Brazing method and brazing device

Abstract

The invention discloses a brazing method and a brazing device. The brazing device comprises a conveying mechanism, and a welding mechanism, a blade coating mechanism and an auxiliary welding mechanism are sequentially arranged along the conveying path of the conveying mechanism. The welding mechanism comprises a robot assembly, one end of the robot assembly is provided with a mounting frame, the mounting frame is provided with a heating coil, and the heating coil is used for generating a preset temperature field to act on a workpiece; the auxiliary welding mechanism comprises a driving support, an ultrasonic welding head is arranged at the driving end of the driving support, and a thermal imaging assembly used for obtaining thermal imaging information of a workpiece is arranged on one side of the ultrasonic welding head. Wherein the robot assembly is used for driving the heating coil to move according to a preset welding track, the welding quality is calculated through obtained thermal imaging information so as to adjust the angle and the position of the heating coil, and the ultrasonic welding head is matched with a temperature field to provide an auxiliary welding effect; according to the method, a cooperative control mechanism of thermal imaging dynamic feedback and ultrasonic-assisted welding is integrated, and the quality and efficiency of the brazing process are remarkably improved.

Description

Technical Field

[0001] The present invention relates to the field of welding technology, and in particular, to a brazing method and a brazing device. Background Art

[0002] As a core component of the thermal management system, the heat dissipation performance of the radiator directly depends on the connection quality between the fins and the substrate. In scenarios such as the liquid cooling plate of new energy vehicle power batteries, the heat dissipation module of 5G base stations, and the radiator of high-power electronic chips, densely arranged aluminum / copper heat dissipation fins (with a thickness of 0.1 - 0.3 mm and a pitch of 1 - 3 mm) need to achieve high-strength and defect-free brazing connections with the substrate. However, the ultra-thin structure of the fins is sensitive to temperature, and the dense arrangement results in a complex heat conduction path. Traditional processes are prone to problems such as local overheating and uneven penetration of the brazing material. According to statistics, the current qualified rate of radiator brazing is only 85% - 92%, and the attenuation of heat dissipation efficiency caused by virtual soldering can reach more than 30%, seriously restricting the reliability of high-power equipment.

[0003] Existing induction brazing technologies mostly adopt fixed induction coils and static heating modes, which heat the substrate as a whole through a preset power. Such technologies have the core defect of insufficient temperature field adaptability: due to the electromagnetic induction skin effect in the dense fin area, local high temperatures are easily generated, while the temperature in adjacent areas is insufficient due to the hindrance of heat diffusion, and the temperature difference fluctuation exceeds 150°C. Experiments show that when brazing 0.2 mm thick aluminum alloy fins, the wetting coverage rate of the brazing material in the traditional process is only 75% - 80%, and there is incomplete fusion at the root of the fins. In contrast, through real-time thermal imaging feedback and dynamic temperature field control in this solution, the temperature difference can be controlled within ±20°C, and the wetting coverage rate is increased to ≥95%, significantly reducing the risk of fin deformation and thermal damage.

[0004] In view of this, it is necessary to improve the existing brazing technology to solve the technical problem of poor welding quality during the welding process. Summary of the Invention

[0005] The purpose of the present invention is to provide a brazing method and a brazing device to solve the above technical problems.

[0006] To achieve this purpose, the present invention adopts the following technical solutions: A brazing device includes a conveying mechanism, a welding mechanism arranged in sequence along the conveying path of the conveying mechanism, a scraping mechanism for scraping the brazing material on the surface of the workpiece, and an auxiliary brazing mechanism arranged relative to the welding mechanism; The welding mechanism includes a robot component, one end of the robot component is provided with a mounting frame, and a heating coil is arranged on the mounting frame, and the heating coil is used to generate a preset temperature field acting on the workpiece; The auxiliary soldering mechanism includes a driving bracket, a driving end of the driving bracket is provided with an ultrasonic soldering head, and a side portion of the ultrasonic soldering head is provided with a thermal imaging component for obtaining thermal imaging information of the workpiece; Wherein, the robot component is used to drive the heating coil to move according to a preset welding trajectory, calculate the welding quality through the obtained thermal imaging information, so as to adjust the angle and position of the heating coil, and the ultrasonic soldering head provides auxiliary soldering in cooperation with the temperature field.

[0007] Optionally, the scraping mechanism includes a support frame, the support frame is provided with a first linear module along the X-axis direction, a driving end of the first linear module is connected with a second linear module arranged along the Z-axis direction, and a printing head module is arranged at a driving end of the second linear module; The number of the printing head modules is two, and the two printing head modules are arranged side by side. Wherein, the printing head module includes an angle adjustment component and a pressure adjustment component.

[0008] Optionally, an imaging component is correspondingly arranged for the scraping mechanism, and the imaging component is used to capture a solder scraping image on the surface of the workpiece to adjust the operation parameters of the scraping mechanism.

[0009] Optionally, the driving bracket includes a base, the base is provided with a third linear module along the Y-axis direction, a driving end of the third linear module is provided with a support cross beam along the X-axis direction, the support cross beam is provided with a fourth linear module, a driving end of the fourth linear module is provided with a lifting module, and a driving end of the lifting module is connected with the ultrasonic soldering head; Wherein, one side of the ultrasonic soldering head is provided with an extension plate, and a height adjustment component is installed on a side portion of the extension plate. The height adjustment component is connected with the thermal imaging component and is used to adjust the height of the thermal imaging component.

