Ultrasonic welding push block and design method thereof and wiring harness welding method

Abstract

The present invention belongs to the technical field of wire harness welding and discloses an ultrasonic welding push block, a design method thereof, and a wire harness welding method. The two push block bodies of the ultrasonic welding push block are each provided with two ribs. The four ribs can jointly clamp the bare wire segments of all stacked wire harnesses, thereby positioning all wire harnesses in the radial direction of the wire harness, thereby preventing all bare wire segments from moving radially during the welding process, thereby preventing the bare wire segments of two adjacent wire harnesses from being misaligned during the welding process. Moreover, for any push block body, a groove is formed between the two ribs, and a channel can be formed between the two grooves for the welding head to move into, thereby radially positioning all wire harnesses without interfering with the welding head. In addition, during the welding process, the gap between the welding head accommodating area and the ribs can allow several wires to be bent to form a transition section, thereby preventing the wires from breaking due to excessive bending.

Description

Technical Field

[0001] The present invention relates to the technical field of wire harness welding, in particular to an ultrasonic welding push block and a design method thereof, as well as a wire harness welding method. Background Art

[0002] At present, ultrasonic welding is generally used for welding wire harnesses. Specifically, when welding two or more wire harnesses together, it is necessary to first peel off the rubber on one side of the wire harness to expose the wires inside the wire harness. The wire harness is formed into a structure consisting of bare wire segments and rubber-covered segments. Afterwards, the two or more wire harnesses are stacked together, and the two adjacent wire harnesses are reversed 180°, and the bare wire segments of all wire harnesses are arranged in sequence in the vertical direction. Then, the position of the wire harness is restricted along the axial direction of the wire harness by an ultrasonic welding push block, and then the wires of all wire harnesses are welded by the welding head.

[0003] However, the ultrasonic welding push block in the prior art does not limit the wire harness in the radial direction of the wire harness, which causes the bare wire segments of two adjacent wire harnesses to be easily misaligned during the welding process, thereby causing the welded structure to fail to meet the requirements. Summary of the Invention

[0004] The purpose of the present invention is to provide an ultrasonic welding push block and a design method thereof, as well as a wiring harness welding method, so as to prevent the bare wire segments of two adjacent wiring harnesses from being misaligned during the welding process, thereby ensuring that the structure after welding meets the requirements.

[0005] To achieve this object, the present invention adopts the following technical solutions:

[0006] In one aspect, the present invention provides an ultrasonic welding push block for clamping two or more stacked wire harnesses, wherein the wire harnesses include bare wire segments and rubber-covered segments. The ultrasonic welding push block includes two push block bodies, which are arranged opposite to each other along a first direction, wherein:

[0007] Two ribs are protruded from opposite sides of the two push block bodies, and the two ribs provided on the same push block body are arranged along a second direction, which is perpendicular to the first direction;

[0008] The four ribs can jointly clamp two or more overlapping bare wire segments, and a welding head accommodating area for a welding head to pass through is formed between the four ribs. A gap exists between the welding head accommodating area and the ribs along the second direction.

[0009] Preferably, one end of the retaining edge used for pressing the wiring harness is a pressing end, and both side edges of the pressing end along the second direction are chamfered.

[0010] Preferably, the pressing end is coated with a flexible material layer.

[0011] Another aspect of the present invention further provides a method for designing an ultrasonic welding push block as described above, comprising:

[0012] The distance between the two ribs arranged opposite to each other along the first direction is equal to the diameter of the portion to be welded on the wire harness, which is calibrated as a first distance a;

[0013] The width of the welding head accommodating area along the first direction is selected to be equal to the width of the welding head, and the length of the welding head accommodating area along the second direction is selected to be equal to the length of the welding head;

[0014] The distance between the two opposite sides of the push block bodies is selected according to the width of the welding head accommodating area, and is calibrated as a second distance b. The difference between the second distance and the width of the welding head accommodating area is c, and c is greater than or equal to 0.05 mm and less than or equal to 0.2 mm.

[0015] After the wire harness is welded, a welding section is formed which is flattened by the welding head. A transition section is formed between the rib and the welding section. Both sides of the transition section along the first direction form an angle α with the axis of the wire harness. α is selected to be greater than or equal to 105° and less than or equal to 135°.

[0016] The gap value L between the welding head accommodating area and the rib along the second direction is calculated based on a, b, and α, wherein:

[0017] , wherein x is the width of the welding head accommodating area along the first direction;

[0018] The distance between the two ribs provided on the same push block body along the second direction is calculated according to the gap value.

[0019] Preferably, the actual gap value L1 between the welding head accommodating area and the rib along the second direction is specifically selected according to the ductility of the wire of the wire harness, wherein:

[0020] , wherein d1 is a calculation coefficient selected according to the ductility of the wire of the harness.

