: The terminal copper strip assembly machine includes a fixing seat for fixing the terminal box body and an assembly fixture for fixing the switch unit copper terminal and the transformer copper terminal. The terminal copper strip assembly machine installs the switch unit copper terminal and the transformer copper terminal to the terminal box body to form a terminal box unit. The welding piece assembly machine includes an automatic cutting and feeding unit, an ultrasonic welding machine, and a first fixture provided with a profiling cavity, wherein the profiling cavity fixes the switch unit or the mutual inductor; the automatic cutting and feeding unit cuts and feeds the welding piece; the ultrasonic welding machine welds the welding piece and the switch unit or the mutual inductor; The welding and inspection integrated machine, the switch unit is fixed with a second conductive member, the transformer is fixed with a third conductive member, the second conductive member and the third conductive member are respectively welded and fixed with welding pieces; the welding and inspection integrated machine welds the second conductive member to the copper terminal of the switch unit; the welding and inspection integrated machine welds the third conductive member to the copper terminal of the transformer; The welding inspection performance testing machine includes a multi-performance floating detection fixture, which can detect the terminal box unit with switch units and transformers welded and fixed.

2. The multi-functional collaborative high-efficiency precision processing and quality control technology and equipment for smart electric meters according to claim 1 is characterized in that: The welding piece assembly machine comprises a turntable, which is provided with a loading station, a detection station, a welding station, and a unloading station. The number of the first clamps is at least four, and the first clamps are respectively located at the corresponding stations; the ultrasonic welding machine cooperates with the welding station.

3. The multi-functional collaborative high-efficiency precision processing and quality control technology and equipment for smart electric meters according to claim 1 or 2 is characterized in that: The first fixture includes an outer sleeve, an inner sleeve, a contour assembly fixture, a support rod, a lower hazelnut, a floating ball and a first elastic member. The inner sleeve is located in the outer sleeve, and the inner sleeve slides axially relative to the outer sleeve. The floating ball and the first elastic member are located between the outer sleeve and the inner sleeve. The first elastic member gives the floating ball an extrusion force to press against the side wall of the inner sleeve. The support rod is linked to one end of the lower hazelnut, and the other end of the lower hazelnut cooperates with the contour assembly fixture; the contour cavity is arranged in the contour assembly fixture.

4. The multi-functional collaborative high-efficiency precision processing and quality control technology and equipment for smart electric meters according to claim 3 is characterized in that: The welding piece assembly machine also includes a lifting and rotating mechanism, which cooperates with the support rod to form the lifting and rotation of the switch unit or the mutual inductor.

5. The multi-functional collaborative high-efficiency precision processing and quality control technology and equipment of smart electric meter according to claim 4 is characterized in that: The welding piece assembly machine also includes a blanking mechanism, which includes a sliding clamping claw. The blanking mechanism cooperates with the blanking station, and the sliding clamping claw cooperates with the welded switch unit or the welded mutual inductor.

6. The multi-functional collaborative high-efficiency precision processing and quality control technology and equipment for smart electric meters according to claim 3 is characterized in that: An assembly fixture is mounted on the contoured assembly fixture. The assembly fixture is composed of a first L-shaped plate. The lower end plate of the first L-shaped plate is provided with a square groove for assembling the switch unit. The square groove is provided with a plurality of array second vacuum suction holes for locking the switch unit; the rear end of the square groove is provided with a fifth U-shaped groove for positioning the communication socket; the left end of the high end plate of the first L-shaped plate is provided with a first U-shaped groove for limiting the moving contact piece, and the L platform for positioning and limiting the first copper welding piece and the third copper welding piece is connected to the first U-shaped groove, and a lower step platform is connected to the limit L platform, and a second U-shaped groove is provided with the lower step platform. The step platform and the second U-shaped groove are used for positioning the pins on the transformer; the positioning and locking groove of the transformer is arranged adjacent to the second U-shaped groove and the limiting L-platform, and the arc groove of the positioning and locking groove is arranged to lock multiple array third vacuum suction holes of the transformer; the third U-shaped groove for limiting the fourth copper welding piece is arranged adjacent to the positioning and locking groove, and the bottom plate of the third U-shaped groove is arranged to limit the fourth U-shaped groove of the B soft wire, and the second L-shaped plate adjacent to the third U-shaped groove on the right end is arranged to position and limit the first copper welding piece and the fourth copper welding piece L-shaped platform, an L-shaped groove plate is arranged on the L-shaped platform, and a vacuum valve is arranged on the L-shaped groove plate.

7. The multi-functional collaborative high-efficiency precision processing and quality control technology and equipment for smart electric meters according to claim 1 is characterized in that: The ultrasonic welding machine includes an ultrasonic generator, a first downward pressure cylinder, a support frame, a shell, a guide column, an ion exhaust fan, and an air pressure valve. The ultrasonic generator is accommodated in the shell, the first downward pressure cylinder is linked to the ultrasonic generator, the ultrasonic generator is connected to the support frame, and the support frame and the guide column slide relatively; the exhaust fan exhausts air in the shell; and the air pressure valve is used to adjust the air pressure.

