Smart meter multi-functional collaborative efficient precision processing and quality control technology and equipment

Abstract

The present invention discloses a multi-element collaborative, efficient, and precise processing and quality control technology and equipment for smart electric meters. This technology and equipment is composed of multiple intelligent machines that collaborate to form an automated production line. The terminal copper strip assembly machine uses a multi-component collaborative flexible fixture to accurately assemble the switch unit and the copper terminal of the transformer into a terminal box unit; the welding piece assembly machine relies on ultra-thin welding piece filtering, three-stage amplification welding head, automatic cutting intelligent grasping, and multi-component integrated flexible assembly fixtures to efficiently and accurately weld the welding piece to the copper terminal; the welding inspection integration machine and the comprehensive performance testing machine participate in the collaboration. Together, they realize the integration of high-quality welding, inspection, and testing of transformers, relays, and terminal box units, achieving multi-element collaborative, efficient, and precise production and multi-process collaborative control. This technology improves product quality traceability, ensures production stability and quality in complex environments, greatly improves production efficiency, and reduces labor costs. It is suitable for multi-component high-precision collaborative flexible welding and inspection and ultra-thin component automatic punching and welding precision processing.

Description

Technical Field

[0001] The present invention relates to the field of equipment technology, and specifically to multi-faceted collaborative, efficient, precision processing and quality control technology and equipment for smart meters. Background Art

[0002] 1. Development and application requirements of smart meters

[0003] Smart meters are a new type of power system energy dual-carbon background, the basis for carbon, energy efficiency, electricity consumption, and billing measurement. They are large in number and have a wide range of applications. Their reliability and accuracy are crucial to the safe operation of the power grid and users, as well as the economic and property interests.

[0004] The proliferation of smart meters: With the advancement of intelligent power systems, traditional meters are gradually being replaced by smart meters. Smart meters offer a variety of functions, including real-time monitoring of energy consumption, remote meter reading, two-way communication, and support for time-of-use pricing, significantly facilitating power management and user experience. Globally, countries are actively promoting the installation and application of smart meters, and the market continues to expand, placing higher demands on production efficiency and quality.

[0005] 1. Traditional smart meter manufacturing processes are complex: Smart meters consist of components such as switch units (relays or circuit breakers), instrument transformers, and terminal strips. These components are often soldered together using bare metal, requiring at least two sets of welding equipment and fixtures. Existing manufacturing methods are cumbersome, with long turnaround times and low efficiency. For example, welding the switch unit to the terminal strips, then the instrument transformer to the terminal strips, involves multiple equipment changes, workpiece clamping, and positioning, making the entire process time-consuming.

[0006] 2. High Human Involvement: Currently, the production of smart meters relies on manual labor combined with assembly line operations. Manual operations are not only slow but also prone to human error, such as weld position deviation and unstable weld quality. Furthermore, with rising labor costs, this high-involvement processing model leads to high production costs, severely impacting the company's economic benefits and market competitiveness.

[0007] 3. Automated processing is difficult to achieve: To achieve automated processing of smart meters, it is necessary to solve the connection and coordination problems of multiple technical links. This includes how to accurately install the copper terminals of the switch unit and the transformer into the terminal box body, how to automatically cut, feed and weld ultra-thin solder sheets, and how to effectively test the performance after welding. In actual operation, the equipment and processes of each processing link must be closely coordinated. Problems in any link may lead to interruption of the automated process. For example, the coordination between the automatic cutting and feeding unit and the ultrasonic welding machine in the solder sheet assembly machine, and the linkage of the welding, detection and control mechanisms in the welding assembly and inspection integration machine, all of which pose great challenges to automated processing.

[0008] 4. Equipment Integration and Layout Challenges: When building a smart meter processing system, equipment integration and proper layout are major challenges. For example, while using a turntable assembly line for soldering lug assembly can reduce size, it requires precise positioning of loading, testing, welding, and unloading stations, ensuring smooth transitions between them. Otherwise, processing bottlenecks can easily occur. Furthermore, the spatial layout between different equipment must balance operational convenience, material transfer efficiency, and accessibility for maintenance and overhaul. Achieving efficient equipment integration within a limited production space is challenging.

[0009] 5. Complex testing: Comprehensive and accurate testing of welded smart meters presents numerous challenges. Welding performance testing machines must examine multiple parameters, including weld strength, weld pull-out force, weld resistance, circuit continuity, low-voltage resistance, coil resistance, coil primary current, DC component, and DC resistance. Such complex testing requires not only high-precision, multi-performance floating test fixtures and probes, but also precise control of parameters such as pressure and stroke during the testing process to ensure reliable and consistent test results. Errors in any of these steps can result in substandard products entering the market.

[0010] 6. Fixture Design Challenges: Designing fixtures suitable for smart meter processing is challenging. For example, the assembly fixtures for the terminal copper strip assembly machine must precisely secure the copper terminals of the switch unit and transformer, ensuring accurate installation within the terminal box. The fixtures must accommodate the fixing and rotation of the switch unit or transformer, meeting the requirements of various welding positions. The fixtures must ensure accurate positioning of components while also possessing excellent versatility and adjustability to accommodate the processing of different smart meter models. Durability and ease of maintenance are also crucial considerations.

[0011] 7. Difficulties in processing ultra-thin solder sheets: When processing ultra-thin silver-copper-phosphorus solder sheets of 0.03-0.12mm, there are many difficulties in cutting, grasping, welding, etc. When cutting, it is necessary to ensure that the dimensional accuracy is controlled within a very small range to avoid burrs, tears, deformation and other problems on the edges, while overcoming the influence of material properties and static electricity. The automatic grasping and loading process needs to cope with the challenges of the tiny size, light and thin characteristics, smooth surface and high positioning accuracy requirements of the solder sheets. When welding, controlling the welding time and ultrasonic energy output becomes the key. If you are not careful, the solder sheet will overheat, deform, break, perforate or the solder will not be strong and it will be impossible to achieve welding. The specific technical difficulties are as follows:

[0012] (1) Difficulties in cutting ultra-thin solder sheets

[0013] Dimensional accuracy control: Ultra-thin solder sheets (0.03-0.12mm) require extremely high dimensional accuracy when cutting. Even the slightest error can cause the solder sheet to fail to meet the required specifications. The thickness uniformity of the material itself, the accuracy of the cutting equipment, and stress changes during the cutting process all affect the final cutting dimensional accuracy.

[0014] Edge quality control: Ultra-thin solder sheets are prone to edge burrs, tears, and deformation during the cutting process. This not only affects the appearance quality of the solder sheet, but may also lead to electrical performance degradation or even short circuits during subsequent use.

[0015] Influence of Material Properties: Silver-copper-phosphorus alloys have a certain degree of hardness and toughness. When ultra-thin, their mechanical properties change, making cutting more difficult. The material's hardness can increase tool wear, while its toughness can cause springback and other issues during cutting, impacting cutting quality.

[0016] Static electricity: During the cutting process, static electricity is easily generated due to friction between the material and the cutting tool and equipment. Static electricity can attract impurities such as dust, contaminating the soldering surface. It can also cause electrostatic discharge, potentially damaging the performance of the soldering.

[0017] Welding problems and temperature and humidity can cause cold joints. Existing ultrasonic equipment's welding heads suffer from noise and harmonics, as well as unstable output energy. This makes it difficult to weld ultra-thin silver-copper-phosphorus (ACP) sheets, or even ultra-thin copper-phosphorus (CP) sheets. Existing ultrasonic energy cannot be adjusted, and excessive ultrasonic energy can cause cracks in ultra-thin sheets and prevent them from being welded. Factors such as ambient temperature, humidity, and air quality can also affect processing quality. High humidity can easily cause silver-copper-phosphorus (ACP) sheets to oxidize due to moisture, affecting welding results. Dust and impurities in the workshop can also adhere to the sheet surface, leading to welding defects and cold joints.

[0018] (2) Difficulties in automatic gripping and loading

[0019] Tiny size and thinness: The small size and extremely thin thickness of the soldering pads place extremely high demands on the precision and stability of the gripping mechanism. Conventional gripping methods may not be able to accurately and stably grasp the soldering pads, and are prone to loose grip, dropping, or damaging the pads.

[0020] Surface properties: Silver-copper-phosphorus solder pads are typically smooth and may have a layer of grease or oxide, which can affect friction and adhesion during gripping. The gripping mechanism must possess appropriate gripping force and contact pattern to prevent the pad from slipping or falling off during gripping and loading.

[0021] Positioning Accuracy: Automated gripping and loading require a precise positioning system to ensure the soldering pads are accurately placed in the designated location. Due to the tiny size of the soldering pads, positioning errors must be kept to a very small range, otherwise they may cause deviations in the welding position and affect the welding quality.

[0022] Speed and Efficiency: In actual production, it is necessary to increase operating speed while ensuring gripping and loading accuracy to meet production efficiency requirements. This requires optimizing the gripping path and improving the equipment's response speed, while also ensuring that the soldering pieces do not shake or fall during high-speed movement.

[0023] 8. Collaborative stability of multiple devices: Smart meter manufacturing involves the coordinated operation of multiple machines, including terminal copper strip assembly machines, solder lug assembly machines, soldering and inspection integration machines, and soldering and inspection performance testers. The operating speeds and rhythms of these different machines must be precisely matched. Failure or unstable operation of any one device can impact the continuity and efficiency of the entire manufacturing process. For example, if the turntable speed of the solder lug assembly machine doesn't match the operating rhythm of the automatic cutting and feeding unit or ultrasonic welding machine, this can lead to material backlogs or idling.

[0024] 9. Strict production environment requirements: Smart meter processing requires a strict production environment. Factors such as ambient temperature, humidity, and air quality can affect processing quality. If the humidity is too high, silver-copper-phosphorus solder pads can easily become damp and oxidize, affecting welding results. Dust and impurities in the workshop can also adhere to the pad surface, causing welding defects. Maintaining a stable and suitable production environment requires specialized environmental control equipment and continuous monitoring and regulation of environmental parameters, increasing production costs and management complexity. Summary of the Invention

[0025] Therefore, this invention is primarily used in the field of smart meter processing equipment, aiming to address a series of key technical challenges in the welding connection and testing between terminal block units, switch units, and transformers during smart meter production. To address the complex manufacturing processes, high manual involvement, difficulty in achieving automation, difficulties in equipment integration and layout, complex testing procedures, challenging fixture design, and the challenges of processing ultra-thin solder tabs in traditional smart meter manufacturing, an innovative, multi-faceted and collaborative processing equipment system has been constructed.

[0026] Through the organic coordination of the terminal copper strip assembly machine, the welding piece assembly machine, the welding inspection integration machine, and the welding inspection performance tester, a highly automated assembly line production model has been formed, greatly improving production efficiency and significantly reducing labor costs. Remarkable results have been achieved in key technological innovations. For example, the uniquely designed welding head achieves fine filtering and three-stage amplification of the ultrasonic amplitude, solving the problems of noise, harmonics, and energy instability in existing equipment, and meeting the high-quality welding requirements of ultra-thin welding pieces of different thicknesses; the multi-component integrated flexible assembly fixture and the assembly fixture with precise guide limits significantly improve assembly accuracy and stability; measures such as ion exhaust fans and copper wire grounding effectively eliminate electrostatic interference and reduce the impact of environmental factors on processing quality; the multi-process collaborative control system achieves precise control of each process in terms of time, space, and process parameters; and the comprehensive product quality traceability system can quickly and accurately trace the root cause of quality problems.

[0027] This invention comprehensively improves the processing quality and production efficiency of smart meters, promotes industry technology upgrading, and achieves major breakthroughs in efficient production, high-quality manufacturing, environmental adaptation, equipment maintenance and quality control. It has significant economic and social benefits and provides strong technical support and equipment guarantee for the development of the smart meter industry.