[0021] Preferably, the actual gap value L2 between the welding head accommodating area and the rib along the second direction is specifically selected according to the hardness of the wires of the wire harness, wherein:

[0022] , wherein d2 is a calculation coefficient selected according to the hardness of the wires of the wiring harness.

[0023] Preferably, the length D of the push block body along the second direction is calculated according to the distance between the two ribs provided on the same push block body along the second direction:

[0024] ,in:

[0025] A is the distance between the two ribs provided on the same push block body along the second direction, , wherein y is the length of the welding head accommodating area along the second direction;

[0026] e is the width of the rib along the second direction, and e is greater than or equal to 0.5 mm and less than or equal to 2 mm.

[0027] Preferably, one end of the retaining edge for pressing the wiring harness is a pressing end, and both side edges of the pressing end along the second direction are chamfered, and the radius of the chamfer is larger than the minimum bending radius of the wires of the wiring harness.

[0028] Preferably, a side of the push block body on which the retaining edge is provided is chamfered with respect to the retaining edge.

[0029] Another aspect of the present invention provides a method for welding a wire harness, wherein the wire harness is clamped and positioned by the ultrasonic welding push block as described above during the welding process, and the method for welding the wire harness comprises:

[0030] Preparing the wire harness: peeling off the rubber on one side of the wire harness along its axial direction to form the bare wire segment, wherein the length of the bare wire segment is equal to the sum of the lengths of the welding head accommodating area, the gap, and the rib along the second direction;

[0031] Stacking the wiring harnesses: stacking two or more wiring harnesses, with the rubber-covered section pressing against the two ribs arranged on the same side along the second direction, and being located on the side of the ribs facing away from the welding head accommodating area;

[0032] Welding the wire harness: the four retaining edges are used to jointly clamp two or more overlapping bare wire segments, and the welding head is extended into the welding head accommodating area to press against all the bare wire segments.

[0033] Beneficial effects of the present invention:

[0034] In the present invention, the two push block bodies of the ultrasonic welding push block are each provided with two ribs, and the four ribs can jointly clamp the bare wire segments of all the stacked wire bundles, so that all the wire bundles can be positioned in the radial direction of the wire bundle, and thus can prevent all the bare wire segments from moving radially during the welding process. Moreover, for any push block body, a groove is formed between the two ribs, and a channel for the welding head to move in can be formed between the two grooves, so that while all the wire bundles are radially positioned, the welding of the welding head will not be interfered with. In addition, during the welding process, the gap between the welding head accommodating area and the ribs can allow several wires to be bent to form a transition section, thereby preventing the wires from breaking due to excessive bending. In summary, the ultrasonic welding push block in the present invention can prevent the bare wire segments of two adjacent wire bundles from being misaligned during the welding process, and avoid wire breakage, thereby ensuring that the structure after welding meets the requirements.

[0035] The present invention designs the gap value between the welding head accommodating area and the retaining edge along the second direction, so as to meet the requirement that the welding head can be pressed down to make the welding section formed by flattening all the bare wire segments cover the entire lower area of ​​the welding head without breaking the wire, and the overall structure of the ultrasonic welding push block will not be too large, thereby avoiding size waste.

[0036] The present invention performs a rubber stripping operation on the wire harness according to the welding head accommodating area, the gap and the length of the rib along the second direction. Thus, when the four ribs can jointly clamp the bare wire segments of all the stacked wire harnesses, the outer sides of the ribs press against the rubber covered segments, that is, along the second direction, the two push block bodies are supported between all the rubber covered segments on one side and all the rubber covered segments on the other side, thereby more effectively limiting all the wire harnesses in the axial direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a schematic diagram of the structure of the ultrasonic welding push block positioning harness in the prior art;

[0038] Figure 2 This is a cross-sectional view of the ultrasonic welding push block positioning wiring harness in the prior art;

[0039] Figure 3 This is a schematic structural diagram of the ultrasonic welding push block positioning harness in the first embodiment of the present invention;

[0040] Figure 4 This is a cross-sectional view of the ultrasonic welding push block positioning harness in Example 1 of the present invention;

[0041] Figure 5 This is a top view of the ultrasonic welding push block positioning harness in Example 1 of the present invention;

[0042] Figure 6 yes Figure 5 A local enlarged view of the R in the middle;

[0043] Figure 7 This is a schematic structural diagram of the ultrasonic welding push block and wiring harness after welding in the first embodiment of the present invention;

[0044] Figure 8 1 is a schematic structural diagram of the wiring harness after welding in the first embodiment of the present invention;

[0045] Figure 9 It is a structural schematic diagram of the push block body in the first embodiment of the present invention;

[0046] Figure 10 This is an exploded view of the push block body in the first embodiment of the present invention;

[0047] Figure 11 It is a structural schematic diagram of the push block body in the fourth embodiment of the present invention.