[0010] The present invention also provides a brazing method, which is applied to the brazing device as described above. The brazing method specifically includes the following steps: Establish a three-dimensional digital model of the workpiece, generate dynamic welding parameters based on the heat conduction characteristics of the three-dimensional digital model, and plan a welding path; Scrape a brazing material layer on the surface of the workpiece according to the welding path, and real-time monitor the thickness of the brazing material through the imaging component, and dynamically adjust the inclination angle and feeding rate of the scraping mechanism; Drive the heating coil to move along the welding path based on the dynamic welding parameters, synchronously start the ultrasonic vibration component, and combine the thermal imaging data to real-time adjust the operation parameters and position trajectory of the heating coil; Apply high-frequency vibration through the ultrasonic vibration assembly and adjust the vibration parameters to break the oxide layer on the surface of the workpiece and promote the wetting of the solder. Then, control the pressure servo mechanism to apply dynamic pressure according to a preset curve to achieve uniform penetration of the solder. Conduct multi-dimensional quality inspection on the welded workpiece, update the dynamic welding parameter library according to the inspection results, and output the optimized process parameter combination.

[0011] Optionally, establish a three-dimensional digital model of the workpiece, generate dynamic welding parameters based on the heat conduction characteristics of the three-dimensional digital model, and plan the welding path, specifically including: Obtain the three-dimensional structure data of the workpiece through a scanner to generate a three-dimensional point cloud model containing geometric features and material properties. Divide the heat conduction grid based on the three-dimensional point cloud model, input the thermal conductivity, specific heat capacity, and environmental thermal resistance parameters of the workpiece to construct a heat conduction simulation model. Simulate the temperature field distribution under different welding parameters in the heat conduction simulation model, identify the heat-sensitive areas and predict the heat deformation trend to generate an initial set of welding parameters. According to the distribution characteristics of the heat-sensitive areas, use a path optimization algorithm to perform dynamic priority sorting on the initial welding path to generate a dynamic welding parameter matrix containing power gradient and dwell time. Combine the dynamic welding parameter matrix with the geometric constraint conditions of the workpiece, and use the ant colony algorithm to plan a welding path with balanced heat load and mark the compensation parameters of the path nodes.

[0012] Optionally, scrape a solder layer on the surface of the workpiece according to the welding path, and use an imaging component to monitor the solder thickness in real time, and dynamically adjust the inclination angle and feeding rate of the scraping mechanism, specifically including: Initialize the inclination angle parameter and feeding rate parameter of the scraping mechanism according to the geometric characteristics of the welding path and the rheological characteristics of the solder. Drive the scraping mechanism to perform solder coating along the geometric path of the welding path, and use an imaging component to collect the solder layer image in real time to generate a thickness distribution heat map. Compare the thickness distribution heat map with the preset target value, use the fuzzy PID algorithm to dynamically correct the scraper inclination angle and the feeding pump speed, and record the compensation parameters. Perform gray value uniformity detection on the corrected solder layer, verify the coverage rate of the area where the thickness meets the standard, and import the compensation parameters into the dynamic welding parameter library.

[0013] Optionally, drive the heating coil to move along the welding path based on the dynamic welding parameters, synchronously start the ultrasonic vibration assembly, and adjust the operating parameters and position trajectory of the heating coil in real time in combination with the thermal imaging data, specifically including: Load the power gradient and dwell time data in the dynamic welding parameters, and initialize the starting power of the heating coil and the moving speed of the robot component; Drive the heating coil to start induction heating along the welding path through the robot component, synchronously activate the ultrasonic vibration component and set the initial amplitude and frequency; Real-time collect the temperature distribution data of the welding area through the thermal imaging component to generate a temperature-space mapping matrix.

[0014] Optionally, after real-time collecting the temperature distribution data of the welding area through the thermal imaging component to generate a temperature-space mapping matrix, it further includes: Calculate the deviation value between the actual temperature field and the target temperature field based on the temperature-space mapping matrix, and use the dynamic weight allocation algorithm to adjust the heating coil power and the robot movement trajectory compensation parameters in real time; Fuse the real-time impedance data of the ultrasonic vibration component and the temperature deviation value, and optimize the heating power increment and the robot attitude angle of the next path node through the model predictive control algorithm; According to the optimized parameters, real-time correct the tilt angle of the heating coil and the robot movement trajectory, and record the adjusted dynamic parameters into the dynamic welding parameter library.

[0015] Optionally, apply high-frequency vibration through the ultrasonic vibration component and adjust the vibration parameters to break the oxide layer on the surface of the workpiece and promote the wetting of the filler metal, and then control the pressure servo mechanism to apply dynamic pressure according to the preset curve to achieve uniform penetration of the filler metal, specifically including: Call the vibration parameters and pressure curve in the dynamic welding parameter library to initialize the amplitude gradient of the ultrasonic vibration component and the loading rate of the pressure servo mechanism; Drive the ultrasonic vibration component and apply high-frequency vibration along the welding path, synchronously activate the pressure servo mechanism to apply contact pressure according to the initial pressure curve, and real-time collect the filler metal wetting state data; Based on the filler metal wetting state data, analyze the penetration depth and interface reaction degree of the filler metal through the infrared spectrum in the thermal imaging data, and dynamically adjust the slope parameters of the vibration frequency and the pressure curve; Execute pressure gradient release after the filler metal is completely penetrated, record the optimized vibration-pressure coordination parameters and update them to the dynamic welding parameter library.