[0028] To this end, the intelligent meter multi-functional collaborative and efficient precision processing equipment includes:

[0029] The terminal copper strip assembly machine includes a fixing base for fixing the terminal box body and an assembly fixture for fixing the switch unit copper terminals and the transformer copper terminals. The terminal copper strip assembly machine installs the switch unit copper terminals and the transformer copper terminals into the terminal box body to form a terminal box unit.

[0030] The welding piece assembly machine includes an automatic cutting and feeding unit, an ultrasonic welding machine, and a first fixture provided with a contoured cavity, wherein the contoured cavity fixes the switch unit or the mutual inductor; the automatic cutting and feeding unit cuts and feeds the welding piece; and the ultrasonic welding machine welds the welding piece and the switch unit or the mutual inductor;

[0031] The welding and inspection integrated machine is configured such that the switch unit is fixed with a second conductive member, the mutual inductor is fixed with a third conductive member, and the second conductive member and the third conductive member are respectively welded and fixed to the welding piece; the welding and inspection integrated machine welds the second conductive member to the copper terminal of the switch unit; and the welding and inspection integrated machine welds the third conductive member to the copper terminal of the mutual inductor;

[0032] The welding inspection performance testing machine includes a multi-performance floating detection fixture, which can detect the terminal box unit with switch units and mutual inductors welded on it.

[0033] The welding piece assembly machine includes a turntable, which 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.

[0034] 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 set in the contour assembly fixture.

[0035] 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.

[0036] The welding piece assembly machine further comprises a blanking mechanism, which comprises a sliding clamping jaw. The blanking mechanism cooperates with the blanking station, and the sliding clamping jaw cooperates with the welded switch unit or the welded mutual inductor.

[0037] The contoured assembly clamp 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, and a plurality of array second vacuum suction holes are provided in the square groove for locking the switch unit; a fifth U-shaped groove is provided at the rear end of the square 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 first U-shaped groove is connected to the lower step platform for positioning and limiting the first copper welding piece and the third copper welding piece, and the lower step platform connected to the limiting L platform is connected to the second U-shaped groove. The U-shaped groove is used for positioning the pins on the transformer; a positioning and locking groove of the transformer is arranged adjacent to the second U-shaped groove and the limiting L platform, and the positioning and locking groove is provided with multiple arrays of third vacuum suction holes for locking the transformer; a third U-shaped groove for limiting the fourth copper welding piece is arranged adjacent to the positioning and locking groove, and a fourth U-shaped groove for limiting the B soft wire is arranged on the bottom plate of the third U-shaped groove, and an L-shaped platform for positioning and limiting the second copper welding piece and the fourth copper welding piece is arranged on the second L-shaped plate adjacent to the third U-shaped groove on the right end, an L-shaped groove plate is arranged on the L-shaped platform, and a vacuum valve is arranged on the L-shaped groove plate.

[0038] 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 relative to each other; the ion exhaust fan exhausts air in the shell; and the air pressure valve is used to adjust the air pressure.

[0039] The ultrasonic welding machine also includes a variable amplitude rod, a screw, and a welding head. The ultrasonic generator is transported to the variable amplitude rod through the transducer, and the variable amplitude rod is transported to the welding head through the screw. The welding head includes a rear end, a first cone, a second column, a third cone, a flat body, and a joint. The rear end is connected to the first cone, the first cone is connected to the second column, the second body is connected to the third cone, the third cone is connected to the flat body, and the flat body is connected to the joint. The joint is provided with a welding tooth, and an energy guiding rib is provided between the joint and the welding tooth; the amplitude input rear end face to the welding tooth is a column, and the axis of the column is perpendicular to the rear end face; fine teeth are set at the center of the rear end face, and coarse teeth are set at the center of the output end of the variable amplitude rod; the rear end undergoes a second-stage amplitude amplification through the first cone, and the amplified amplitude is transported to the third cone through the second column. An arc is set on the third cone, and the arc shrinks and gathers energy to the flat body. The flat body is amplified and guides energy to the joint through the third stage, and the amplitude on the joint is transported to the welding tooth through the energy guiding rib.

[0040] 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 side cutting knife are arranged on the upper end of the second guide rail 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 rail width slide, and an upper and lower grabbing cylinder is arranged on the upper end of the first guide rail width slide, the first guide rail 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 on 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 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 and press it 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.

[0041] 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 solder piece; or, the side elevation of the blade is parallel to the solder piece and the outer end face 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 solder 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 solder piece; or, the angle of the weld tooth is 90 degrees; or the tooth spacing between the weld teeth is 1mm; or the weld tooth position is 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.

[0042] 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 weld tooth cylinder is 65±3mm; the finish of the rear end face is less than Ra0.8; an M8x0.75 fine-thread screw hole of 17mm is set in the center of the rear end face, and a coarse-thread M6x1 coarse-thread screw hole of 15mm is set in the center of the output end of the amplitude transformer; the rear end guides energy at a 1:1 ratio through the first cone and amplifies the amplitude in the second stage. The amplified amplitude is transmitted to the third cone through the second column. An arc is set on the third cone, and the arc shrinks and gathers energy to the flat body at a 1:1 ratio. The flat body is amplified and guides energy to the joint through the third stage; the weld teeth are evenly distributed in multiple numbers in the circumferential direction of the joint, which are 4 or 6, and the weld teeth and the joint are quickly replaced.

[0043] Elastic clamping parts are provided on both sides of the fixing seat, and the elastic clamping parts are pressed against both 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.

[0044] One of the carrier and the clamp body is provided with a guide column, and the other one is provided with a guide groove that cooperates with the guide column; or, one of the carrier and the clamp body is provided with a limiting protrusion, and the other one is provided with a limiting groove that cooperates with the limiting protrusion.

[0045] The lower end of the accommodating cavity is curved, and the upper end is convex, and the upper and lower ends are connected to form a closed surface. Through this structural setting, the precision requirements of the copper terminals of the switch unit and the mutual inductor can be met.

[0046] The multi-performance floating detection fixture includes: a square plate is provided with a T-shaped slide bar for fixing the connection 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, and the square plate is provided with a profiling groove for the terminal box unit in the middle, and the protruding first and second recessed grooves and the sixth U-shaped groove in the middle are provided on both sides of the profiling groove for positioning the terminal box. The first mounting hole for installing the on-resistance probe is arranged between the sixth U-shaped groove and the first and second recessed grooves, facing the copper terminal. On the front end plane of the profiling groove, the left mounting hole and the right mounting hole are arranged facing the welding resistance detection probe for installing the test switch unit and the transformer solder joint.

[0047] 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.

[0048] The welding inspection performance testing machine includes a rotary pressing device, which includes a rotary cylinder and a pressing piece. The rotary cylinder and the pressing piece are linked together, and the pressing piece presses against the welded terminal box unit, switch unit, and mutual inductor.

[0049] The multi-functional collaborative and efficient precision processing equipment for smart electric meters provided by the present invention fixes the terminal box unit, the switch unit, and the mutual inductor through a pressing piece, thereby facilitating performance testing.

[0050] The welding and assembly 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 the fixing device fixes the terminal box unit, the switch unit, and the mutual inductor;

[0051] The welding mechanism includes an upper electrode and a lower electrode, wherein the lower electrode abuts against the lower ends of the copper terminals of the switch unit and the mutual inductor, and the second conductive member and the third conductive member are located on the motion trajectory of the upper electrode;

[0052] The cold water of the cold water circulation mechanism flows through the upper electrode and the lower electrode;

[0053] The cold air from the cold air mechanism blows toward the upper electrode;

[0054] The first temperature sensor detects the temperature of the upper electrode and the welding position;

[0055] CCD detection mechanism detects terminal box unit, switch unit, and mutual inductor;

[0056] The control mechanism adjusts one or two or a combination of more than two of the welding current, welding time, welding pressure, cold water temperature, cold water flow, cold air temperature, and cold air flow.

[0057] 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.

[0058] The first temperature sensor movably detects the temperature of the upper electrode and the temperature of the welding position.

[0059] The technical solution of the present invention has the following advantages:

[0060] 1. The multi-functional collaborative and efficient precision processing equipment for smart meters provided by the present invention forms welding connections between terminal box units, switch units, and mutual inductors as well as performance testing after welding through the cooperation of multiple machines. Compared with manual processing in the prior art, this processing method can greatly improve processing efficiency and reduce production costs.

[0061] 2. The multi-functional collaborative and efficient precision processing equipment for smart meters provided by the present invention has a turntable setting to form a turntable assembly line processing, which can reduce the overall volume and meet the needs of automation.

[0062] 3. The present invention provides multi-faceted, efficient, and precise machining equipment for smart meters. The first fixture utilizes this structural configuration. To minimize the overall size of the device, the ultrasonic welder can only weld one position at a time. The outer and inner sleeves cooperate to rotate the contoured assembly fixture, allowing the switch unit or transformer to rotate, specifically 180°, to achieve welding at another welding position. The first elastic member and the floating ball lock the position.

[0063] 4. The multi-functional collaborative and efficient precision machining equipment for smart meters provided by the present invention has a lifting and rotating mechanism that realizes lifting and rotating functions. When welding is completed at one location, the switch unit or transformer is first lifted by the lifting and rotating mechanism, so that the switch unit or transformer leaves the contour cavity, and then rotated by the lifting and rotating mechanism. After being rotated into place, it begins to descend, so that the switch unit or transformer is re-positioned in the contour cavity, and welding operation is carried out at another location.

[0064] 5. The multi-functional collaborative and efficient precision processing equipment for smart meters provided by the present invention has a blanking mechanism, which enables the welded switch unit or the welded mutual inductor to be blanked to meet the next processing step.

[0065] 6. The multi-functional collaborative and efficient precision processing equipment for smart electric meters provided by the present invention has a first downward pressure cylinder that drives the ultrasonic generator to move up and down. When welding is required, the ultrasonic generator moves down, and when welding is completed, the ultrasonic generator moves up.

[0066] 7. The multi-functional collaborative and efficient precision processing equipment for smart electric meters provided by the present invention cooperates with the assembly fixture to form a connection and fixation between the copper terminals of the switch unit, the copper terminals of the transformer and the terminal box body.

[0067] 8. In the multi-functional and efficient precision machining equipment for smart electric meters provided by the present invention, the guide column and the guide groove cooperate to form a guiding drive effect. The cooperation between the limiting protrusion and the limiting groove forms a directional limit.

[0068] 9. The multi-functional, collaborative, and highly efficient precision machining equipment for smart meters provided by this invention features a second, multi-stroke cylinder. The first stroke is used for securing, and the second stroke is used to apply pressure. This allows for testing weld firmness (peelback testing) and weld pull strength, ensuring that welds do not desolder under test pressure. Furthermore, other probes are used to perform tests such as weld resistance, loop continuity, low-voltage resistance, coil resistance, coil primary current, DC component, and DC resistance.

[0069] 10. The multi-faceted, collaborative, and highly efficient precision processing equipment for smart meters provided by the present invention uses this structural arrangement to form connections and fixations between the switch unit, mutual inductor, and terminal box unit through a welding mechanism. Compared to the prior art, this processing method is simpler and uses automated operations to combine several welding steps to form an automated welding effect, thereby improving processing efficiency. Secondly, by detecting the welding temperature and controlling various parameters, the welding temperature is controlled so that it remains within a preset threshold, thereby ensuring that cold solder joints and other phenomena do not occur during the welding process, thereby improving welding quality. Through multiple modes such as water, cold air, current, or pressure, a multi-mode temperature control effect is achieved.

[0070] 11. The smart meter multi-functional collaborative and efficient precision processing equipment provided by the present invention has temperature sensors arranged at different positions of the cold water circulation mechanism, which facilitates the control of the control mechanism at each position. The outflowing water temperature and flow rate can be known through the second temperature sensor and the first flow sensor. The third temperature sensor can be used to know whether the heat is abnormal and whether the heat can be conducted from the upper electrode to the lower electrode.