[0048] In the picture:

[0049] 110, wiring harness; 111, bare wire section; 112, rubber-covered section; 120, welding section; 130, transition section;

[0050] 210, base; 220, block;

[0051] 310, push block body; 311, rib; 3111, pressing end; 3112, inclined surface; 312, groove; 313, first component; 3131, mounting groove; 3132, docking groove; 3133, threaded hole; 314, second component; 3141, docking block; 3142, clamping hole; 315, bolt; 320, welding head accommodating area;

[0052] 400, welding head. DETAILED DESCRIPTION

[0053] The present invention will be further described in detail below with reference to the accompanying drawings and examples. It will be understood that the specific embodiments described herein are intended only to illustrate the present invention and are not intended to limit the present invention. It should also be noted that, for ease of description, the accompanying drawings only illustrate portions relevant to the present invention, not all structures.

[0054] In the description of the present invention, unless otherwise expressly specified or limited, the terms "connected," "connected," and "fixed" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integration; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention in specific circumstances.

[0055] In the present invention, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Furthermore, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0056] In the description of this embodiment, terms such as "upper," "lower," "right," and "left" are used to refer to positions or locations based on those shown in the accompanying drawings. These terms are intended solely to facilitate description and simplify operation, and are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second" are used solely for descriptive purposes and have no special meaning.

[0057] Example 1

[0058] Based on the above mentioned content, Figure 1 and Figure 2 As shown, in the prior art, the wiring harness welding is to stack and weld two or more wiring harnesses 110 together. Specifically, taking three wiring harnesses 110 as an example, in the process of welding the three wiring harnesses 110 together, it is necessary to first peel off the rubber on one side of the three wiring harnesses 110, so that part of the wires of the three wiring harnesses 110 are exposed, that is, the three wiring harnesses 110 are composed of bare wire segments 111 and rubber-covered segments 112, wherein the bare wire segments 111 are the wires on the wiring harness 110. The exposed section, that is, the bare wire section 111 is composed of several bare wires, and the rubber-coated section 112 is the section of the wire harness 110 that is covered with rubber. Then, the three wire harnesses 110 are stacked together and placed on the base 210. For example, the two adjacent wire harnesses 110 are reversed at 180°, and the bare wire sections 111 of the three wire harnesses 110 are arranged in sequence in the vertical direction, that is, two of the three wire harnesses 110 are placed in the same direction, while the other is placed in the opposite direction.

[0059] Moreover, the wiring harness 110 is axially limited by the ultrasonic welding push block. Specifically, when three wiring harnesses 110 are placed, the two blocks 220 of the ultrasonic welding push block can be close to each other, and the three bare wire segments 111 are placed between the two blocks 220, and the two blocks 220 can be supported between the two rubber-covered segments 112 on the same side and the rubber-covered segments 112 on the other side, thereby limiting all wiring harnesses 110 in the axial direction.

[0060] However, since the welding head 400 needs to extend between the two blocks 220 and flatten all the bare wire segments 111 during the welding process, sufficient spacing needs to be left between the two blocks 220. Therefore, during the welding process, all wire bundles 110 are prone to move along their radial direction, causing the two adjacent bare wire segments 111 to be misaligned in the horizontal direction, and thus causing the structure after welding to not meet the requirements.

[0061] To resolve the above issues, please refer to Figures 3 to 10 This embodiment provides an ultrasonic welding push block. Based on the above, the wire harness 110 to be welded includes a bare wire segment 111 and a rubber-covered segment 112. The ultrasonic welding push block provided in this embodiment is used to clamp two or more stacked wire harnesses 110. Still taking three wire harnesses 110 as an example, the ultrasonic welding push block is used to clamp the three stacked wire harnesses 110.

[0062] Specifically, the ultrasonic welding push block includes two push block bodies 310, which are arranged opposite to each other along a first direction, wherein two ribs 311 are protruding from opposite sides of the two push block bodies 310, and the two ribs 311 arranged on the same push block body 310 are arranged along a second direction, which is perpendicular to the first direction.

[0063] It is understandable that the retaining edge 311 and the push block body 310 can be integrally formed or fixedly connected by welding or other methods, and this embodiment does not impose any specific restrictions on this.