8. The multi-functional collaborative high-efficiency precision processing and quality control technology and equipment for smart electric meters according to claim 7 is characterized in that: The ultrasonic welding machine also includes a transformer, a screw, and a welding head. The ultrasonic generator is input to the transformer through a transducer, and the transformer is transmitted to the welding head through the screw. The amplitude of the input welding head is a column from the rear end face to the welding tooth, and the axis of the column is perpendicular to the rear end face; a fine-thread screw hole is set at the center of the rear end face, and a coarse-thread screw hole is set at the center of the output end of the transformer; the rear end is guided at a 1:1 ratio through the first cone and the amplitude energy is amplified in the second stage, and the amplified amplitude energy is transmitted to the third cone through the second column, an arc is set on the third cone, the arc shrinks and gathers energy to the flat body, the flat body is amplified and guided to the welding head through the third stage, and the amplitude and energy on the welding head are transmitted to the welding tooth through the energy guiding ribs.

9. The multi-functional collaborative high-efficiency precision processing and quality control technology and equipment for smart electric meters according to claim 7 is characterized in that: The automatic cutting and feeding unit includes a stand, on which a friction adjustment unit, a friction gap, and a first guide groove are arranged in sequence from right to left; a cutting cylinder and a cutting knife are arranged on the side at the upper end of the second guide width slide, and the side elevation of the blade is parallel to the welding piece and the outer end surface of the first guide groove plate; a U-shaped suction nozzle is arranged adjacent to the cutting knife gap, and a pair of first vacuum suction holes are arranged on the bottom surfaces of both ends of the U-shaped suction nozzle; the U-shaped suction nozzle is installed on the side of the first guide width slide, and an upper and lower grabbing cylinder is arranged on the upper end of the first guide width slide, the first guide width slide and the upper and lower grabbing cylinders are fixed on the frame, and a driving cylinder is arranged perpendicular to the grabbing cylinder; the friction adjustment unit is arranged at Driven by the motor, the fixed length is automatically set to send the welding piece through the first guide groove to the position below the U-shaped suction nozzle. The upper and lower grabbing cylinders press the U-shaped suction nozzle down on the guide rail table. The cutting cylinder drives the cutter to cut the welding piece and then reset it. The upper and lower grabbing cylinders grab the welding piece sucked by the U-shaped suction nozzle, grab and lift it up. The driving cylinder drives the upper and lower grabbing cylinders to send the welding piece sucked by the U-shaped suction nozzle down to the position of the copper terminal of the switch unit and the copper terminal of the transformer. The welding teeth on the welding head are inserted into the U-shaped suction nozzle to ultrasonically weld the welding piece to the copper terminal of the switch unit and the copper terminal of the transformer. The driving cylinder drives the upper and lower grabbing cylinders to lift and reset the U-shaped suction nozzle.

10. The smart meter multi-functional collaborative high-efficiency precision processing and quality control technology and equipment according to claim 9, characterized in that: The blade angle of the cutter is 28 to 31 degrees; or, the friction gap is less than 0.8-0.9 times the thickness of the welding piece; or, the side elevation of the blade is parallel to the welding piece and the outer end surface of the first guide groove plate, and the gap from the side elevation of the blade to the U-shaped suction nozzle is less than 1.5 to 1 times the thickness of the welding piece; or, the gap from the side bevel of the blade to the U-shaped suction nozzle is 2 to 3 times the thickness of the welding piece; or, the angle of the welding tooth is 90 degrees; or the tooth spacing between the welding teeth is 1mm; or the welding teeth are straight; or the weld tooth tip plane is 0.2mmx0.2mm; or, the weld tooth bottom plane is 0.4mmx0.4mm; or, the weld tooth height is 0.5mm; the weld tooth tips are distributed in a 4x4 array, a 3x3 array, or a 5x5 array.

11. The smart meter multi-functional collaborative high-efficiency precision processing and quality control technology and equipment according to claim 8, characterized in that: The ultrasonic generator is a 40K ultrasonic generator; the screws are M6x1x13 and M8x0.75x15; the total length from the rear end face of the welding head to the welding tooth cylinder is 65±3mm; the finish of the rear end face is less than Ra0.8; a M8x0.75 fine-thread screw hole 17mm is set in the center of the rear end face, and a coarse-thread M6x1 coarse-thread screw hole 15mm is set in the center of the output end of the amplitude transformer; the rear end conducts energy at a ratio of 1:1 through the first cone and amplifies the amplitude energy in the second stage, and the amplified amplitude energy is transmitted to the third cone through the second cylinder, and an arc is set on the third cone, and the arc shrinks and gathers energy to the flat body at a ratio of 1:1, and the flat body conducts energy to the welding head through the third stage amplification; the welding teeth are evenly arranged in multiple 4 or 6 in the circumferential direction of the welding head, and the welding teeth and the welding head are quickly replaced.