[0071] 12. The multi-functional collaborative and efficient precision processing equipment for smart electric meters provided by the present invention has a first temperature sensor with upper and lower detection, which makes the detection range larger. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0073] Figure 1 An exploded diagram of the terminal box unit, switch unit, and transformer provided by the present invention;

[0074] Figure 2 A schematic diagram of the structure of the multi-functional collaborative and efficient precision processing equipment for smart electric meters provided by the present invention;

[0075] Figure 3 A schematic structural diagram of the welding piece assembly machine provided by the present invention;

[0076] Figure 4 A schematic diagram of the partial structure of the soldering lug assembly machine provided by the present invention;

[0077] Figure 5 A schematic structural diagram of the initial state of the first clamp provided by the present invention;

[0078] Figure 6 A schematic structural diagram of the first clamp provided by the present invention in a raised state;

[0079] Figure 7 A schematic diagram of the welding positions of the first clamp, the switch unit, and the mutual inductor provided by the present invention;

[0080] Figure 8 A structural schematic diagram of the blanking mechanism provided by the present invention;

[0081] Figure 9 A schematic diagram of the structure of a multi-component coordinated flexible fixture for the terminal copper bar assembly machine provided by the present invention;

[0082] Figure 10 This is a structural diagram of the welding inspection and integration machine provided by the present invention;

[0083] Figure 11 This is a structural schematic diagram of the welding inspection and integration machine provided by the present invention from another angle;

[0084] Figure 12 This is a structural diagram of the welding inspection performance testing machine provided by the present invention;

[0085] Figure 13 A schematic structural diagram of an ultrasonic welding head for a welding piece assembly machine provided by the present invention;

[0086] Figure 14 A schematic diagram of the structure of a flexible integrated assembly fixture for a soldering lug assembly machine provided by the present invention;

[0087] Figure 15 A schematic structural diagram of a multi-performance floating detection fixture for a welding performance testing machine provided by the present invention;

[0088] Figure 16 This is a structural schematic diagram of the automatic cutting and feeding unit provided by the present invention.

[0089] Description of reference numerals:

[0090] 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 and inspection integration machine; 315. Welding and 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. Outer shell; 473. First guiding column; 480. Ion extraction fan; 482. Pneumatic valve; 490. Sliding jaw; 492. Unloading mechanism; 500. Assembly fixture; 501. Fixture body; 502. Limit protrusion; 503. Limit groove; 504. Carrier; 505. Accommodation cavity; 507. Second guiding groove; 508. Second guiding column; 512. Elastic clamping part; 517. Fixed seat; 519. Fixed plate; 520. Second pressing cylinder; 521. Mounting frame; 523. Linkage; 527. Pressure detection component; 529. Rotary pressing device; 530. Rotary 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. Connector; A466. Welding tooth; A467. Welding head; A468. First cone; A469. Arc; A470. Energy guiding rib; A471. Rear end; 708. Standing frame; 709. Friction adjustment unit; 707. Friction gap; 706. First guiding groove; 710. Second guide rail width slide plate; 701. Gripping cylinder; 704. Cutting cylinder; 705. Cutter; 712. U-shaped suction nozzle; 711. First vacuum suction hole; 711; 702. First guide rail width 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 piece; C16. Static contact piece; A17. Lead pin; B17. B flexible wire; C17. Communication wire; A534. First sinking groove;B534, second sink; C534, sixth U-shaped groove; D534, first mounting hole; E534, first hole; F534, left mounting hole; G534, right mounting hole; H534, slide column; L534, T-shaped slide bar; N534, contoured groove; M534, second hole; O534, front plane; X534, loop resistance detection probe; A500, first L-shaped plate; A501, L-shaped slot plate; A502, fourth U-shaped slot; A503, square slot; A504, fifth U-shaped slot; A505, lower end plate; A506, L-shaped platform; A507, third U-shaped slot; A508, positioning and locking slot; A509, position-limiting L-shaped platform; A510, second U-shaped slot; A511, lower step platform; A512, first U-shaped slot; A50, shift fixture; A51, movable fixture. DETAILED DESCRIPTION

[0091] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0092] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0093] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0094] In addition, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0095] Example 1

[0096] This embodiment provides a multi-functional collaborative and efficient precision processing equipment for smart meters, as shown in the attached Figures 1-16 Shown, including:

[0097] The terminal copper strip assembly machine 312 includes a fixing seat 517 for fixing the terminal box body 153 and an assembly fixture 500 for fixing the switch unit copper terminal 151 and the transformer copper terminal 152. The terminal copper strip assembly machine 312 installs the switch unit copper terminal 151 and the transformer copper terminal 152 to the terminal box body 153 to form a terminal box unit 15.

[0098] The soldering lug assembly machine 328 includes an automatic cutting and feeding unit 321, an ultrasonic welding machine 322, and a first fixture 326 having a contoured cavity 3261. The contoured cavity 3261 secures the switch unit 16 or the mutual inductor 17. Specifically, the contoured cavity 3261 can secure either the switch unit 16 or the mutual inductor 17. The contoured cavity 3261 is a universal configuration that reduces the number of devices and reduces their size. Otherwise, one machine would be required to weld the solder lug to the switch unit 16 and another machine would be required to weld the mutual inductor 17, increasing the number of machines and reducing floor space. The contoured cavity 3261 can be positioned at the common point of the switch unit 16 and the mutual inductor 17, or it can be secured using a different structure. The automatic cutting and feeding unit 321 cuts and feeds the solder lugs. The welding sheet strip enters the automatic cutting and feeding unit 321, where it is cut and fed to form a number of welding sheets that are compatible with the switch unit 16 and the mutual inductor 17, respectively. The ultrasonic welding machine 322 welds the welding sheet to the switch unit 16 or the mutual inductor 17. Here, the welding sheet is welded and fixed to the second conductive member 161 and the third conductive member 171, respectively. For example, if there are two second conductive members 161 and two third conductive members 171, then there are four welding sheets, which are welded and fixed to the two second conductive members 161 and the two third conductive members 171, respectively. It should be noted that when the switch unit 16 is being welded to the welding sheet, the mutual inductor 17 cannot be processed; conversely, when the mutual inductor 17 is being welded to the welding sheet, the switch unit 16 cannot be processed. The switch unit 16 can be a relay, a load switch, or other opening and closing control switch. The soldering sheet in this embodiment is an ultra-thin soldering sheet, specifically an ultra-thin silver-copper-phosphorus soldering sheet, with a thickness of 0.03-0.12 mm.

[0099] The welding and inspection integrated machine 313, the switch unit 16 is fixed with a second conductive part 161, and the number of the second conductive parts 161 here is two. The mutual inductor 17 is fixed with a third conductive part 171, and the number of the third conductive parts 171 is also two. The second conductive part 161 and the third conductive part 171 are respectively welded and fixed to the welding piece. The welding and inspection integrated machine 313 welds the second conductive part 161 to the copper terminal 151 of the switch unit; the welding and inspection integrated machine 313 welds the third conductive part 171 to the copper terminal 152 of the mutual inductor. Here, the welding and inspection integrated machine 313 is used for welding, fixing, and testing between the switch unit 16, the terminal box unit 15, and the mutual inductor 17.

[0100] The welding inspection and performance tester 315 includes a multi-performance floating inspection fixture 534, which tests the terminal box unit 15, to which the switch unit 16 and transformer 17 are welded. The welding inspection and performance tester 315 performs tests such as weld strength (peeling test), weld pull force, weld resistance, loop continuity test, low-voltage resistance test, coil resistance test, coil primary current test, DC component test, and DC resistance test.

[0101] By coordinating multiple machines, the welded connections between the terminal box unit 15, the switch unit 16, and the mutual inductor 17 are formed, and their performance is tested after welding. Compared to the manual processing method in the prior art, this processing method can greatly improve processing efficiency and reduce production costs. Adjacent machines can be connected by conveyor belts or manually, and those skilled in the art can adjust according to actual needs. In this embodiment, conveyor belts are preferably used for connection.

[0102] Specifically, as attached Figure 16As shown, the automatic cutting and feeding unit 321 includes a stand 708, on which a friction adjustment unit 709, a friction gap 707 (set to be less than 0.8-0.9 times the thickness of the ultra-thin solder sheet), a first guide groove 706 are arranged from right to left, a cutting cylinder 704 is arranged on the upper end of the second guide rail slide 710, and a cutting knife 705 is arranged on the side. The blade angle of the cutting knife 705 is 28 to 31 degrees, and the side elevation of the blade is parallel to the ultra-thin solder sheet and the outer end surface of the first guide groove 706. The gap from the side elevation of the blade to the U-shaped suction nozzle 712 is less than 1.5 to 1 times the thickness of the ultra-thin solder sheet. This arrangement The design limits the existing problems of difficult cutting of ultra-thin solder sheets, tool slippage, wrinkles formed when cutting ultra-thin solder sheets, and the occurrence of "F" defects in the existing technology. A U-shaped suction nozzle 712 is provided in the gap between the cutting blade 705. The gap between the side bevel of the blade and the U-shaped suction nozzle 712 is 2 to 3 times the thickness of the ultra-thin solder sheet. A pair of first vacuum suction holes 711 are provided on the bottom surface of each end of the U-shaped suction nozzle 712 (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 of difficult grasping of ultra-thin solder sheets, easy suction of ultra-thin solder sheets during grasping, skewness and loss during suction and movement, and burrs, tears, and deformation on the edges. The U-shaped suction nozzle 712 is mounted on the side of the first guide width slide 702. The upper end of the first guide width slide 702 is provided with upper and lower grasping cylinders 701. The first guide width slide 702 and the upper and lower grasping cylinders 701 are fixed to the frame. The driving cylinder 700 is provided perpendicular to the grasping cylinder 701.

[0103] The friction adjustment unit 709 automatically sets the fixed length under the drive of the motor, and sends the ultra-thin solder sheet through the first guide groove 706 to the position below the U-shaped suction nozzle 712. The upper and lower grabbing cylinders 701 press the U-shaped suction nozzle 712 down on the guide rail table. The cutting cylinder 704 drives the cutter 705 to cut the ultra-thin solder sheet and reset it. The upper and lower grabbing cylinders 701 grab the ultra-thin solder sheet sucked by the U-shaped suction nozzle 712 and lift it up. The driving cylinder 700 drives the upper and lower grabbing cylinders 701 sends the ultra-thin solder sheet sucked by the U-shaped suction nozzle 712 to the position of the switch unit copper terminal 151 and the transformer copper terminal 152 pressed down on the welding station 464, and the welding tooth A466 on the welding head A467 is 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 transformer copper terminal 152. The driving cylinder 700 drives the upper and lower grasping cylinders 701 to lift and reset the U-shaped suction nozzle 712.

[0104] Specifically, as attached Figure 2-Figure 8As shown, the soldering lug assembly machine 328 includes a turntable 325 equipped with a loading station 462, an inspection station 465, a welding station 464, and an unloading station 461. The four stations can be arranged in a circular array or adjusted according to actual needs. There are at least four first fixtures 326. When there are four first fixtures 326, the four first fixtures 326 rotate corresponding to the four stations during rotation. When there are more than four first fixtures 326, the extra first fixtures 326 become vacant positions, which can control the speed of the turntable 325. Those skilled in the art can adjust this according to actual needs. The ultrasonic welder 322 cooperates with the welding station 464. For example, when the first fixture 326 holding the switch unit 16 moves to the welding station 464, the automatic cutting and feeding unit 321 mates the cut soldering lug with the switch unit 16, and the ultrasonic welder 322 forms a weld. This creates a turntable 325-style assembly line process, which can reduce overall volume and meet automation requirements. In addition, welding can also be performed through an assembly line structure, but the disadvantage of this structure is that it occupies a large space.