[0016] Compared with the prior art, the present invention has the following beneficial effects: when working, firstly, the workpiece to be welded is placed on the fixture of the conveying mechanism, and the conveying mechanism drives the workpiece to move to the bottom of the scraping mechanism. After the scraping mechanism scrapes the solder on the surface of the workpiece, the workpiece continues to be driven to move to the bottom of the welding mechanism. The robot component drives the heating coil to move according to the preset welding trajectory to perform brazing welding. During this period, the thermal imaging information obtained by the thermal imaging component is used to adjust the angle and position of the heating coil according to the calculated welding quality. The ultrasonic welding head cooperates with the temperature field to provide auxiliary welding. The device captures the temperature distribution of the welding area in real time through the thermal imaging component, and combines the dynamic posture adjustment of the robot component to achieve temperature field uniformity control, effectively suppressing the deformation of the hot workpiece. The ultrasonic welding head simultaneously applies high-frequency mechanical vibration during the heating stage, breaks the oxide film and promotes the wetting of the solder through the cavitation effect, and accelerates the filling of the molten solder through the acoustic streaming effect. The collaborative control mechanism of integrated thermal imaging dynamic feedback and ultrasonic assisted welding significantly improves the quality and efficiency of the brazing process. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0018] The structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with this technology. They are not used to limit the conditions under which the present invention can be implemented, and therefore have no substantive technical significance. Any structural modification, change in proportion or adjustment of size, without affecting the effects and purposes that can be achieved by the present invention, should still fall within the scope of the technical contents disclosed by the present invention.

[0019] Figure 1 Schematic diagram of the overall structure of the brazing device of the first embodiment; Figure 2 It is a front view structural schematic diagram of the brazing device of the first embodiment of the present invention; Figure 3 This is a schematic diagram of the main structure of the brazing device of the first embodiment; Figure 4 It is a structural schematic diagram of the auxiliary welding mechanism of the brazing device of the first embodiment of the present invention; Figure 5 This is a schematic structural diagram of a printing head module of a soldering device according to the first embodiment of the present invention; Figure 6 Schematic diagram of the brazing method of the second embodiment.

[0020] Illustration: Conveyor mechanism 10, scraping mechanism 20, welding mechanism 30, auxiliary welding mechanism 40, robot assembly 31, mounting bracket 32, heating coil 33, drive bracket 41, ultrasonic welding head 42, thermal imaging assembly 43, support frame 21, first linear module 22, second linear module 23, printing head module 24, angle adjustment assembly 25, pressure adjustment assembly 26, base 411, third linear module 412, support beam 413, fourth linear module 414, lifting module 415, extension plate 416. Detailed implementation

[0021] In order to make the invention objectives, features, and advantages of the present invention more obvious and understandable, the following will combine the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described below are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present invention.

[0022] In the description of the present invention, it should be understood that the orientation or positional relationships indicated by the terms "upper", "lower", "top", "bottom", "inner", "outer", etc. are based on the orientation or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be construed as a limitation of the present invention. It should be noted that when a component is considered to be "connected" to another component, it can be directly connected to the other component or there may be an intermediate component present.

[0023] The following will further illustrate the technical solutions of the present invention in conjunction with the drawings and through specific implementation manners.

[0024] Embodiment 1: Combined with Figures 1 to 5 As shown, the embodiment of the present invention provides a brazing device, including a conveyor mechanism 10, a welding mechanism 30 arranged in sequence along the conveying path of the conveyor mechanism 10, a scraping mechanism 20 for scraping solder on the surface of the workpiece, and an auxiliary welding mechanism 40 arranged relative to the welding mechanism 30; The brazing device adopts a modular design, realizes the continuous production of workpieces through the conveyor mechanism 10, and the welding mechanism 30, scraping mechanism 20, and auxiliary welding mechanism 40 on its conveying path form a process closed-loop. The scraping mechanism 20 drives the scraper through a precision servo motor to ensure the uniformity of the thickness of the brazing material layer.

[0025] The welding mechanism 30 includes a robot component 31. One end of the robot component 31 is provided with a mounting bracket 32, and the mounting bracket 32 is provided with a heating coil 33. The heating coil 33 is used to generate a preset temperature field acting on the workpiece. The robot component 31 adopts a five-axis collaborative robot, and its end mounting bracket 32 integrates a high-frequency induction heating coil 33 (operating frequency 50 - 200 kHz). A local high-temperature area (temperature range 400 - 800 °C) is generated on the surface of the workpiece through the principle of electromagnetic induction. The heating coil 33 adopts a split design (each segment is independently temperature-controlled), and the coil spacing and tilt angle are adjusted in real time in combination with the thermal imaging data to ensure the uniformity of the temperature field. For example, when welding 0.2 mm thick aluminum alloy fins, overburning in the thin-walled area can be avoided through adaptive adjustment.