[0064] From the above, the four ribs 311 can jointly clamp the three stacked bare wire segments 111. Specifically, the wire harness 110 can be placed between the two push block bodies 310 in an axially parallel posture to the second direction. The two ribs 311 on one push block body 310 can be pressed against one side of all the wire harnesses 110 along its radial direction, and the two ribs 311 on the other push block body 310 can be pressed against the other side of all the wire harnesses 110 along its radial direction, thereby limiting the radial position of all the wire harnesses 110. Since the wire harness 110 is clamped by the four ribs 311, the wire harness 110 can also be limited in the axial direction.

[0065] Moreover, a welding head accommodating area 320 for the welding head 400 to pass through is formed between the four ribs 311 . It can be understood that, in this embodiment, the welding head accommodating area 320 covers the overlapping areas of all bare wire segments 111 along the vertical direction.

[0066] It is worth noting that in other optional embodiments, for more than two wiring harnesses 110 placed between two push block bodies 310, the rubber-covered sections 112 of two adjacent wiring harnesses 110 can also be placed on the same side of the push block body 310. This embodiment does not impose any specific restrictions on this.

[0067] In addition, it is worth mentioning that the principle of ultrasonic welding of wire harnesses is solid-state welding. Specifically, the welding head 400 applies constant pressure to the bare wire segments 111 to force all bare wire segments 111 to fit tightly together, thereby forcing the wire to undergo plastic deformation and atomic diffusion in the solid state to achieve direct bonding between atoms.

[0068] After welding is completed, all bare wire segments 111 will be flattened and combined together, that is, all bare wire segments 111 will be flattened to form welding segments 120, and all wire harnesses 110 will be combined through the welding segments 120. Since the bare wire segments 111 will expand outward along the first direction during the flattening process, the part of the bare wire segment 111 located between the welding head accommodating area 320 and the rubber covering segment 112 will bend, but under the restriction of the guard edge 311, the wire can only bend around the guard edge 311.

[0069] Based on the above, in order to prevent the wire from breaking due to excessive bending, in this embodiment, the welding head accommodating area 320 and the retaining edge 311 have a gap along the second direction. Therefore, during the welding process, a trapezoidal transition section 130 will appear between the bare wire segment 111 and the rubber-coated segment 112 that are flattened and combined together. The transition section 130 is formed by bending a number of wires, and the transition section 130 is formed in the gap, thereby preventing the wire from breaking due to excessive bending.

[0070] Based on the above, in this embodiment, the two pusher block bodies 310 of the ultrasonic welding pusher block are each provided with two ribs 311. The four ribs 311 can jointly clamp the bare wire segments 111 of all the stacked wire harnesses 110, thereby positioning all the wire harnesses 110 in the radial direction of the wire harnesses 110, and thus preventing all the bare wire segments 111 from moving radially during the welding process. Moreover, for any pusher block body 310, a groove 312 is formed between the two ribs 311. The two grooves 312 can form a channel for the welding head 400 to move into, thereby radially positioning all the wire harnesses 110 without interfering with the welding of the welding head 400. In addition, during the welding process, the gap between the welding head accommodating area 320 and the ribs 311 can allow several wires to be bent to form transition sections 130, thereby preventing the wires from breaking due to excessive bending. In summary, the ultrasonic welding push block in this embodiment can prevent the bare wire segments 111 of two adjacent wire harnesses 110 from being misaligned during the welding process and avoid wire breakage, thereby ensuring that the structure after welding meets the requirements.

[0071] Based on the above, it should be noted that if the gap between the welding head accommodating area 320 and the retaining edge 311 along the second direction is too small, then during welding, if the welding section 120 formed by all the bare wire segments 111 being flattened covers the entire lower area of ​​the welding head 400, the bending angle of the wire is large, which makes it easy to break. In order to avoid wire breakage, the welding head 400 cannot be pressed down too much, which will cause the welding section 120 formed by all the bare wire segments 111 being flattened to fail to cover the entire lower area of ​​the welding head 400. At this time, the transition section 130 will extend to the bottom of the welding head 400, that is, at this time, the transition section 130 will occupy the welding area, resulting in a decrease in the final welding quality. However, if the gap between the welding head accommodating area 320 and the retaining edge 311 along the second direction is too large, although it can meet the requirement that the welding head 400 can be pressed down to make the welding section 120 formed by the flattening of all the bare wire segments 111 cover the entire lower area of ​​the welding head 400 without breaking the wire, the overall structure of the ultrasonic welding push block is too large, resulting in size waste.

[0072] Based on the above, in order to ensure that the welding head 400 can be pressed down to the point where the welding section 120 formed by flattening all the bare wire segments 111 covers the entire lower area of ​​the welding head 400 without breaking the wire, this embodiment also provides a design method for an ultrasonic welding push block, which is used to design the gap value between the welding head accommodating area 320 and the rib 311 along the second direction, and thereby calculate the spacing between the two ribs 311 arranged on the same push block body 310 along the second direction, thereby avoiding wire breakage while meeting the welding quality.