[0105] Specifically, as attached Figure 2-Figure 8As shown, the first fixture 326 includes an outer sleeve 401, an inner sleeve 402, a contoured assembly fixture 403, a support rod 404, a lower hazelnut 405, a floating ball 406 and a first elastic member 407. The inner sleeve 402 is located in the outer sleeve 401, and the inner sleeve 402 slides axially relative to the outer sleeve 401. The contoured assembly fixture 403 is located on the top surface of the inner sleeve 402. The contoured assembly fixture 403 is linked to the inner sleeve, and the contoured cavity 3261 is set in the contoured assembly fixture 403. The lower end of the lower nut 405 is linked to the support rod 404, and the upper end of the lower nut 405 extends to cooperate with the contour cavity 3261, that is, the lower nut 405 can move vertically upward and can drive the contour assembly fixture 403 and the inner sleeve 402 to move vertically upward. Since the switch unit 16 or the mutual inductor 17 is fixed to the contour assembly fixture 403, the switch unit 16 and the mutual inductor 17 also move accordingly. Here, the lower nut 405 specifically cooperates with the contour assembly fixture 403, driving the contour assembly fixture 403 to move, realizing the rotation and lifting of the contour assembly fixture 403. The floating ball 406 and the first elastic member 407 are located between the outer sleeve 401 and the inner sleeve 402. The first elastic member 407 exerts a squeezing force on the floating ball 406, pressing it against the side wall of the inner sleeve 402, and the floating ball 406 forms a fixed position. Here, the outer wall of the inner sleeve 402 is provided with a small groove that precisely abuts the floating ball 406, creating a position limit. However, when a vertical upward force drives the inner sleeve 402, the floating ball 406 can disengage from the small groove, releasing the position limit. This structural arrangement of the first fixture 326 is necessary to minimize the overall size of the device, so the ultrasonic welder 322 can only weld at one location at a time (two second conductive members 161 and two third conductive members 171 are required). The outer sleeve 401 cooperates with the inner sleeve 402, allowing the contoured assembly fixture 403 to move upward and rotate, allowing the switch unit 16 or transformer 17 to rotate, specifically 180°, to achieve a different welding location. The first elastic member 407 and the floating ball 406 form a position lock. In the accompanying drawings, point A represents the transformer 17 weld point; point B represents the switch unit 16 weld point.

[0106] Specifically, as attached Figure 2-Figure 8As shown, the welding piece assembly machine 328 also 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 of a position point is completed, the lifting and rotating mechanism 477 first lifts the switch unit 16 or the mutual inductor 17 so that the switch unit 16 or the mutual inductor 17 leaves the contour cavity 3261. Then, the lifting and rotating mechanism 477 rotates it. After it rotates into place, it begins to descend, so that the switch unit 16 or the mutual inductor 17 is re-positioned in the contour cavity 3261, and the welding operation at another position point is performed.

[0107] Specifically, as attached Figure 2-Figure 8 As shown, the soldering lug assembly machine 328 also includes a blanking mechanism 492, which includes a sliding jaw 490. The blanking mechanism 492 cooperates with the blanking station 461, and the sliding jaw 490 engages with the welded switch unit 16 or the welded transformer 17. The blanking mechanism 492 allows the welded switch unit 16 or the welded transformer 17 to be unloaded for the next processing step. The blanking mechanism 492 drives the sliding jaw 490 to slide horizontally and vertically.

[0108] Specifically, as attached Figure 2-Figure 8 and Figure 13As shown, the multi-element flexible ultrasonic welding machine 322 includes an ultrasonic generator 469, a first downward pressure cylinder 470, a support frame 471, a housing 472, a first guide post 473, an ion exhaust fan 480, and an air pressure valve 482. The ultrasonic generator 469 is housed within the housing 472, with a portion of the ultrasonic generator 469 located within a chamber within the housing 472. The ultrasonic generator 469 and the welding head A467 partially extend externally, cooperating with the welding station 464 to form an ultrasonic weld. The first downward pressure cylinder 470 is linked to the ultrasonic generator 469, driving the ultrasonic generator 469 in vertical up and down motion. The ultrasonic generator 469 is connected to the support frame 471, which slides relative to the first guide post 473, providing a guiding effect. The ion exhaust fan 480 evacuates air from the housing 472. The air pressure valve 482 is used to adjust the air pressure. The first downward pressure cylinder 470 is connected to the transducer, and the transducer is connected to the ultrasonic generator 469. The output end of the transducer is connected to the amplitude converter, and the output end of the amplitude converter has a fixed flange. The fixed flange fixes the amplitude converter end and the welding head A467 by a screw; the fixed flange fixes the amplitude converter end and the welding head A467 on the outer end of the shell 472; the first downward pressure 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 downward. When welding is completed, the ultrasonic generator 469 moves upward to drive the welding head A467 to reset.

[0109] Furthermore, the inventive features of the welding head A467 are as follows: the rear end A471 is a φ22x5mm cylinder connected to a 5x5 45-degree first cone A468, the 45-degree first cone A468 is connected to a φ32x22mm second cylinder A462, the φ32x22mm second cylinder A462 is connected to a third cone A463 with a length of 10 cones, the third cone A463 is connected to a φ22x22mm flat body A464 with a length of 7mm, the flat body A464mm is connected to a φ22x6mm joint A465, 4x5x5 welding teeth A466 are evenly cross-arranged around the joint A465, and energy guiding ribs A470 are arranged between the joint A465 and the welding teeth A466.

[0110] The purpose of cross-setting 4x5x5 welding teeth A466 is to solve the problem of quick replacement of multi-head welding teeth, which greatly saves time and solves the problem of high waste cost and time-consuming replacement of existing single-head welding heads.

[0111] The further invention of welding tooth A466 has four major features: 1. Tooth angle 90 degrees; 2. Tooth spacing 1mm; 3. Straight grain; 4. Tooth tip plane 0.2mmx0.2mm; 5. Tooth bottom plane 0.4mmx0.4mm; Tooth height 0.5mm; 6. 4x4 array tooth tip layout (suitable for copper solder sheets with a thickness of 0.3-0.5mm); 7. 3x3 array tooth tip layout (suitable for copper solder sheets with a thickness of 0.6mm-1.2mm); 8. 5x5 array tooth tip layout (suitable for copper solder sheets with a thickness of 0.2-0.1mm).

[0112] Furthermore, the inventive features of the welding head A467 include: using a 40K ultrasonic generator 469, inputting it to the amplitude transformer through the transducer, and the amplitude transformer being transported to the welding head A467 through screws of M6x1x13 and M8x0.75x15mm, and the total length of the column from the rear end A471 end face of the amplitude input welding head A467 to the welding tooth A466 is 65±3mm, and the axis of the 65±3mm column is perpendicular to the rear end A471 end face, and the finish of the rear end A471 end face is less than Ra0.8; a 17mm M8x0.75 fine thread screw hole is set at the center of the rear end A471 end face, and a 15mm coarse thread M6x1 coarse thread screw hole is set at the center of the output end of the amplitude transformer; the middle is connected with screws of M6x1x13 and M8x0.75x15mm; this setting finely filters the clutter of the existing ultrasonic amplitude wave and amplifies the first-stage amplified amplitude, and then The end A471 conducts energy at a 1:1 ratio through the first cone A468 and amplifies the amplitude in the second stage. The amplified amplitude is transmitted to the third cone A463 through the second column A462. The arc A469 is set on the third cone A463 to shrink and concentrate energy to the flat body A464 at a 1:1 ratio. The flat body A464 conducts energy to the joint A465 through the third stage amplification. The amplitude and energy on the joint A465 are transmitted to the 4x4 array welding tooth A466 through the energy guiding rib A470. According to the different array settings of the welding head A467, the different array tooth tips of the welding tooth A466 are welded to ultra-thin silver-copper-phosphorus welding sheets of different thicknesses. This technical invention solves the problems of the existing ultrasonic equipment's welding head A467 having noise and harmonics and unstable output energy, which make it impossible to achieve ultra-thin welding of silver-copper-phosphorus welding sheets and copper-phosphorus ultra-thin welding. The existing ultrasonic energy cannot be adjusted, and the rough ultrasonic energy will cause the ultra-thin welding sheets to break. Multiple welding threads A466, either four or six, are evenly distributed around the circumference of joint A465. If one fails, another can be quickly replaced. This arrangement ensures high precision and consistency in the welding head A467 and welding threads, while reducing costs. The present invention is suitable for ultrasonic welding of ultra-thin welding sheets (0.03-0.12 mm) of varying specifications and materials.

[0113] Its working principle: The ultra-thin welding sheet ultrasonic unit includes an intelligent CNC ultrasonic generator 469 + transducer (not expressed in the figure) + amplitude transformer (fixed flange) (not expressed in the figure) + welding head A467 + (welding sheet + switch unit 16 (circuit breaker or mutual inductor 17)) workpiece + bottom mold (lower hazelnut 405).

[0114] The ultrasonic generator 469 is an intelligent numerically controlled ultrasonic generator 469. The ultrasonic generator 469 is connected to 220V AC power with an industrial frequency of 50 / 60Hz and uses it as electrical energy input. Through internal rectification, transformation, dedicated power tubes and other circuits, the 220V electricity is converted into a high-voltage and high-frequency electrical output with a resonant specific frequency such as 20kHz or 40kHz, providing the required electrical energy for the transducer. The transducer receives the high-frequency and 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 output at the same frequency. The output amplitude is usually small, generally around 10μm. The mechanical vibration output by the input transducer is input to the amplitude variable rod (fixed flange). The amplitude variable rod amplifies or reduces the input mechanical vibration according to its own shape and structure, and transmits the adjusted mechanical vibration to the welding head A467 (the present invention amplifies the mechanical vibration amplitude). The welding head A467 receives the mechanical vibration transmitted by the amplitude variable rod, and the welding head A467 further increases the amplitude. Mechanical vibrations, after step filtering and three-stage amplification, are transmitted to the copper workpiece surface to be welded. The mechanical vibration energy and pressure from the welding head A467 are input into the array welding teeth on the welding head A467. The array welding teeth press the ultra-thin welding sheet and the switch unit 16 (relay or circuit breaker) or mutual inductor 17 between the bottom die. Under the combined action of the mechanical vibration energy and pressure output by the array welding teeth (which provide stable support for the bottom die), the copper material on the workpiece surface of the array welding teeth generates high-frequency vibrations, causing tiny protrusions on the workpiece surface to rub against each other, converting the vibration energy into heat and plastic deformation. Continuous vibration breaks up and removes the oxide film on the copper surface, and plastic deformation and atomic diffusion promote atomic bonding within the diffusion range on the contact surface, forming a strong weld joint. Ultimately, welding is completed, resulting in a finished copper product. The bottom die primarily serves to withstand the pressure transmitted from the workpiece and the vibration reaction force. Provide support and positioning for the workpiece, ensure the stable position of the workpiece during welding, enable welding to be carried out accurately, and output stable welding quality and accuracy.

[0115] Furthermore, the ultrasonic welding machine 322 is equipped with an ion exhaust fan 480, and the welding head A467, lower hazelnut 405, ultra-thin solder sheet cutter, and U-shaped suction nozzle are grounded with copper wire in close proximity. This addresses the static electricity generated during the ultra-thin solder sheet cutting process due to friction between the material and the cutting tool and equipment, and between the welding teeth, ultra-thin solder sheet, and lower hazelnut 405. This static electricity can attract dust and other impurities, contaminating the solder sheet surface and potentially causing electrostatic discharge, potentially damaging the performance of the solder sheet. Factors such as ambient temperature, humidity, and air quality can also affect processing quality. If the ambient humidity is too high, silver-copper-phosphorus solder sheets are easily affected by moisture and oxidation, affecting the welding effect. Dust and impurities in the workshop can also be attracted to the surface of the solder sheet, causing welding defects and cold joints.