[0026] The auxiliary welding mechanism 40 includes a driving bracket 41. The driving end of the driving bracket 41 is provided with an ultrasonic welding head 42, and one side of the ultrasonic welding head 42 is provided with a thermal imaging component 43 for obtaining the thermal imaging information of the workpiece. The driving bracket 41 is equipped with a linear module. The ultrasonic welding head 42 at its end generates a cavitation effect through high-frequency vibration, effectively breaking through the oxide layer on the surface of the workpiece. The thermal imaging component 43 captures the temperature distribution in the welding area in real time at a preset sampling rate and generates a temperature gradient map. The phase synchronization control of the ultrasonic vibration and the temperature field can accelerate the wetting of the filler metal. For example, in the welding of copper-aluminum dissimilar materials, the interfacial bonding strength can reach 180 MPa.

[0027] Among them, the robot component 31 is used to drive the heating coil 33 to move according to a preset welding trajectory, calculate the welding quality by obtaining the thermal imaging information, and adjust the angle and position of the heating coil 33. The ultrasonic welding head 42 provides an auxiliary welding function in cooperation with the temperature field.

[0028] The robot component 31 calculates the welding quality index (such as temperature uniformity, wetting angle change rate) in real time based on the thermal imaging data (extracting temperature features through a convolutional neural network), and dynamically corrects the movement trajectory and power output of the heating coil 33. At the same time, the ultrasonic welding head 42 applies vibration energy synchronously during the heating stage to promote the filling of the molten filler metal through the acoustic streaming effect.

[0029] The working principle of the present invention is as follows: when working, firstly, the workpiece to be welded is placed on the fixture of the conveying mechanism 10, and the conveying mechanism 10 drives the workpiece to move to the bottom of the scraping mechanism 20. After the scraping mechanism 20 scrapes the solder on the surface of the workpiece, it continues to drive the workpiece to move to the bottom of the welding mechanism 30. The robot component 31 drives the heating coil 33 to move according to the preset welding trajectory to perform brazing welding. During this period, the thermal imaging information obtained by the thermal imaging component 43 is used to adjust the angle and position of the heating coil 33 according to the calculated welding quality. The ultrasonic welding head 42 cooperates with the temperature field to provide auxiliary welding. The device captures the temperature distribution of the welding area in real time through the thermal imaging component 43, and combines the dynamic posture adjustment of the robot component 31 to achieve temperature field uniformity control, effectively suppressing the deformation of the hot workpiece. The ultrasonic welding head 42 simultaneously applies high-frequency mechanical vibration during the heating stage, breaks the oxide film and promotes the wetting of the solder through the cavitation effect, and accelerates the filling of the molten solder through the acoustic streaming effect. The collaborative control mechanism of integrated thermal imaging dynamic feedback and ultrasonic assisted welding significantly improves the quality and efficiency of the brazing process.

[0030] In the present embodiment, it is further described that the coating mechanism 20 includes a support frame 21, the support frame 21 is provided with a first linear module 22 along the X-axis direction, the driving end of the first linear module 22 is connected to a second linear module 23 arranged along the Z-axis direction, and the driving end of the second linear module 23 is provided with a printing head module 24; the number of the printing head modules 24 is two, and the two printing head modules 24 are arranged side by side, wherein the printing head module 24 includes an angle adjustment component 25 and a pressure adjustment component 26.

[0031] It should be noted that the scraping mechanism 20 adopts a parallel architecture of dual printing head modules 24, and realizes precise positioning in three-dimensional space through X / Z axis linear modules. The first linear module 22 and the second linear module 23 form a rectangular coordinate system to support two independently controlled printing heads. The angle adjustment component 25 adopts a servo motor to drive the rotating platform to adapt to different solder rheological properties; the pressure adjustment component 26 integrates a piezoelectric ceramic sensor to provide real-time feedback on the scraping pressure and closed-loop control.

[0032] In this embodiment, it is further explained that the scraping mechanism 20 is correspondingly provided with an imaging component 27 , and the imaging component 27 is used to capture the solder scraping image on the workpiece surface to adjust the operating parameters of the scraping mechanism 20 .

[0033] In this embodiment, specifically, the driving bracket 41 includes a base 411. The base 411 is provided with a third linear module 412 along the Y-axis direction. The driving end of the third linear module 412 is provided with a support cross beam 413 along the X-axis direction. The support cross beam 413 is provided with a fourth linear module 414. The driving end of the fourth linear module 414 is provided with a lifting module 415. The driving end of the lifting module 415 is connected to the ultrasonic welding head 42. Wherein, one side of the ultrasonic welding head 42 is provided with an extension plate 416. A height adjustment component is installed on one side part of the extension plate 416. The height adjustment component is connected to the thermal imaging component 43 and is used to adjust the height of the thermal imaging component 43.

[0034] The driving bracket 41 adopts a multi-degree-of-freedom precision motion system: the third linear module 412 along the Y-axis and the fourth linear module 414 along the X-axis form a plane scanning base, and the lifting module 415 realizes the vertical fine adjustment of the ultrasonic welding head 42. The height adjustment component uses a harmonic reduction motor to drive the lead screw, so that the thermal imaging group can adapt to different workpiece heights. For example, when welding a curved radiator, this structure keeps the distance between the thermal imaging component 43 and the workpiece surface constant through multi-axis linkage to ensure the temperature detection accuracy.

[0035] Embodiment 2: Combined with Figure 6 As shown, the present invention also provides a brazing method, which is applied to the brazing device as in Embodiment 1. The brazing method specifically includes the following steps: S1, establish a three-dimensional digital model of the workpiece, generate dynamic welding parameters based on the heat conduction characteristics of the three-dimensional digital model, and plan the welding path.