[0073] Based on the above, the design method includes:

[0074] The distance between the two ribs 311 arranged opposite to each other along the first direction is equal to the diameter of the portion to be welded on the wire harness 110 , which is calibrated as a first distance a.

[0075] The width of the welding head accommodating area 320 along the first direction is selected to be equal to the width of the welding head 400, and the length of the welding head accommodating area 320 along the second direction is selected to be equal to the length of the welding head 400;

[0076] The distance between the two opposing sides of the push block bodies 310 is selected based on the width of the welding head accommodating area 320 and is calibrated as the second distance b. The difference between the second distance and the width of the welding head accommodating area 320 is c, which is greater than or equal to 0.05 mm and less than or equal to 0.2 mm.

[0077] After welding, the wire harness 110 forms a welding section 120 that is flattened by the welding head 400. A transition section 130 is formed between the rib 311 and the welding section 120. Both sides of the transition section 130 along the first direction form an angle α with the axis of the wire harness 110. α is selected to be greater than or equal to 105° and less than or equal to 135°.

[0078] The gap value L between the welding head accommodating area 320 and the rib 311 along the second direction is calculated based on a, b, and α, where:

[0079] , where x is the width of the welding head accommodating area 320 along the first direction;

[0080] The distance between the two ribs 311 provided on the same push block body 310 along the second direction is calculated according to the gap value.

[0081] Specifically, this embodiment sets the spacing between the two ribs 311 disposed opposite each other along the first direction equal to the diameter of the portion to be welded on the wire harness 110. In other words, this embodiment sets the spacing between the two ribs 311 disposed opposite each other along the first direction equal to the diameter of the bare wire segment 111. Therefore, this method is designed under the assumption that the two push block bodies 310 jointly clamp all of the wire harnesses 110. Based on the foregoing, during the welding process, the gap between the welding head accommodating area 320 and the ribs 311 can accommodate several wires to bend to form the transition section 130. This embodiment is designed under the assumption that the transition section 130 is formed only between the welding head accommodating area 320 and the ribs 311, thereby preventing the transition section 130 from encroaching on the welding area. Specifically, based on the content mentioned above, during the welding process, the gap between the welding head accommodating area 320 and the retaining edge 311 can allow several wires to be bent to form a trapezoidal transition section 130. Therefore, this embodiment designs and calculates the gap value between the welding head accommodating area 320 and the retaining edge 311 along the second direction based on the length of the retaining edge 311 along the first direction and the angle between the side of the trapezoid and the axis of the wire harness 110. The angle between the side of the trapezoid and the axis of the wire harness 110 is the maximum bending angle of the wire after welding.

[0082] Among them, the width of the welding head accommodating area 320 along the first direction is equal to the width of the welding head 400, and the length of the welding head accommodating area 320 along the second direction is equal to the length of the welding head 400, thereby meeting the requirement for the welding head 400 to pass through. In order to avoid the push block body 310 affecting the movement of the welding head 400, the spacing between the opposite sides of the two push block bodies 310 needs to be larger than the width of the welding head accommodating area 320, but in order to avoid size waste, the difference between the second spacing and the width of the welding head accommodating area 320 is selected to be greater than or equal to 0.05mm and less than or equal to 0.2mm. In this way, the length of the retaining edge 311 along the first direction can be calculated based on the width of the welding head accommodating area 320 along the first direction and the diameter of the bare wire segment 111.

[0083] The angle between the side of the trapezoid and the axis of the wire harness 110 is selected to be greater than or equal to 105° and less than or equal to 135°, that is, the maximum bending angle of the wire selected in this embodiment is greater than or equal to 105° and less than or equal to 135°, so as to ensure that the gap between the welding head accommodating area 320 and the retaining edge 311 along the second direction is as small as possible while meeting the requirement that the wire will not break. It can be understood that the angle between the side of the trapezoid and the axis of the wire harness 110 is the angle between the side of the trapezoid and one side of the bare wire segment 111 along the first direction.

[0084] Preferably, in this embodiment, α is equal to 120°.

[0085] Based on the above, this embodiment calculates the length of the rib 311 along the first direction based on the spacing between the opposite sides of the two push block bodies 310 and the diameter of the bare wire segment 111, and then uses the selected α and combines the trigonometric function design to calculate the gap value between the welding head accommodating area 320 and the rib 311 along the second direction. The gap value designed in this way can meet the requirements that the welding head 400 can be pressed down to make the welding section 120 formed by all the bare wire segments 111 being flattened cover the entire lower area of ​​the welding head 400 without breaking the wire, and the overall structure of the ultrasonic welding push block will not be too large, thereby avoiding size waste.