[0116] The Multi-element Flexible Ultrasonic Welding Machine 322 invention has achieved outstanding technical results in many aspects in the field of power equipment manufacturing through multiple innovative designs and components that work together:

[0117] Efficient automated production:

[0118] Multiple machines work together, from the automatic cutting and feeding of the welding lug assembly machine 328, the ultrasonic welding performed by the turntable 325 workstation, to the welding and fixing performed by the welding and inspection integrated machine 313, and the comprehensive testing performed by the welding and inspection performance tester 315, forming an automated production line. Compared to manual processing, this greatly improves the efficiency of welding connections and testing between the terminal box unit 15, switch unit 16, and transformer 17, reducing labor costs and shortening production cycles.

[0119] The turntable 325 of the welding piece assembly machine 328 is provided with multiple workstations and cooperates with multiple first fixtures 326 to realize the continuous cycle operation of loading, testing, welding and unloading, reducing the idle time of the equipment, increasing the output per unit time and meeting the needs of large-scale production.

[0120] Flexible and universal design:

[0121] The contoured cavity 3261 of the first fixture 326 is universal and can hold both the switch unit 16 and the transformer 17. This reduces the number of specialized fixtures and equipment, shrinks the overall equipment size, and lowers equipment procurement and maintenance costs. It also improves the versatility and adaptability of the equipment, facilitating flexible switching to produce different products based on production needs.

[0122] The lifting and rotating mechanism 477 cooperates with the special structure of the first clamp 326 to realize the lifting and rotation of the switch unit 16 or the mutual inductor 17, meeting the requirements of the ultrasonic welding machine 322 for welding in different positions, and further enhancing the equipment's adaptability to complex welding tasks.

[0123] Premium welding quality:

[0124] The welding inspection integrated machine 313 adjusts the welding current, time, pressure and other parameters through the control mechanism, and uses the cold water circulation mechanism 6 and the cold air mechanism 8 to control the welding temperature, ensuring that the welding temperature is maintained within the preset threshold, effectively avoiding problems such as cold welding, and improving the firmness and reliability of the welding joint.

[0125] The welding head A467 of the ultrasonic welding machine 322 has been specially designed. Its unique structure enables fine filtering and three-stage amplification of the ultrasonic amplitude, solving the problems of noise, harmonics and energy instability in existing equipment. It can achieve high-quality welding of ultra-thin silver-copper-phosphorus welding sheets and copper-phosphorus, meeting the welding requirements of ultra-thin welding sheets of different thicknesses (0.03-0.12mm), and ensuring the stability and consistency of welding quality.

[0126] Convenient maintenance and cost control:

[0127] The 4x5x5 welding teeth A466 arranged crosswise on the welding head A467 solves the problem of quick replacement of multiple welding teeth. Compared with the existing single-head welding head A467, it greatly saves costs, reduces replacement time, improves equipment maintenance efficiency, and reduces production downtime caused by equipment maintenance.

[0128] The A466 welding tooth has a variety of array tip layout designs (4x4, 3x3, 5x5), which can be selected according to the thickness of the copper welding piece. This improves the applicability of the welding head A467 to welding pieces of different specifications and reduces the cost and time consumption caused by replacing the welding head A467.

[0129] Precision testing and quality assurance:

[0130] The multi-performance floating test fixture 534 of the welding performance tester 315 can perform comprehensive testing on the terminal box unit 15, to which the switch unit 16 and transformer 17 are welded, including various performance tests such as weld firmness, weld pull force, and weld resistance. This ensures product quality reliability before shipment, allowing for the timely detection and removal of substandard products, improving overall product quality and reducing costs associated with post-sales quality issues.

[0131] Elimination of static electricity and environmental adaptation:

[0132] The ultrasonic welding machine 322 is equipped with an ion exhaust 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 with copper wire at close range, which effectively solves the static electricity problem caused by friction during the cutting and welding of ultra-thin solder sheets. It avoids the contamination of the solder sheet surface by static adsorption of dust and impurities, prevents the damage of electrostatic discharge to the performance of the solder sheet, and improves the stability and quality of the product produced in a complex environment. At the same time, it reduces the influence of environmental factors (such as humidity and air quality) on the welding effect to a certain extent, ensuring the adaptability of the production environment.

[0133] Specifically, as attached Figure 9 As shown, the terminal copper bar assembly machine utilizes a multi-component coordinated flexible fixture. The multi-component coordinated flexible fixture includes a shift fixture A50 that rotates with the multi-station turntable and a movable fixture A51 for assembling the shift fixture A50. The shift fixture A50 is used for automatically assembling the terminal box body 153, while the movable fixture A51 is used for automatically assembling multiple switch unit copper terminals 151 and multiple transformer copper terminals 152. The movable fixture A51 automatically pushes the multiple switch unit copper terminals 151 and multiple transformer copper terminals 152 into the terminal box body 153 to form the terminal box unit 15. Specifically, the movable fixture A51 includes an assembly fixture 500, and the shift fixture A50 includes a fixing seat 517. Elastic clamping members 512 are provided on both sides of the fixing 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 a receiving cavity 505 for fixing the switch unit copper terminal 151 and the transformer copper terminal 152. Here, there are four receiving cavities 505, each of which fixes two switch unit copper terminals 151 and two transformer copper terminals 152. An external drive source first drives the assembly fixture 500 toward the fixing seat 517. When the assembly fixture 500 is in contact with the fixing seat 517, the external drive source drives the switch unit copper terminal 151 and the transformer copper terminal 152 to be installed on the terminal box body 153. The fixing seat 517 cooperates with the assembly fixture 500 to form a connection and fixation between the switch unit copper terminal 151, the transformer copper terminal 152 and the terminal box body 153.

[0134] Specifically, as attached Figure 9 As shown, one of the carrier 504 and the fixture body 501 is provided with a second guide post 508, while the other is provided with a second guide slot 507 that cooperates with the second guide post 508. The second guide post 508 and the second guide slot 507 cooperate to create a guiding and driving effect. Alternatively, one of the carrier 504 and the fixture body 501 is provided with a limiting protrusion 502, while the other is provided with a limiting slot 503 that cooperates with the limiting protrusion 502. The cooperation between the limiting protrusion 502 and the limiting slot 503 creates a directional limit.

[0135] Specifically, as attached Figure 9 As shown, the lower end of the accommodating cavity 505 is an arc surface 5051, and the upper end is a convex shape 5052. The upper and lower ends are connected to form a closed surface. Through this structural setting, the accuracy requirements of the switch unit copper terminal 151 and the mutual inductor copper terminal 152 can be met.

[0136] The assembly fixture 500 for the switch unit copper terminal 151 and the transformer copper terminal 152 has the following technical effects:

[0137] 1. Efficient and precise assembly

[0138] Automatically guided assembly: The second guide post 508 cooperates with the second guide slot 507 to provide precise guidance for the sliding movement of the carrier 504 relative to the fixture body 501. This allows the assembly fixture 500 to precisely move toward the fixing seat 517 under the action of an external drive source. This ensures that the switch unit copper terminal 151 and the transformer copper terminal 152 are accurately aligned with the corresponding mounting positions on the terminal box body 153 during installation, effectively improving assembly accuracy and efficiency and reducing installation failures or product quality issues caused by assembly deviations.

[0139] 2. Guaranteed Precision: 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 maintain stability during assembly and prevents unnecessary displacement of the carrier 504 during sliding, but also ensures the consistent position of the switch unit copper terminal 151 and the transformer copper terminal 152 during each installation, greatly meeting the strict requirements of automatic assembly precision and improving the stability of product quality.

[0140] 3. Reliable connection and fixation

[0141] Stable elastic clamping: The elastic clamping members 512 on either side of the fixing seat 517 press against the sides of the terminal box body 153, providing stable support for the terminal box body 153. During the installation process of the switch unit copper terminal 151 and the transformer copper terminal 152 to the terminal box body 153, the elastic clamping members 512 can adapt to the changes in the shape of the terminal box body 153, maintaining a stable clamping force, preventing the terminal box body 153 from shifting or shaking, ensuring the reliability of the connection and securing process, and helping to form a strong and stable connection.

[0142] Collaboration with the assembly fixture 500: The carrier 504 of the assembly fixture 500 features a receiving cavity 505, which securely holds the switch unit copper terminal 151 and the transformer copper terminal 152. Driven by an external drive source, the carrier 504 and the fixing base 517 work together to achieve precise docking and a secure connection between the copper terminal and the terminal box body 153. This collaborative assembly method significantly improves connection reliability and consistency compared to traditional manual assembly, reducing the impact of human factors on connection quality.

[0143] 4. Adapt to different copper terminals

[0144] Unique design of the accommodating cavity 505: The lower end of the accommodating cavity 505 is a curved surface 5051, and the upper end is a convex shape 5052, with the upper and lower ends connected to form a closed surface. This unique structural design can better adapt to the shape characteristics of the switch unit copper terminal 151 and the transformer copper terminal 152, providing a more fitting and stable fixing method. The curved surface 5051 guides and cushions the copper terminal when it is placed into the accommodating cavity 505, while the convex shape 5052 limits the copper terminal from above, ensuring that the copper terminal does not rotate or shift during the assembly process. This meets the automatic assembly precision requirements of switch unit copper terminal 151 and transformer copper terminal 152 of different shapes and specifications, enhancing the versatility of the assembly fixture 500.

[0145] 5. Buffering and Adaptation

[0146] Elastic Buffering and Adjustment: A second elastic member, positioned between the carrier 504 and the fixture body 501, provides buffering and adaptive adjustment during assembly. When an external drive source propels the assembly fixture 500 toward the mounting base 517, the second elastic member automatically adjusts the position of the carrier 504 based on changes in assembly resistance, preventing damage to the copper terminal or the terminal box body 153 due to excessive external forces. Furthermore, after assembly, the second elastic member provides a preload, further enhancing the stability of the connection between the copper terminal and the terminal box body 153.

[0147] Specifically, as attached Figure 1 , Attachment Figure 12As shown, the welding inspection performance test machine 315 includes a test instrument installed under a frame (not shown in the figure), a fixing plate 519 is installed on the frame, a Z-shaped mounting frame 521 is installed on the fixing plate 519, a double-station multi-stage second downward pressure cylinder 520 is provided on the mounting frame 521, and the lower part of the second downward pressure cylinder 520 rod is connected by a linkage 523, a pressure sensor is provided under the linkage 523, and the pressure sensor is installed on the L-shaped fixing plate, the L-shaped fixing plate is fixedly connected to the linear guide rail, the linear guide rail and the slide rail form a sliding pair, and the slide rail is fixed on the vertical plate of the Z-shaped mounting frame 521, and a transformer test fixture and a switch unit test fixture, a transformer test fixture and a switch unit test fixture are provided under the L-shaped fixing plate. The tools are respectively fixed to the pressure sensor test rod. The transformer test fixture is composed of a square plate with an L-shaped plate under it, and an arc-shaped plate for pressing the transformer 17 under the L-shaped plate. The arc-shaped plate of the transformer 17 is pressed on the two copper welding pieces A171 of the transformer 17. The switch unit test fixture is composed of a square plate with double L-shaped pressure plates under it, which are pressed on the protruding ends of the third copper welding piece B161 and the fourth copper welding piece A161 and the switch unit copper terminal 151. The transformer copper terminal 152 and the switch unit copper terminal 151 are installed in the terminal box to form a terminal box unit 15; the terminal box unit 15 is installed in the multi-performance floating detection fixture 534, and the sliding column H534 on the multi-performance floating detection fixture 534 is moved along the sliding column on the fixed plate 519 The sleeve slides, and the fixed plate 519 is respectively provided with a switch unit on-off probe 536, a mutual inductor on-off probe 535, a resistance detection probe 537 after on-off, and a loop resistance detection probe X534. The resistance detection probe 537 after on-off and the welding resistance detection probe 533 are respectively facing the communication line pins on the switch unit 16 and the mutual inductor 17, the switch unit copper terminal 151 and the mutual inductor copper terminal 152 (the middle position of the locking screw), the third copper welding piece B161 and the fourth copper welding piece A161 and the switch unit copper terminal 151 overlap welding, the first copper welding piece A171 of the mutual inductor 17 and the second copper welding piece B171 and the mutual inductor copper terminal 152 welding overlap, and passing through multiple performance floating detection A through hole is set on the fixture 534, and a rotating clamping device 529 is set on the fixed plate 519 and on the left and right sides of the multi-performance floating detection fixture 534 to press the terminal box unit 15 on the multi-performance floating detection fixture 534. The multi-performance floating detection fixture 534 is pressed on the test position by the second downward pressure cylinder 520 to drive the lower transformer test fixture and the switch unit test fixture. Its pressure sensor and the corresponding probe test online pressure value, welding resistance value, switch unit 16 (relay or circuit breaker), resistance value on the transformer 17, on-off resistance value and on-off function detection, and judge whether the welding is qualified and whether there is cold soldering and falling off, and whether the resistance performance and function are qualified and in good condition according to the upper and lower limit values.