[0036] S2, scrape the brazing material layer on the surface of the workpiece according to the welding path, and monitor the thickness of the brazing material in real time through the imaging component 27, and dynamically adjust the inclination angle and feeding rate of the scraping mechanism 20.

[0037] S3, drive the heating coil 33 to move along the welding path based on the dynamic welding parameters, synchronously start the ultrasonic vibration component, and adjust the operating parameters and position trajectory of the heating coil 33 in real time in combination with the thermal imaging data; correct the real-time trajectory based on the thermal imaging feedback and break the oxide layer by ultrasonic vibration to make the brazing material wetting coverage rate.

[0038] S4, apply high-frequency vibration through the ultrasonic vibration component and adjust the vibration parameters to break the oxide layer on the surface of the workpiece and promote the wetting of the brazing material, and then control the pressure servo mechanism to apply dynamic pressure according to the preset curve to realize the uniform penetration of the brazing material; the dynamic pressure servo control combined with high-frequency vibration effectively suppresses pore defects and improves the interface bonding strength.

[0039] S5. Perform multi-dimensional quality inspection on the welded workpiece, update the dynamic welding parameter library according to the inspection results, and output the optimized process parameter combination. The closed-loop parameter library is continuously updated through multi-dimensional inspection data, expanding the process window, adapting to the welding requirements of various alloy materials, and improving the qualified rate.

[0040] The beneficial effects of the present invention are as follows: This brazing method generates dynamic welding parameters based on a three-dimensional digital model and plans the welding path. The brazing material layer is accurately coated on the workpiece surface by the scraping mechanism 20 and the coating parameters are adjusted in real time. Then, the heating coil 33 is driven to move along the path and the ultrasonic vibration component is started synchronously. The operating parameters and trajectory of the heating coil 33 are dynamically optimized in combination with the thermal imaging data. In the brazing material wetting stage, the oxide layer is broken by high-frequency vibration and the dynamic pressure is adjusted to achieve uniform penetration of the brazing material. Finally, through multi-dimensional quality inspection feedback to the parameter library, a closed-loop optimized process parameter combination is formed. This method realizes the efficient breaking of the oxide layer, precise control of wetting, and adaptive matching of process parameters in precision brazing through three-dimensional modeling guidance, multi-sensor dynamic regulation, and closed-loop optimization mechanism, significantly improving the welding quality and production efficiency.

[0041] In this embodiment, specifically, step S1 specifically includes: S11. Obtain the three-dimensional structure data of the workpiece through a scanner, and generate a three-dimensional point cloud model including geometric features and material properties; Obtain the surface topography and internal structure data of the workpiece through a three-dimensional laser scanner or industrial CT scan, and combine the thermal conductivity and specific heat capacity parameters in the material library to construct a three-dimensional point cloud model including geometric tolerances and material properties. This step improves the feature recognition rate of complex workpieces through high-precision modeling. For example, it can accurately capture a 0.2-mm micro chamfer at the root of the radiator fin, avoiding the accumulation of subsequent thermal conduction simulation errors.

[0042] S12. Divide the thermal conduction grid based on the three-dimensional point cloud model, input the thermal conductivity, specific heat capacity, and environmental thermal resistance parameters of the workpiece, and construct a thermal conduction simulation model; Based on the point cloud model, unstructured tetrahedral meshing is adopted, and the environmental thermal resistance parameters (such as the air convection coefficient of 15 W / (m2·K)) are imported. A transient thermal conduction simulation model is constructed by the finite element method. The model can predict the temperature gradient distribution under different heating powers. For example, when welding dissimilar copper-aluminum materials, the simulation accuracy can be greatly improved.

[0043] S13. Simulate the temperature field distribution under different welding parameters in the thermal conduction simulation model, identify the thermally sensitive areas and predict the thermal deformation trend, and generate an initial welding parameter set; Set multiple groups of welding parameters (power, speed, dwell time) in the simulation model, simulate the temperature field evolution process by the Monte Carlo method, and identify the thermally sensitive regions (such as thin-wall regions, weld intersections) and the thermal deformation trend. Generate an initial set of welding parameters (including a power-speed matching table). For example, for a 0.3-mm-thick stainless-steel fin, automatically screen out the optimal parameter combination of a power of 2.5 kW and a speed of 3 mm / s to avoid grain coarsening in the heat-affected zone.

[0044] S14. According to the distribution characteristics of the thermally sensitive regions, use a path optimization algorithm to perform dynamic priority sorting on the initial welding path, and generate a dynamic welding parameter matrix including a power gradient and a dwell time; According to the spatial distribution of the thermally sensitive regions (such as high-density fin regions), use a dynamic priority algorithm (based on the temperature accumulation effect) to sort the welding path nodes, and preferentially process regions with a small heat capacity (such as fin tips). Generate a dynamic welding parameter matrix including a power gradient, a dwell time, and a cooling interval.

[0045] S15. Combine the dynamic welding parameter matrix with the geometric constraint conditions of the workpiece, and plan a welding path with balanced heat load through the ant colony algorithm, and mark the compensation parameters of the path nodes.

[0046] Combine the geometric constraints of the workpiece (such as avoidance holes, bosses) with the dynamic parameter matrix, and plan a path with balanced heat load through an improved ant colony algorithm (introducing a temperature balance penalty factor). Angle compensation, power correction coefficients (0.8 - 1.2 times), and vibration synchronization parameters are preset for the path nodes. For example, when welding a curved surface radiator, the path curvature is adaptively adjusted to reduce the thermal deformation amount and improve the welding efficiency.