12. The smart meter multi-functional collaborative high-efficiency precision processing and quality control technology and equipment according to claim 1, characterized in that: Elastic clamping parts are provided on both sides of the fixing seat, and the elastic clamping parts are pressed against the two sides of the terminal box body; the assembly fixture includes a fixture body, a carrier, and a second elastic part. The carrier slides relative to the fixture body, one end of the second elastic part is pressed against the carrier, and the other end of the second elastic part is pressed against the fixture body. The carrier is provided with a accommodating cavity for fixing the copper terminal of the switch unit and the copper terminal of the transformer; the external driving source first drives the assembly fixture to move toward the fixing seat, and when the assembly fixture is fitted with the fixing seat, the external driving source drives the copper terminal of the switch unit and the copper terminal of the transformer to be installed to the terminal box body.

13. The smart meter multi-functional collaborative high-efficiency precision processing and quality control technology and equipment according to claim 12, characterized in that: One of the carrier and the fixture body is provided with a guide column, and the other of the carrier and the fixture body is provided with a guide groove that cooperates with the guide column; or, one of the carrier and the fixture body is provided with a limiting protrusion, and the other of the carrier and the fixture body is provided with a limiting groove that cooperates with the limiting protrusion.

14. The smart meter multi-functional collaborative high-efficiency precision processing and quality control technology and equipment according to claim 1, characterized in that: The welding inspection performance tester includes a second downward pressure cylinder, a multi-performance floating detection fixture, a pressure detection assembly, a mutual inductor on-off probe, a switch unit on-off probe, a welding resistance detection probe, and a resistance detection probe after on-off; The welded terminal box unit, switch unit, and transformer are fixed on a multi-performance floating detection fixture. The second downward pressure cylinder drives the pressure detection assembly to press against the welded terminal box unit, switch unit, and transformer. The second downward pressure cylinder is a multi-stroke cylinder. The transformer on-off probe is connected to the transformer; the switch unit on-off probe is connected to the switch unit; the welding resistance detection probe and the on-off resistance detection probe test the corresponding resistance value.

15. The smart meter multi-functional collaborative high-efficiency precision processing and quality control technology and equipment according to claim 14, characterized in that: The welding inspection performance testing machine includes a rotary clamping device, which includes a rotary cylinder and a clamping piece. The rotary cylinder is linked with the clamping piece, and the clamping piece presses against the welded terminal box unit, switch unit, and transformer.

16. The smart meter multi-functional collaborative high-efficiency precision processing and quality control technology and equipment according to claim 14, characterized in that: The multi-performance floating detection fixture includes: a square plate is provided with a T-shaped slide bar for fixing and connecting diagonally, the T-shaped slide bar and the sliding sleeve fixed on the fixed plate form a sliding pair, the spring in the middle of the T-shaped slide bar is arranged on the back of the fixed plate, a profiling groove of the terminal box unit is arranged in the middle of the square plate, and the first and second recessed grooves protruding from the shape of the terminal box and the sixth U-shaped groove protruding in the middle are arranged on both sides of the profiling groove for clamping the terminal box. A first mounting hole for installing a probe for conducting resistance is arranged between the sixth U-shaped groove and the first recessed groove and the second recessed groove, facing the copper terminal, and a left mounting hole and a right mounting hole are arranged on the front end plane of the profiling groove, facing the welding resistance detection probe for installing the test switch unit and the transformer solder joint.

17. The smart meter multi-functional collaborative high-efficiency precision processing and quality control technology and equipment according to claim 1, characterized in that: The welding inspection integrated machine includes a fixing device, a welding mechanism, a cold water circulation mechanism, a cold air mechanism, a first temperature sensor, a CCD detection mechanism, a control mechanism, and a fixing device fixing terminal box unit, a switch unit, and a mutual inductor; The welding mechanism comprises an upper electrode and a lower electrode, the lower electrode abuts against the lower ends of the copper terminal of the switch unit and the copper terminal of the transformer, and the second conductive member and the third conductive member are located on the movement track of the upper electrode; The cold water of the cold water circulation mechanism flows through the upper electrode and the lower electrode; The cold air of the cold air mechanism blows toward the upper electrode; The first temperature sensor detects the temperature of the upper electrode and the welding position; The CCD detection mechanism detects the terminal box unit, switch unit, and transformer; The control mechanism detects the welding temperature and adjusts one or a combination of two or more of the welding current, welding time, welding pressure, cold water temperature, cold water flow, cold air temperature, and cold air flow.

18. The smart meter multi-functional collaborative high-efficiency precision processing and quality control technology and equipment according to claim 17, characterized in that: The cold water circulation mechanism is provided with a water inlet and a water return port. The water inlet is provided with a second temperature sensor for detecting the cold water temperature and a first flow sensor for detecting the cold water flow; the water return port is provided with a third temperature sensor for detecting the cold water temperature.

19. The smart meter multi-functional collaborative high-efficiency precision processing and quality control technology and equipment according to claim 17, characterized in that: The first temperature sensor movably detects the temperature of the upper electrode and the temperature of the welding position.

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