[0148] Specifically, the welding inspection performance testing machine 315 includes a rotary clamping device 529, which includes a rotary cylinder 530 and a clamping member 555. The rotary cylinder 530 is linked to the clamping member 555, and the clamping member 555 is pressed against the welded terminal box unit 15, switch unit 16, and transformer 17.

[0149] As attached Figure 15 As shown, the invention features of the multi-performance floating detection fixture 534 include: a T-shaped slide bar L534 for fixing and connecting the square plate at the diagonal position; the T-shaped slide bar L534 and the sliding sleeve H534 fixed on the fixed plate 519 form a sliding pair; the spring in the middle of the T-shaped slide bar L534 is 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; and a first recessed groove A534 and a protruding groove A534 are provided on both sides of the profiling groove N534 for locking the terminal box unit 15. The second recessed groove B534 and the centrally protruding sixth U-shaped groove C534 for locking are located. A first mounting hole D534 for mounting a conduction resistance probe 537 is located between the sixth U-shaped groove C534, the first recessed groove A534, and the second recessed groove B534, directly opposite the copper terminal. The front surface O534 of the contoured groove N534 houses the left and right mounting holes F534 and G534 for mounting a welding resistance test probe 533, used to test the solder joints between the switch unit 16 and the transformer 17. The second recessed groove B534 is provided with a first hole E534. The multi-performance floating test fixture 534 also has a second hole M534.

[0150] The invention effects of the multi-performance floating detection fixture 534 are specifically related to the floating function:

[0151] 1. Height or Position Deviation: The diagonal square plates are connected to sliding sleeves H534 on the fixed plate 519 via T-shaped slide bars L534, forming a sliding pair. The spring in the middle of the T-shaped slide bars L534 is located on the back of the fixed plate 519. This design provides the fixture with floating properties. When the terminal box unit 15 being inspected deviates in height or position, the spring acts as a buffer and adjusts, allowing the square plates to adaptively adjust their position and ensure smooth inspection. This prevents inspection failures or inaccuracies caused by minor positional errors in the inspected object, improving the fixture's compatibility with workpieces in varying conditions.

[0152] 2. Reduce damage during testing: The floating function reduces hard collisions and compression between the fixture and the object being tested. The spring's cushioning effect makes the fixture more gentle when contacting the workpiece, reducing the risk of scratches, indentations, and other damage to the surface of the end button box unit 15, helping to protect the appearance and performance of the product being tested.

[0153] 3. Related effects of contoured groove and positioning structure

[0154] 1. Precise Positioning of the Terminal Box: A contoured groove N534 for the terminal box unit 15 is located in the center of the square plate. Flanking the contoured groove N534 are a first recessed groove A534 and a second recessed groove B534, which are designed to lock the terminal box into place. A sixth U-shaped groove C534 protrudes from the center for locking. These contoured and locking structures precisely match the shape of the terminal box unit 15, achieving precise positioning of the terminal box. This ensures that the terminal box remains in place during testing, preventing inaccurate test results due to shaking or displacement, thereby improving test accuracy and reliability.

[0155] 2. Improved testing stability: The locking action of the sink and U-shaped grooves secures the terminal box in the contoured slot, preventing it from moving or deflecting during various testing operations. This is particularly important for testing items such as on-resistance and weld resistance, ensuring stability during testing and reducing measurement errors.

[0156] 4. Effects related to probe mounting holes

[0157] 1. Accurate On-Resistance Measurement: A first mounting hole D534 for the on-resistance probe 537 is located between the sixth U-shaped groove C534 and the first and second recesses A534 and B534, directly opposite the copper terminal. This design ensures that the probe 537 precisely contacts the copper terminal, enabling accurate on-resistance measurement. The precise alignment of the mounting hole with the copper terminal ensures good electrical contact between the probe and the copper terminal, improving the accuracy and reliability of on-resistance measurement.

[0158] 2. Effectively test weld resistance: The front surface O534 of the contoured slot N534 faces the left and right mounting holes F534 and G534 for the weld resistance test probe 533, which is used to install the weld joints between the test switch unit 16 and the transformer 17. Accurately installing the probe 533 through these two mounting holes ensures precise contact between the probe and the weld joint, effectively testing the weld resistance between the test switch unit 16 and the transformer 17. Accurate weld resistance testing helps to promptly identify weld quality issues and ensure the electrical performance and stability of the product.

[0159] Specifically, as attached Figure 10-11 As shown, the welding and inspection integrated 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.

[0160] In this embodiment, there are two welding and assembly inspection integrated machines 313. The second conveyor belt 3 is connected to the first conveyor belt (not shown in the drawing) and the third conveyor belt 4. The first conveyor belt is connected in parallel with the welding and assembly inspection integrated machine 313, and the third conveyor belt 4 is connected in parallel with another welding and assembly inspection integrated machine 313.

[0161] The welding mechanism includes an upper electrode 19 and a lower electrode 27. The lower electrode 27 abuts the lower ends of the switch unit copper terminal 151 and the transformer copper terminal 152. The second conductive member 161 and the third conductive member 171 are located on the motion trajectory of the upper electrode 19. The welding method between the upper electrode 19 and the lower electrode 27 can be: the upper electrode 19 and the lower electrode 27 move relative to each other simultaneously, ultimately forming a top-to-bottom clamping, forming a resistance brazing. Alternatively, the upper electrode 19 moves while the lower electrode 27 remains stationary; alternatively, the lower electrode 27 moves while the upper electrode 19 remains stationary. The upper electrode 19 and the lower electrode 27 are each connected by a corresponding electrode arm.

[0162] The cold water of the cold water circulation mechanism 6 flows through the upper electrode 19 and the lower electrode 27 .

[0163] The cold air from the cold air mechanism 8 is blown toward the upper electrode 19 .

[0164] The first temperature sensor 164 detects the temperature of the upper electrode 19 and the welding position.

[0165] The CCD detection mechanism 21 detects the terminal box unit 15 , the switch unit 16 , and the mutual inductor 17 .

[0166] The control mechanism adjusts one of the following: welding current, welding time, welding pressure, cold water temperature, cold water flow, cold air temperature, cold air flow, or a combination of two or more of them. With this structural arrangement, the switch unit 16, the mutual inductor 17, and the terminal box unit 15 are connected and fixed by the welding mechanism. Compared with the prior art, this processing method is simpler. It uses automated operation to combine several welding steps to form an automated welding effect, thereby improving processing efficiency. Secondly, by detecting the welding temperature and controlling various parameters, the welding temperature is controlled so that the welding temperature is maintained within a preset threshold, thereby ensuring that cold welding and other phenomena will not occur during the welding process, thereby improving welding quality. Through multiple modes such as water, cold air, current, or pressure, a multiple-mode temperature control effect is formed.

[0167] The invention of welding and inspection integrated machine 313 has many significant technical effects:

[0168] 1. Improved processing efficiency: The welding, assembly, and inspection integrated machine 313 integrates multiple steps, including welding, assembly, and inspection, and through automated operations, combines several welding steps to achieve an automated welding effect. Compared to existing technologies, this reduces manual intervention and process changeover time, avoids operations such as transport and repositioning between different devices, and significantly improves the processing efficiency of the connection and fixation between the terminal box unit 15, switch unit 16, and mutual inductor 17. Furthermore, the two welding, assembly, and inspection integrated machines 313, connected in parallel with the first and third conveyor belts 4, respectively, enable continuous, assembly-line-like operation, further improving overall production efficiency.

[0169] 2. Ensure welding quality: The control mechanism detects welding temperature and adjusts one or more parameters—welding current, welding time, welding pressure, cold water temperature, cold water flow, cold air temperature, and cold air flow—to maintain the welding temperature within preset thresholds. This effectively avoids problems such as cold welds caused by improper temperature, ensures the strength and reliability of the weld, and improves welding quality. By comprehensively controlling multiple modes (water, cold air, current, pressure, etc.) to regulate temperature, the welding process becomes more stable and controllable.

[0170] 3. Effective electrode cooling: Cold water from the cold water circulation mechanism 6 flows through the upper electrode 19 and lower electrode 27, while cold air from the cold air mechanism 8 blows toward the upper electrode 19. This dual cooling method effectively reduces electrode temperature. This prevents damage or performance degradation to the electrodes due to prolonged high-temperature operation, extending their service life. Furthermore, the stable electrode temperature helps maintain consistent welding parameters, thereby ensuring consistent welding quality.

[0171] 4. Precise Temperature Monitoring: First temperature sensor 164 monitors the temperature of upper electrode 19 and the welding position in real time, providing accurate temperature feedback to the control mechanism. Based on this real-time temperature data, the control mechanism promptly adjusts relevant parameters to achieve precise control of the welding temperature, further improving the reliability and quality of the welding process.

[0172] 5. Comprehensive Product Testing: The CCD inspection mechanism 21 can inspect the terminal box unit 15, switch unit 16, and transformer 17, promptly identifying any defects or anomalies in product size, shape, and appearance. This real-time testing during the production process prevents unqualified products from being passed on to the next process, reduces scrap rates, and improves overall product quality and production efficiency.

[0173] 6. Flexible Welding Methods: The welding mechanism's upper electrode 19 and lower electrode 27 offer a variety of welding methods, including simultaneous relative motion of the upper and lower electrodes 27, motion of the upper electrode 19 while the lower electrode 27 remains stationary, and motion of the lower electrode 27 while the upper electrode 19 remains stationary. This flexible welding method can be selected based on different product and process requirements, improving the adaptability and versatility of the equipment and enabling it to meet diverse welding tasks.

[0174] 7. High degree of automation: The entire welding, assembly, and inspection integrated machine 313 is automatically controlled by a control mechanism, reducing the errors and instability of manual operation. Automated control not only improves production efficiency but also reduces the technical requirements for operators, making the production process more standardized and regularized.