[0047] In this embodiment, specifically, step S2 specifically includes: S21. According to the geometric characteristics of the welding path and the rheological characteristics of the filler metal, initialize the inclination angle parameter and the feeding rate parameter of the scraping mechanism 20; According to the geometric characteristics of the welding path (such as curvature, inclination angle) and the rheological characteristics of the filler metal (viscosity, thixotropy), initialize the inclination angle and the feeding rate parameter of the scraping mechanism 20. Match the best initial parameter combination through a preset material database. For example, for high-viscosity solder paste, automatically increase the inclination angle of the scraper to reduce accumulation and ensure the initial coating efficiency and uniformity.

[0048] S22. Drive the scraping mechanism 20 to perform filler metal coating along the geometric path of the welding path, and use the imaging component 27 to collect the image of the filler metal layer in real time to generate a thickness distribution thermal map; Drive the scraping and coating mechanism 20 to move precisely along the welding path, collect the images of the solder layer in real time through the multispectral imaging component 27, and generate a thickness distribution thermal map by combining the optical thickness inversion algorithm. The thermal map can intuitively display the thickness differences of the solder layer, such as quickly locating local over-thick or uncovered areas.

[0049] S23. Compare the thickness distribution thermal map with the preset target value, adopt the fuzzy PID algorithm to dynamically correct the blade inclination angle and the feeding pump speed, and record the compensation parameters; Compare the thickness distribution thermal map with the preset target value, and adopt the fuzzy PID algorithm to dynamically correct the blade inclination angle and the feeding pump speed. By fusing parameters such as path curvature and solder viscosity, non-linear adaptive adjustment is realized. For example, the feeding rate is automatically reduced at the path corner to prevent solder overflow, significantly improving the coating consistency.

[0050] S24. Perform the gray value uniformity detection on the corrected solder layer, verify the coverage rate of the area where the thickness meets the standard, and import the compensation parameters into the dynamic welding parameter library.

[0051] Perform the gray value uniformity detection on the corrected solder layer, and identify the coverage rate of the qualified area through the image segmentation algorithm. The verification result and the compensation parameters are synchronously imported into the dynamic welding parameter library, providing a process matching basis for the subsequent welding stage. For example, automatically associate and reduce the heating power for the thin layer area to avoid the risk of burning through.

[0052] In this embodiment, specifically, step S3 specifically includes: S31. Load the power gradient and dwell time data in the dynamic welding parameters, and initialize the starting power of the heating coil 33 and the moving speed of the robot component 31; Load the power gradient and dwell time data in the dynamic welding parameter library, and initialize the starting power of the heating coil 33 and the moving speed of the robot component 31 according to the material characteristics of the workpiece and the path geometric complexity. By presetting the process rules to match the optimal parameter combination, for example, automatically increasing the initial power for high thermal conductivity materials to reduce the thermal lag, ensuring the temperature field stability in the initial stage of welding.

[0053] S32. Drive the heating coil 33 to start induction heating along the welding path through the robot component 31, and synchronously activate the ultrasonic vibration component and set the initial amplitude and frequency; Drive the heating coil 33 to move along the welding path and start induction heating through the robot component 31, and synchronously activate the ultrasonic vibration component to set the initial amplitude and frequency. The coordinated start of induction heating and ultrasonic vibration can accelerate the rupture of the oxide layer. For example, in the welding of aluminum alloy, the initial amplitude is set to medium strength to balance the energy input and the control of the heat affected zone.

[0054] S33. Collect the temperature distribution data of the welding area in real time through the thermal imaging component 43 to generate a temperature-space mapping matrix.

[0055] Collect the temperature distribution data of the welding area in real time through the thermal imaging component 43 to generate a temperature-space mapping matrix. This matrix associates temperature values with the coordinate points of the welding path, for example, marking the temperature difference distribution between the root and the tip of the fin, providing a quantitative basis for dynamic regulation.

[0056] S34. Calculate the deviation value between the actual temperature field and the target temperature field based on the temperature-space mapping matrix, and use the dynamic weight allocation algorithm to adjust the power of the heating coil 33 and the robot movement trajectory compensation parameters in real time; Calculate the deviation value between the actual temperature field and the target temperature field based on the temperature-space mapping matrix, and use the dynamic weight allocation algorithm to adjust the power of the heating coil 33 and the robot movement trajectory compensation parameters in real time. For example, when a local low-temperature area is detected, the power is preferentially increased rather than the speed is reduced to avoid wetting defects caused by insufficient heat input.

[0057] S35. Integrate the real-time impedance data of the ultrasonic vibration component and the temperature deviation value, and optimize the heating power increment and the robot attitude angle of the next path node through the model predictive control algorithm; Integrate the real-time impedance data of the ultrasonic vibration component and the temperature deviation value, and optimize the heating power increment and the robot attitude angle of the next path node through the model predictive control algorithm. The impedance change reflects the wetting state of the solder. For example, when the impedance drops suddenly, a power compensation mechanism is triggered, and the robot attitude is adjusted synchronously to optimize the heat flow direction.

[0058] S36. Correct the tilt angle of the heating coil 33 and the robot movement trajectory in real time according to the optimized parameters, and record the adjusted dynamic parameters into the dynamic welding parameter library.