[0086] It can be understood that after the gap value between the welding head accommodating area 320 and the rib 311 along the second direction is designed, the spacing between the two ribs 311 provided on the same push block body 310 along the second direction can be calculated based on the gap value between the welding head accommodating area 320 and the rib 311 along the second direction. Specifically, the spacing between the two ribs 311 provided on the same push block body 310 along the second direction is A, , wherein y is the length of the welding head accommodating area 320 along the second direction, that is, y is the length of the welding head 400.

[0087] Furthermore, since wires of different materials have different ductility, correspondingly, the degree of deformation during the welding process is also different. If the ductility of the wire is poor, the larger α is, and accordingly, the actual required gap value between the welding head accommodating area 320 and the rib 311 along the second direction is also larger than L calculated according to the above content. On the contrary, if the ductility of the wire is good, α can be smaller. Accordingly, the actual required gap value between the welding head accommodating area 320 and the rib 311 along the second direction is also smaller than L calculated according to the above content. In this embodiment, after the gap value between the welding head accommodating area 320 and the rib 311 along the second direction is calculated, the actual gap value L1 between the welding head accommodating area 320 and the rib 311 along the second direction is specifically selected according to the ductility of the wire of the wire harness 110, wherein:

[0088] , where d1 is a calculation coefficient selected according to the ductility of the wires of the wire harness 110 .

[0089] For example, the wire harness 110 generally uses aluminum wires and copper wires, wherein the extensibility of the copper wires is better than that of the aluminum wires. Therefore, when calculating the actual gap value:

[0090] For the wire harness 110 using copper wire, ;

[0091] For the wiring harness 110 using aluminum wire, .

[0092] In addition, based on the above-mentioned content, according to the distance between the two ribs 311 provided on the same push block body 310 along the second direction, the length D of the push block body 310 along the second direction can also be calculated:

[0093] ,in:

[0094] A is the distance between the two ribs 311 provided on the same push block body 310 along the second direction, , where y is the length of the welding head accommodating area 320 along the second direction;

[0095] e is the width of the rib 311 along the second direction, and e is greater than or equal to 0.5 mm and less than or equal to 2 mm.

[0096] As described above, in this embodiment, the retaining edge 311 is directly disposed on the edge of the push block body 310 along the second direction, thereby further avoiding size waste.

[0097] It is also worth noting that the end of the retaining edge 311 used to press the wire harness 110 is the pressing end 3111, and the edges on both sides of the pressing end 3111 along the second direction are chamfered, so that the contact area between the retaining edge 311 and the wire is smoother, thereby preventing the retaining edge 311 from cutting the wire.

[0098] Moreover, the radius of the chamfer is larger than the minimum bending radius of the wires of the wire harness 110, that is, the radius of the chamfer is larger than the bending radius of the wires when bent to the maximum angle within the allowable range, thereby more effectively ensuring that all wires will not break after welding.

[0099] In addition, a surface of the push block body 310 on which the retaining edge 311 is provided is also chamfered with the retaining edge 311 , thereby enhancing the structural strength of the retaining edge 311 .

[0100] Furthermore, the pressing end 3111 is coated with a flexible material layer. For example, in this embodiment, the pressing end 3111 is coated with a polyurethane material layer, thereby further protecting the bare wire segment 111 of the wiring harness 110 .

[0101] Furthermore, based on the above, this embodiment further provides a wire harness welding method. During the welding process, the wire harness 110 is clamped and positioned by the ultrasonic welding push block as described above. Specifically, the wire harness welding method includes:

[0102] Prepare the wire harness 110: peel off the rubber on one side of the wire harness 110 along its axial direction to form a bare wire segment 111. The length of the bare wire segment 111 is equal to the sum of the lengths of the welding head accommodating area 320, the gap and the rib 311 along the second direction.

[0103] That is, this embodiment performs a rubber stripping operation on the wire harness 110 according to the welding head accommodating area 320, the gap and the length of the rib 311 along the second direction. Thus, when the four ribs 311 can jointly clamp the bare wire segments 111 of all the stacked wire harnesses 110, the outer side of the rib 311 presses against the rubber covering segment 112, that is, along the second direction, the two push block bodies 310 are supported between all the rubber covering segments 112 on one side and all the rubber covering segments 112 on the other side, thereby more effectively limiting all the wire harnesses 110 in the axial direction.

[0104] The welding methods of wire harnesses also include:

[0105] Stacking the wire harnesses 110: stacking two or more wire harnesses 110, with the rubber-coated section 112 pressing against the two ribs 311 arranged on the same side along the second direction, and located on the side of the ribs 311 facing away from the welding head accommodating area 320;

[0106] Welding the wire harness 110 : The four ribs 311 are used to clamp two or more overlapping bare wire segments 111 , and the welding head 400 is inserted into the welding head accommodating area 320 to press against all the bare wire segments 111 .