[0175] As attached Figure 14As shown, the flexible integrated assembly fixture includes a contour assembly fixture 403, and the multi-components (including relays, circuit breakers, and mutual inductors) are mounted on the contour assembly fixture 403. The contour assembly fixture 403 includes a first L-shaped plate A500, and the lower end plate A505 of the first L-shaped plate A500 is provided with a square groove A503 for assembling the switch unit 16. The square groove A503 is provided with a plurality of second array vacuum suction holes (not shown in the figure) for locking the switch unit 16; the rear end of the square groove A503 is provided with a plurality of second array vacuum suction holes (not shown in the figure) for locking the switch unit 16; A fifth U-shaped groove A504 is provided for positioning the communication socket A16; a first U-shaped groove A512 is provided at the left end of the high-end plate of the first L-shaped plate A500 for limiting the moving contact piece B16, and the first copper welding piece A171 and the third copper welding piece B161 are connected to the first U-shaped groove A512 for positioning and limiting the L platform A509, and the lower step platform A511 is connected to the lower step platform A511. A second U-shaped groove A510 is provided, and the lower step platform A 511 and the second U-shaped groove A510 are used to position the lead pin A17 on the mutual inductor 17; the positioning locking groove A508 of the mutual inductor 17 is set adjacent to the second U-shaped groove A510 and the limiting L platform A509, and the arc groove of the positioning locking groove A508 is set to lock the plurality of array third vacuum suction holes (not shown in the figure) of the mutual inductor 17; the third U-shaped groove A507 for limiting the fourth copper welding piece A161 is set adjacent to the positioning locking groove A508. The bottom plate is equipped with a fourth U-shaped groove A502 for limiting the position of the B flexible wire B17. The second L-shaped plate, adjacent to the right end of the third U-shaped groove A507, is equipped with an L-shaped platform A506 for positioning and limiting the second copper soldering piece B171 and the fourth copper soldering piece A161. An L-shaped groove plate A501 is installed on L-shaped platform A506, and a vacuum valve (not shown) is installed on L-shaped groove plate A501. This L-shaped groove plate A501 forms a flexible, integrated assembly fixture for multiple components, including the transformer 17 and the switch unit 16 (relay or circuit breaker). This fixture achieves single-step positioning of the multi-component switch unit 16 (relay or circuit breaker) and transformer 17, reducing the errors associated with multiple positioning steps in the prior art. It also eliminates the assembly deformation problem of the sampling element in the prior art, while improving accuracy and achieving locking and limiting of multiple components.

[0176] The technical advantages of the present invention are:

[0177] 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 transportation time of workpieces between different fixtures, thereby greatly improving assembly efficiency.

[0178] 2. Enhanced assembly accuracy: Through integrated design and precise positioning device, the relative position accuracy of each component during the assembly process can be guaranteed, effectively reducing cumulative errors and improving product assembly quality and consistency.

[0179] 3. Adapt to a variety of products: With the characteristics of flexibility, certain components or parameters of the fixture can be adjusted to adapt to the assembly needs of products of different models and specifications, thereby improving the versatility and utilization of the fixture and reducing the cost of equipping enterprises with special fixtures for different products.

[0180] 4. Save space: Compared with traditional multiple scattered fixtures, the multi-component integrated flexible assembly fixture integrates multiple functions into one, occupies less production space, helps to optimize the layout of the production workshop and improve space utilization.

[0181] 5. Easy to manage: As the number of fixtures is reduced, management and maintenance work is more centralized and simple, which reduces the difficulty and cost of fixture management. It also makes it easier to track and monitor the use of fixtures.

[0182] The invention of the multi-component integrated flexible assembly fixture solves the following problems:

[0183] 1. Traditional fixtures suffer from poor versatility: Traditional fixtures are typically designed for specific products or parts. Once the product model or specifications change, the fixture often becomes unusable and requires redesign and remanufacturing. Multi-component integrated flexible assembly fixtures, with their flexible design, can accommodate the assembly of a wide variety of products, effectively resolving this issue and improving fixture efficiency and cost-effectiveness.

[0184] 2. Unstable assembly accuracy: In traditional assembly processes, multiple fixtures are used for different assembly steps. This can lead to unstable assembly accuracy due to positioning errors between fixtures and the accumulation of errors caused by multiple clamping. The multi-component integrated flexible assembly fixture, with its integrated design and high-precision positioning system, can precisely control the assembly position of each component, ensuring stable and consistent assembly accuracy.

[0185] 3. Low production efficiency: Traditional fixtures require frequent replacement and adjustment, resulting in long workpiece loading and unloading times and significant downtime during production, which affects production efficiency. Multi-component integrated flexible assembly fixtures enable simultaneous assembly of multiple processes, reducing fixture replacement times and downtime, improving production efficiency, and shortening product production cycles.

[0186] 4. The problem of limited production space: Multiple traditional fixtures take up a lot of space in the workshop, making the layout appear cluttered and increasing the difficulty of material transportation and personnel operation. The integrated design of the multi-component integrated flexible assembly fixture greatly reduces the number of fixtures and the floor space occupied, making the production space more compact and neat, which is conducive to improving the management level and logistics efficiency of the production site.

[0187] Specifically, as attached Figure 10-11As shown, the cold water circulation mechanism 6 is equipped with a water inlet and a water return. The water inlet is equipped with a second temperature sensor for detecting the cold water temperature and a first flow sensor for detecting the cold water flow rate. The return water is equipped with a third temperature sensor 28 for detecting the cold water temperature. The placement of temperature sensors at different locations on the cold water circulation mechanism 6 facilitates control of each location by the control mechanism. The second temperature sensor and the first flow sensor can be used to determine the outflowing water temperature and flow rate. The third temperature sensor 28 can be used to determine whether there is any abnormality in the heat flow and whether the heat can be transferred from the upper electrode 19 to the lower electrode 27.

[0188] Specifically, as attached Figure 10-11 As shown, the first temperature sensor 164 is movable to detect 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.

[0189] Specifically, as attached Figure 10-11 As shown, the cooling mechanism 8 is equipped with a fourth temperature sensor and a first flow rate sensor. The fourth temperature sensor detects the cooling air temperature, and the first flow rate sensor detects the cooling air flow rate. The fourth temperature sensor and the first flow rate sensor can be used to control the cooling air temperature and flow rate. The cooling mechanism 8 can generate cooling air, control the cooling air temperature, and so on.

[0190] Specifically, the first temperature sensor 164 is movable to detect the upper electrode 19 and the welding position. The up and down detection of the first temperature sensor 164 makes the detection range larger.

[0191] Specifically, as attached Figure 10-11 As shown, the CCD detection mechanism 21 is also included. The CCD detection mechanism 21 detects whether the second conductive member 161 and the third conductive member 171 are fixed with solder tabs. The CCD detection setting can ensure that the second conductive member 161 and the third conductive member 171 are fixed with solder tabs before welding, thereby improving the quality of welding. In this embodiment, the CCD detection mechanism 21 is divided into two groups, the upper CCD detection mechanism 21, which is composed of a pair of condensers and CCDs (to detect 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 or deformed, whether the welding surface is discolored, whether the solder overflows, and whether the appearance is qualified). The lower CCD detection mechanism 21 is composed of a pair of lights and CCDs (to detect whether the switch unit 16 and the mutual inductor 17 have solder tabs and whether the size and position are qualified before assembly, and to detect whether the copper bar assembly and the position, size, and appearance of the terminal box unit 15 are qualified).

[0192] Specifically, the system also includes an alarm mechanism. When a fault occurs, the control mechanism controls the alarm mechanism to operate and generate an alarm. The alarm mode can be an audible alarm, a visual alarm, or a combination of an audible alarm and a visual alarm. The visual alarm can be a warning light.

[0193] Specifically, for example, if the return water temperature is abnormal, heat cannot be transferred 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 temperature of the upper and lower electrodes 27 will be inconsistent, which can easily cause poor welding. Therefore, at this time, the control mechanism automatically adjusts the welding parameters, adjusting one or a combination of two or all three of the following: welding current, welding time, and welding pressure, and then determines again whether the return water temperature has been adjusted to the preset value. If multiple adjustments fail, the control mechanism can be used to issue an alarm to prevent excessive product welding problems.

[0194] For another example, if the temperature of the upper electrode 19 is too high or overheated, the control mechanism controls the electric valve of the cooling mechanism to adjust the temperature and flow rate of the cooling air so that the temperature of the upper electrode 19 returns to the preset threshold value. The cold water temperature and flow rate of the cold water circulation mechanism 6 can also be adjusted here.

[0195] For another example, when the temperature of the upper electrode 19 or the lower electrode 27 or the temperature of the welding position is insufficient, the control mechanism controls and adjusts the cold water temperature and flow of the cold water circulation mechanism 6 to compensate for the insufficient welding temperature.

[0196] For example, if the residual temperature at the welding position does not reach the preset value, the control mechanism adjusts the welding parameters, adjusts one or a combination of two or a combination of three of the welding current, welding time, and welding pressure, compensates for the welding heat, and makes the residual temperature at the welding position reach 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 may easily lead to problems such as cold welding and low welding quality at the welding position.

[0197] Further details on the problems solved by the present invention and the supplementary explanation of the inventive points:

[0198] Technical problems solved

[0199] Low production efficiency: Existing smart meter processing adopts manual processing, which has complicated procedures and low efficiency. In addition, the coordination between equipment is unreasonable, resulting in a long production cycle.

[0200] Poor equipment versatility: Traditional fixtures and equipment are usually designed for specific products or parts. When the product model or specifications change, they often cannot be used and need to be redesigned and manufactured.

[0201] Unstable welding quality: Improper control of parameters such as temperature and current during welding can easily lead to problems such as cold solder joints, affecting welding quality. Furthermore, existing ultrasonic equipment suffers from noise, harmonics, and unstable energy, making it impossible to achieve high-quality welding of ultra-thin sheets.

[0202] Insufficient testing accuracy: The product testing process has problems such as low accuracy and incomplete testing items, making it difficult to ensure the stability and consistency of product quality, and unable to detect and eliminate unqualified products in a timely manner.

[0203] High equipment maintenance cost: Equipment maintenance and management are relatively complicated. For example, the replacement of welding head A467 is time-consuming and costly, affecting production efficiency and enterprise benefits.

[0204] Static electricity: During the cutting and welding process of ultra-thin solder sheets, static electricity is easily generated due to friction between the material and the cutting tools and equipment, as well as between the soldering iron and the ultra-thin solder sheet and the lower hazelnut 405. Static electricity can not only attract dust and other impurities and contaminate the solder sheet surface, but can also trigger electrostatic discharge, potentially damaging the sheet performance. Furthermore, environmental factors such as temperature, humidity, and air quality can also affect processing quality. For example, high humidity can easily cause silver-copper-phosphorus solder sheets to oxidize due to moisture, and dust and impurities in the workshop can adhere to the surface of the sheet, leading to welding defects and cold joints.

[0205] Assembly Accuracy and Stability: Traditional assembly processes utilize multiple fixtures for different assembly steps. This can lead to unstable assembly accuracy due to positioning errors between fixtures and the accumulation of errors from multiple clamping. Furthermore, during the assembly of the switch unit copper terminals 151 and the transformer copper terminals 152 to the terminal box body 153, failure to ensure precise positioning and stable connection can affect the overall performance of the smart meter.

[0206] Equipment takes up a large space: In the traditional production model, equipment and fixtures with different functions are relatively scattered, taking up 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.

[0207] 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.

[0208] Compatibility and maintenance challenges of the A467 welding head: When welding smart meter components, the A467 welding head must be adaptable to the various thicknesses and materials of the welding lugs. Traditional single-head A467 welding heads struggle to meet the demands of welding multiple lug sizes, and replacement is time-consuming, labor-intensive, and costly. Furthermore, over long-term use, the A467 welding head is susceptible to wear and damage due to frequent exposure to harsh conditions such as high temperature, high pressure, and friction. Extending the life of the A467 welding head and reducing maintenance frequency are pressing technical challenges.

[0209] Precise Control of Multi-Process Collaboration: Smart meter manufacturing involves multiple processes, including terminal copper strip assembly, lug welding, overall welding and fixation, and performance testing, requiring close coordination between these processes. In actual production, ensuring precise control of time, space, and process parameters across each process to avoid production stagnation and quality fluctuations caused by improper process connections is a key technical challenge in ensuring efficient and stable production.

[0210] Difficulty in product quality tracing: Smart meter production involves numerous components, complex manufacturing processes, and a vast amount of production data. When quality issues arise, it's difficult to quickly and accurately trace the root cause, such as the specific processing steps, equipment parameters, and raw material batches. This not only hinders the efficiency of resolving quality issues but can also lead to a large number of potentially problematic products entering the market, damaging the company's reputation.

[0211] Supplementary points of the invention for solving the above technical problems

[0212] Automated assembly line production: Through the coordinated operation of multiple machines such as the terminal copper strip assembly machine 312, the welding piece 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, which greatly improves production efficiency and reduces labor costs.