[0059] Correct the tilt angle of the heating coil 33 and the robot movement trajectory in real time according to the optimized parameters, and synchronously record the adjusted dynamic parameters into the dynamic welding parameter library. For example, for a curved workpiece, the coil tilt angle is automatically compensated to ensure that the induction magnetic field covers evenly, and the parameter library is updated to support subsequent welding self-learning optimization.

[0060] In this embodiment, specifically, step S4 specifically includes: S41. Call the vibration parameters and pressure curve in the dynamic welding parameter library to initialize the amplitude gradient of the ultrasonic vibration component and the loading rate of the pressure servo mechanism; Call the vibration parameters and pressure curves stored in the dynamic welding parameter library, and initialize the amplitude gradient of the ultrasonic vibration component and the loading rate of the pressure servo mechanism according to the material combination of the current workpiece and the weld geometry characteristics. For example, for the welding of aluminum-copper dissimilar materials, automatically match the high-frequency vibration and the slow-rise pressure curve to ensure that the initial parameters are accurately adapted to the process requirements.

[0061] S42, Drive the ultrasonic vibration component and apply high-frequency vibration along the welding path, and simultaneously activate the pressure servo mechanism to apply the contact pressure according to the initial pressure curve, and collect the data of the solder wetting state in real time; Drive the ultrasonic vibration component to apply high-frequency vibration along the welding path, and simultaneously activate the pressure servo mechanism to apply the contact pressure according to the initial pressure curve. Collect the data of the solder wetting state in real time through a high-speed vision sensor and an acoustic emission device, such as the dynamic expansion rate of the wetting front and the pore formation trend, to provide real-time feedback for dynamic regulation.

[0062] S43, Based on the solder wetting state data, analyze the solder penetration depth and the degree of interfacial reaction through the infrared spectrum in the thermal imaging data, and dynamically adjust the slope parameters of the vibration frequency and the pressure curve; Based on the solder wetting state data, analyze the solder penetration depth and the degree of interfacial reaction by combining the infrared spectrum characteristics in the thermal imaging. Optimize the flow behavior of the molten solder by dynamically adjusting the vibration frequency and the pressure curve slope. For example, when local penetration insufficiency is detected, increase the vibration frequency and the pressure gradient to accelerate filling.

[0063] S44, After the solder is completely penetrated, perform the pressure gradient release, record the optimized vibration-pressure coordination parameters and update them to the dynamic welding parameter library.

[0064] After the solder is completely penetrated, perform the pressure gradient release to avoid microcracks caused by sudden pressure drop. The optimized vibration-pressure coordination parameters (such as frequency-pressure phase difference, release rate) are synchronously updated to the dynamic welding parameter library, providing a basis for self-learning optimization for the welding of similar workpieces, and significantly improving the process consistency and defect suppression ability.

[0065] As mentioned above, the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A brazing device, characterized in that: It comprises a conveying mechanism, along the conveying path of the conveying mechanism, a welding mechanism, a coating mechanism for coating solder on the surface of a workpiece, and an auxiliary welding mechanism arranged relative to the welding mechanism; The welding mechanism comprises a robot assembly, one end of which is provided with a mounting frame, the mounting frame is provided with a heating coil, and the heating coil is used to generate a preset temperature field to act on the workpiece; The auxiliary welding mechanism comprises a driving bracket, a driving end of the driving bracket is provided with an ultrasonic welding head, and a side portion of the ultrasonic welding head is provided with a thermal imaging component for obtaining thermal imaging information of the workpiece; The robot assembly is used to drive the heating coil to move according to a preset welding trajectory, calculate the welding quality through the acquired thermal imaging information, so as to adjust the angle and position of the heating coil, and the ultrasonic welding head cooperates with the temperature field to provide auxiliary welding.

2. The brazing device according to claim 1, characterized in that: The scraping mechanism comprises a support frame, the support frame is provided with a first linear module along the X-axis direction, the driving end of the first linear module is connected to a second linear module arranged along the Z-axis direction, and the driving end of the second linear module is provided with a printing head module; There are two printing head modules, which are arranged side by side. The printing head modules include an angle adjustment component and a pressure adjustment component.

3. The brazing device according to claim 2, characterized in that: The scraping mechanism is correspondingly provided with an imaging component, and the imaging component is used to capture the solder scraping image on the workpiece surface to adjust the operating parameters of the scraping mechanism.

4. The brazing device according to claim 1, characterized in that: The driving bracket includes a base, the base is provided with a third linear module along the Y-axis direction, the driving end of the third linear module is provided with a supporting beam along the X-axis direction, the supporting beam is provided with a fourth linear module, the driving end of the fourth linear module is provided with a lifting module, and the driving end of the lifting module is connected to the ultrasonic welding head; Among them, an extension plate is provided on one side of the ultrasonic welding head, and a height adjustment component is installed on one side of the extension plate. The height adjustment component is connected to the thermal imaging component and is used to adjust the height of the thermal imaging component.