[0107] That is, in this embodiment, given that the length of the bare wire segment 111 of the wiring harness 110 is equal to the sum of the lengths of the welding head accommodating area 320, the gap and the rib 311 along the second direction, before stacking more than two wiring harnesses 110, the two push block bodies 310 can be moved until the spacing between the two ribs 311 arranged opposite to each other along the first direction is smaller than the diameter of the rubber-coated segment 112, but larger than the diameter of the bare wire segment 111, so that subsequent staff only need to stack the wiring harness 110 in a manner that the rubber-coated segment 112 presses against the outer side of the rib 311 to ensure that the wiring harness 110 is accurately placed along its axial direction, and after stacking, the overlapping area of ​​the two or more wiring harnesses 110 is automatically aligned with the welding head accommodating area 320.

[0108] Based on the above, it is worth noting that in this embodiment, a mounting slot 3131 is formed on the push block body 310, and the push block body 310 is connected to a driving member in the welding equipment through the mounting slot 3131. The driving member drives the push block body 310 to move in a first direction, thereby limiting the position of all wire harnesses 110 on both sides.

[0109] It is understandable that the driving member may be a linear driving structure such as a pneumatic cylinder or an electric cylinder, and this embodiment does not impose any specific limitation on this.

[0110] It is also worth noting that, to reduce costs, the push block body 310 adopts a detachable design. Specifically, the push block body 310 includes a first component 313 and a second component 314 detachably connected to the first component 313. A mounting slot 3131 is located in the first component 313, and a rib 311 is provided on the second component 314, located on a side of the second component 314 away from the first component 313 along the first direction. The first component 313 is provided with a docking slot 3132 and a threaded hole 3133 connected to the docking slot 3132. A docking block 3141 is fixedly provided on the side of the second component 314 away from the rib 311, which is configured to engage with the docking slot 3132. The docking block 3141 is provided with a clamping hole 3142, which corresponds to the threaded hole 3133. After the docking block 3141 is clamped in the docking groove 3132 , the threaded hole 3133 is aligned with the clamping hole 3142 . At this time, the first component 313 and the second component 314 can be stably connected by the bolt 315 .

[0111] As described above, through the detachable design of the first component 313 and the second component 314 , when dealing with different types of wiring harnesses 110 , in this embodiment, only the second component 314 needs to be replaced.

[0112] Example 2

[0113] Compared with the first embodiment, the present embodiment is different in that the actual gap value between the welding head accommodating area 320 and the rib 311 along the second direction is specifically designed according to the hardness of the wire.

[0114] Specifically, since the hardness of wires of different materials is different, the degree of deformation during the welding process is also different accordingly. If the hardness of the wire is high, the actual required gap value between the welding head accommodating area 320 and the rib 311 along the second direction is also larger than L calculated according to the above content, so that deformation can be more fully accommodated. On the contrary, if the hardness of the wire is low, the actual required gap value between the welding head accommodating area 320 and the rib 311 along the second direction may also be smaller than L calculated according to the above content. In this embodiment, after calculating the gap value between the welding head accommodating area 320 and the rib 311 along the second direction, the actual gap value L2 between the welding head accommodating area 320 and the rib 311 along the second direction is specifically selected according to the hardness of the wire of the wire harness 110, where:

[0115] , where d2 is a calculation coefficient selected according to the hardness of the wires of the wire harness 110 .

[0116] For example, depending on the specific material of the wire, d2 can be selected within the range of 0.8-1.2, and this embodiment does not impose any specific limitation on this.

[0117] Example 3

[0118] Compared with the first and second embodiments, the present embodiment differs in that the actual gap value between the welding head accommodating area 320 and the rib 311 along the second direction is specifically designed according to the ductility and hardness of the wire.

[0119] That is, in this embodiment, after calculating the gap value between the welding head accommodating area 320 and the rib 311 along the second direction, the actual gap value L3 between the welding head accommodating area 320 and the rib 311 along the second direction is specifically selected based on the ductility and hardness of the wires of the wire harness 110, where: .

[0120] Example 4

[0121] like Figure 11 As shown, compared with the first embodiment, the difference of this embodiment is that a bevel 3112 is provided on the inner side of the retaining edge 311, and the wire can be bent around the bevel 3112. That is, this embodiment provides the bevel 3112 on the retaining edge 311, thereby increasing the bending and deformation space of the bare wire segment 111 without affecting the length of the push block body 310 along the second direction, thereby further preventing the wire from breaking.