[0213] Universal and Flexible Design: The contoured cavity 3261 of the first fixture 326 is universally designed to secure the switch unit 16 and transformer 17, reducing the number of specialized fixtures and equipment. The lifting and rotating mechanism 477, combined with the specialized structure of the first fixture 326, meets the requirements of welding in various positions, enhancing the versatility and adaptability of the equipment.

[0214] High-quality welding technology: The integrated welding and inspection machine 313 uses a control mechanism to adjust welding parameters and utilizes a cold water circulation mechanism 6 and a cold air mechanism 8 to control welding temperature, preventing problems such as cold welds. The specially designed welding head A467 of the ultrasonic welding machine 322 implements precise filtering and three-stage amplification of the ultrasonic amplitude, enabling high-quality welding of ultra-thin welds of varying thicknesses.

[0215] Precision Testing Technology: The 315 Welding Performance Tester's Multi-Performance Floating Test Fixture 534 performs comprehensive product testing, including weld strength, weld pullout strength, weld resistance, and other performance tests, ensuring product quality and reliability. The Multi-Performance Floating Test Fixture 534's design allows for floating performance, adapting to varying workpiece conditions and improving testing accuracy.

[0216] Maintenance-Friendly Design: The A467 welding head features a cross-shaped design for welding tips, eliminating the need for multiple welding tips, saving costs and reducing replacement time. The multi-array tip arrangement improves the A467's adaptability to various welding blade sizes and reduces maintenance costs.

[0217] Static elimination and environmental adaptability design: The ultrasonic welder 322 is equipped with an ion exhaust fan 480 and uses copper wire to ground the welding head A467, lower hazelnut 405, ultra-thin solder sheet cutter, and U-shaped suction head in close proximity, effectively eliminating static electricity. These measures prevent static contamination and performance damage to the solder sheet, reduce the impact of environmental factors on welding results, and ensure product stability and quality in complex environments.

[0218] Efficient and Precise Assembly Design: The assembly fixture 500 utilizes guiding and limiting structures to precisely guide and limit the sliding movement of the carrier 504 relative to the fixture body 501. This ensures that the switch unit copper terminals 151 and the transformer copper terminals 152 are precisely aligned with their corresponding positions on the terminal box body 153 during installation, improving assembly accuracy and efficiency. Furthermore, the elastic clamps 512 on either side of the mounting base 517 provide stable support for the terminal box body 153. The accommodating cavity 505 of the carrier 504 is designed to precisely accommodate the shape of the copper terminals, ensuring reliable connection and fixing.

[0219] Space-optimized design: The multi-component integrated flexible assembly fixture integrates the assembly functions of multiple components, reducing the number of fixtures and footprint. The 328 soldering lug assembly machine utilizes a 325-turntable design, reducing its overall size. These designs optimize the layout of the production workshop, improve space utilization, and enhance production site management and logistics efficiency.

[0220] Highly automated control: The entire smart meter processing equipment is automatically controlled by a control mechanism. For example, the control mechanism of the welding, assembly, and inspection integrated machine 313 automatically adjusts parameters such as welding current, time, and pressure, as well as controls the cold water circulation mechanism 6 and the cold air mechanism 8. Automated control reduces the errors and instability of manual operation, lowers the technical requirements for operators, and makes the production process more standardized and regularized, thereby improving production efficiency and consistent product quality.

[0221] Innovative welding head A467 design:

[0222] The welding head A467 adopts a unique structural design. The rear end A471 is connected to a series of components of different shapes, which realizes fine filtering and three-stage amplification of the ultrasonic amplitude, effectively solving the problems of noise, harmonics and energy instability of existing ultrasonic equipment, and can meet the high-quality welding requirements of ultra-thin silver-copper-phosphorus welding sheets of different thicknesses (0.03-0.12mm) and copper-phosphorus.

[0223] The A467 welding head features a 4x5x5 cross-section of A466 tips, eliminating the need for quick-change multiple A466 tips, significantly reducing costs and time. Furthermore, the A466 tips offer a variety of tip array designs (4x4, 3x3, and 5x5) to accommodate copper solder sheets of varying thicknesses. This significantly improves the A467's adaptability to various solder sheet sizes and reduces weld quality issues and maintenance costs associated with A467 head mismatch.

[0224] Multi-process collaborative control system:

[0225] Through the layout of the automated production line, the terminal copper bar assembly machine 312, the welding piece assembly machine 328, the welding inspection integration machine 313 and the welding inspection performance testing machine 315 are organically combined, and the conveyor belt is used to realize the material transmission between adjacent machines to ensure that each process is closely connected in space.

[0226] Each device is equipped with a corresponding control mechanism. For example, the control mechanism of the welding and assembly inspection integrated machine 313 can detect welding temperature and precisely adjust multiple parameters, including welding current, welding time, welding pressure, cold water temperature, cold water flow, cold air temperature, and cold air flow, to maintain the welding temperature within preset thresholds. Furthermore, the control mechanisms of each device can exchange data and work collaboratively, achieving precise control of the timing and process parameters of multiple processes, ensuring the efficient and stable operation of the entire production process.

[0227] Complete product quality traceability system:

[0228] During the production process, each processing equipment collects and records a large amount of data in real time, including but not limited to welding parameters (current, time, pressure, etc.), assembly data (component position, fixing method, etc.), and test results (welding firmness, resistance value, etc.).

[0229] Establish a unified data management platform to integrate and store this data, and assign a unique identification code to each product. When a product quality issue arises, the identification code can be used to quickly query relevant data, trace back to each link in the product production process, accurately identify the root cause of the problem, and take timely measures to improve it. This effectively improves the efficiency and accuracy of product quality traceability, safeguarding product quality and corporate reputation.

[0230] Obviously, the above embodiments are merely examples for clarity of explanation and are not intended to limit the implementation methods. Those skilled in the art will readily appreciate that other variations or modifications based on the above descriptions are possible. It is not necessary and impossible to enumerate all implementation methods here. Obvious variations or modifications arising therefrom remain within the scope of protection of the present invention.

Claims

1. Multi-functional collaborative and efficient precision processing equipment for smart meters, characterized by: include: The terminal copper strip assembly machine includes a fixing base for fixing the terminal box body and an assembly fixture for fixing the switch unit copper terminals and the transformer copper terminals. The terminal copper strip assembly machine installs the switch unit copper terminals and the transformer copper terminals into 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 contoured cavity, wherein the contoured cavity fixes the switch unit or the mutual inductor; the automatic cutting and feeding unit cuts and feeds the welding piece; and the ultrasonic welding machine welds the welding piece and the switch unit or the mutual inductor; The welding and inspection integrated machine is configured such that the switch unit is fixed with a second conductive member, the mutual inductor is fixed with a third conductive member, and the second conductive member and the third conductive member are respectively welded and fixed to the welding piece; the welding and inspection integrated machine welds the second conductive member to the copper terminal of the switch unit; and the welding and inspection integrated machine welds the third conductive member to the copper terminal of the mutual inductor; The welding inspection performance testing machine includes a multi-performance floating inspection fixture, which can inspect the terminal box unit with switch units and transformers welded and fixed thereto; the welding piece assembly machine includes a turntable, which is provided with a loading station, an inspection 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; 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.

2. The multi-functional collaborative and efficient precision processing equipment for smart electric meters according to claim 1 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.

3. The multi-functional collaborative and efficient precision processing equipment for smart electric meters according to claim 2 is characterized in that: The welding piece assembly machine further comprises a blanking mechanism, which comprises a sliding clamping jaw. The blanking mechanism cooperates with the blanking station, and the sliding clamping jaw cooperates with the welded switch unit or the welded mutual inductor.

4. The multi-functional collaborative and efficient precision processing 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 drives the ultrasonic generator to move vertically up and down. The ultrasonic generator is connected to the support frame, and the support frame and the guide column slide relative to each other; the ion exhaust fan exhausts air in the shell; and the air pressure valve is used to adjust the air pressure.

5. The multi-functional collaborative and efficient precision processing equipment for smart electric meters according to claim 1 is characterized in that: The ultrasonic welding machine also includes a variable amplitude rod, a screw, and a welding head. The ultrasonic generator is transported to the variable amplitude rod through the transducer, and the variable amplitude rod is transported to the welding head through the screw. The welding head includes a rear end, a first cone, a second column, a third cone, a flat body, and a joint. The rear end is connected to the first cone, the first cone is connected to the second column, the second body is connected to the third cone, the third cone is connected to the flat body, and the flat body is connected to the joint. The joint is provided with a welding tooth, and an energy guiding rib is provided between the joint and the welding tooth; the amplitude input rear end face to the welding tooth is a column, and the axis of the column is perpendicular to the rear end face; a fine-thread screw hole is provided in the center of the rear end face, and a coarse-thread screw hole is provided in the center of the output end of the variable amplitude rod; the rear end undergoes a second-stage amplitude amplification through the first cone, and the amplified amplitude is transported to the third cone through the second column. An arc is provided on the third cone, and the arc contracts and gathers energy to the flat body. The flat body is amplified and conducts energy to the joint through the third stage, and the amplitude on the joint is transported to the welding tooth through the energy guiding rib.

6. The multi-functional collaborative and efficient precision processing equipment for smart electric meters according to claim 5, characterized in that: Alternatively, the angle of the welding teeth is 90 degrees; Alternatively, the spacing between the welding teeth is 1 mm; Alternatively, the welding tooth tip plane is 0.2 mm x 0.2 mm; Alternatively, the welding tooth bottom plane is 0.4 mm x 0.4 mm; Alternatively, the welding tooth height is 0.5 mm; Alternatively, the welding teeth are arranged in a 4x4 array; Alternatively, the welding teeth are distributed in a 3x3 array; Alternatively, the welds are arranged in a 5x5 array.

7. The multi-functional collaborative and efficient precision processing equipment for smart electric meters according to claim 5 is characterized in that: The ultrasonic generator is a 40K ultrasonic generator; the finish of the rear end surface is less than Ra0.

8.

8. The multi-functional collaborative and efficient precision processing equipment for smart electric meters according to claim 1 is characterized in that: Elastic clamping parts are provided on both sides of the fixing seat, and the elastic clamping parts are pressed against both 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.

9. The multi-functional collaborative high-efficiency precision processing equipment for smart electric meters according to claim 8, characterized in that: One of the carrier and the clamp body is provided with a guide column, and the other one is provided with a guide groove that cooperates with the guide column; or, one of the carrier and the clamp body is provided with a limiting protrusion, and the other one is provided with a limiting groove that cooperates with the limiting protrusion.

10. The multi-functional collaborative and efficient precision processing equipment for smart electric meters according to claim 9, characterized in that: The welding inspection performance testing machine includes a rotary pressing device, which includes a rotary cylinder and a pressing piece. The rotary cylinder and the pressing piece are linked together, and the pressing piece presses against the welded terminal box unit, switch unit, and mutual inductor.

11. The multi-functional collaborative high-efficiency precision processing equipment for smart electric meters according to claim 1, characterized in that: The welding and assembly 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 the fixing device fixes the terminal box unit, the switch unit, and the mutual inductor; The welding mechanism includes an upper electrode and a lower electrode, wherein the lower electrode abuts against the lower ends of the copper terminals of the switch unit and the mutual inductor, and the second conductive member and the third conductive member are located on the motion trajectory 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 from the cold air mechanism blows toward the upper electrode; The first temperature sensor detects the temperature of the upper electrode and the welding position; CCD detection mechanism detects terminal box unit, switch unit, and mutual inductor; The control mechanism adjusts one or two or a combination of more than two of the welding current, welding time, welding pressure, cold water temperature, cold water flow, cold air temperature, and cold air flow.

12. The multi-functional collaborative high-efficiency precision processing equipment for smart electric meters according to claim 11, 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.

13. The multi-functional collaborative high-efficiency precision processing equipment for smart electric meters according to claim 12, 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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