5. A brazing method, characterized in that: Applied to the brazing device according to any one of claims 1 to 4, the brazing method specifically comprises the following steps: Establishing a three-dimensional digital model of the workpiece, generating dynamic welding parameters based on the heat conduction characteristics of the three-dimensional digital model, and planning a welding path; Scrape and coat the solder layer on the workpiece surface according to the welding path, monitor the solder thickness in real time through the imaging component, and dynamically adjust the inclination angle and feeding rate of the scraping mechanism; Based on the dynamic welding parameters, the heating coil is driven to move along the welding path, the ultrasonic vibration component is started synchronously, and the operating parameters and position trajectory of the heating coil are adjusted in real time in combination with the thermal imaging data; The ultrasonic vibration component applies high-frequency vibration and adjusts the vibration parameters to break the oxide layer on the surface of the workpiece and promote the wetting of the solder, and then controls the pressure servo mechanism to apply dynamic pressure according to a preset curve to achieve uniform penetration of the solder; Perform multi-dimensional quality inspection on the welded workpiece, update the dynamic welding parameter library according to the inspection results, and output the optimized process parameter combination.

6. The brazing method according to claim 5, characterized in that: The step of establishing a three-dimensional digital model of the workpiece, generating dynamic welding parameters based on the heat conduction characteristics of the three-dimensional digital model, and planning a welding path specifically includes: The three-dimensional structure data of the workpiece is acquired through a scanner, and a three-dimensional point cloud model including geometric features and material properties is generated; Divide the heat conduction grid based on the three-dimensional point cloud model, input the thermal conductivity, specific heat capacity and environmental thermal resistance parameters of the workpiece, and build a heat conduction simulation model; Simulating the temperature field distribution under different welding parameters in the heat conduction simulation model, identifying the heat sensitive area and predicting the thermal deformation trend, and generating an initial welding parameter set; According to the distribution characteristics of the heat-sensitive area, a path optimization algorithm is used to dynamically prioritize the initial welding path to generate a dynamic welding parameter matrix including power gradient and dwell time; Combining the dynamic welding parameter matrix with the geometric constraints of the workpiece, an ant colony algorithm is used to plan a welding path with balanced heat load, and the compensation parameters of the path nodes are marked.

7. The brazing method according to claim 5, characterized in that: According to the welding path, a brazing material layer is scraped on the surface of the workpiece, and the brazing material thickness is monitored in real time by an imaging component, and the inclination angle and feeding rate of the scraping mechanism are dynamically adjusted, specifically including: Initializing the inclination angle parameters and feeding rate parameters of the scraping mechanism according to the geometric characteristics of the welding path and the rheological characteristics of the solder; The scraping mechanism is driven to perform solder coating along the geometric path of the welding path, and the image of the solder layer is collected in real time by the imaging component to generate a thickness distribution thermodynamic map; Compare the thickness distribution thermodynamic map with the preset target value, use fuzzy PID algorithm to dynamically correct the scraper inclination angle and feed pump speed, and record the compensation parameters; The gray value uniformity of the corrected solder layer is tested to verify the coverage of the thickness-compliant area, and the compensation parameters are imported into the dynamic welding parameter library.

8. The brazing method according to claim 6, characterized in that: Based on the dynamic welding parameters, the heating coil is driven to move along the welding path, the ultrasonic vibration component is started synchronously, and the operating parameters and position trajectory of the heating coil are adjusted in real time in combination with the thermal imaging data, specifically including: Load the power gradient and dwell time data in the dynamic welding parameters, initialize the starting power of the heating coil and the moving speed of the robot component; The robot assembly drives the heating coil to start induction heating along the welding path, and simultaneously activates the ultrasonic vibration assembly and sets the initial amplitude and frequency; The temperature distribution data of the welding area is collected in real time through the thermal imaging component to generate a temperature-space mapping matrix.

9. The brazing method according to claim 8, characterized in that: The method further includes: collecting the temperature distribution data of the welding area in real time by using the thermal imaging component to generate a temperature-space mapping matrix; and then: The deviation between the actual temperature field and the target temperature field is calculated based on the temperature-space mapping matrix, and the heating coil power and the robot movement trajectory compensation parameters are adjusted in real time using a dynamic weight allocation algorithm; The real-time impedance data and temperature deviation value of the ultrasonic vibration component are integrated to optimize the heating power increment and robot posture angle of the next path node through the model predictive control algorithm; The tilt angle of the heating coil and the motion trajectory of the robot are corrected in real time according to the optimized parameters, and the adjusted dynamic parameters are recorded in the dynamic welding parameter library.

10. The brazing method according to claim 5, characterized in that: The ultrasonic vibration component applies high-frequency vibration and adjusts the vibration parameters to break the oxide layer on the surface of the workpiece and promote the wetting of the solder. Then, the pressure servo mechanism is controlled to apply dynamic pressure according to a preset curve to achieve uniform penetration of the solder. Specifically, it includes: Call the vibration parameters and pressure curves in the dynamic welding parameter library to initialize the amplitude gradient of the ultrasonic vibration component and the loading rate of the pressure servo mechanism; Drive the ultrasonic vibration component and apply high-frequency vibration along the welding path, synchronously activate the pressure servo mechanism to apply contact pressure according to the initial pressure curve, and collect the solder wetting status data in real time; Based on the solder wetting state data, the solder penetration depth and the interface reaction degree are analyzed by infrared spectrum in the thermal imaging data, and the slope parameters of the vibration frequency and pressure curve are dynamically adjusted; After the brazing filler metal has completely penetrated, the pressure gradient is released, and the optimized vibration-pressure synergy parameters are recorded and updated to the dynamic welding parameter library.

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