[0122] Obviously, the above embodiments of the present invention are merely examples for the purpose of clearly illustrating the present invention and are not intended to limit the embodiments of the present invention. A person skilled in the art would be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is not necessary and impossible to enumerate all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the claims of the present invention.

Claims

1. An ultrasonic welding push block for clamping two or more stacked wire harnesses (110), wherein the wire harnesses (110) include a bare wire segment (111) and a rubber-coated segment (112), characterized in that: The ultrasonic welding push block comprises two push block bodies (310), the two push block bodies (310) being arranged opposite to each other along a first direction, wherein: Two ribs (311) are protruded from opposite sides of the two push block bodies (310), and the two ribs (311) provided on the same push block body (310) are arranged along a second direction, which is perpendicular to the first direction. The four ribs (311) can jointly clamp two or more superimposed bare wire segments (111), and a welding head accommodating area (320) for a welding head (400) to pass through is formed between the four ribs (311), and a gap exists between the welding head accommodating area (320) and the ribs (311) along the second direction.

2. The ultrasonic welding push block according to claim 1, characterized in that: One end of the retaining edge (311) used for pressing the wiring harness (110) is the pressing end (3111), and the edges on both sides of the pressing end (3111) along the second direction are chamfered.

3. The ultrasonic welding push block according to claim 2, characterized in that: The pressing end (3111) is coated with a flexible material layer.

4. The method for designing an ultrasonic welding push block according to any one of claims 1 to 3, wherein: include: The distance between the two ribs (311) arranged opposite to each other along the first direction is equal to the diameter of the portion to be welded on the wire harness (110), and is calibrated as a first distance a; The width of the welding head accommodating area (320) along the first direction is selected to be equal to the width of the welding head (400), and the length of the welding head accommodating area (320) along the second direction is selected to be equal to the length of the welding head (400); The distance between the two opposite sides of the push block bodies (310) is selected according to the width of the welding head accommodating area (320), and is calibrated as a second distance b, and the difference between the second distance and the width of the welding head accommodating area (320) is c, and c is greater than or equal to 0.05 mm and less than or equal to 0.2 mm; After welding, the wire harness (110) forms a welding section (120) flattened by the welding head (400), a transition section (130) is formed between the retaining edge (311) and the welding section (120), and both sides of the transition section (130) along the first direction form an angle α with the axis of the wire harness (110), and α is selected to be greater than or equal to 105° and less than or equal to 135°; The gap value L between the welding head accommodating area (320) and the retaining edge (311) along the second direction is calculated based on a, b and α, wherein: , wherein x is the width of the welding head accommodating area (320) along the first direction; The distance between the two retaining edges (311) provided on the same push block body (310) along the second direction is calculated according to the gap value.

5. The design method of the ultrasonic welding push block according to claim 4, characterized in that: According to the ductility of the wires of the wire harness (110), the actual gap value L1 between the welding head accommodating area (320) and the retaining edge (311) along the second direction is specifically selected, wherein: , wherein d1 is a calculation coefficient selected according to the ductility of the wire of the harness (110).

6. The method for designing an ultrasonic welding push block according to claim 4, characterized in that: According to the hardness of the wires of the wire harness (110), an actual gap value L2 between the welding head accommodating area (320) and the retaining edge (311) along the second direction is specifically selected, wherein: , wherein d2 is a calculation coefficient selected according to the hardness of the wires of the harness (110).

7. The method for designing an ultrasonic welding push block according to claim 4, characterized in that: The length D of the push block body (310) along the second direction is calculated based on the spacing between the two retaining edges (311) provided on the same push block body (310) along the second direction: ,in: A is the distance between the two retaining edges (311) provided on the same push block body (310) along the second direction, , wherein y is the length of the welding head accommodating area (320) along the second direction; e is the width of the rib (311) along the second direction, and e is greater than or equal to 0.5 mm and less than or equal to 2 mm.

8. The method for designing an ultrasonic welding push block according to claim 4, characterized in that: One end of the retaining edge (311) used for pressing the wire harness (110) is the pressing end (3111), and the edges on both sides of the pressing end (3111) along the second direction are chamfered, and the radius of the chamfer is greater than the minimum bending radius of the wires of the wire harness (110).

9. The method for designing an ultrasonic welding push block according to claim 4, characterized in that: A chamfer is formed between a surface of the push block body (310) on which the retaining edge (311) is provided and the retaining edge (311).

10. A method for welding a wire harness, wherein the wire harness (110) is clamped and positioned by an ultrasonic welding push block according to any one of claims 1 to 3 during the welding process, characterized in that: The wiring harness welding method includes: Preparing the wire harness (110): peeling off the rubber on one side of the wire harness (110) along its axial direction to form the bare wire segment (111), wherein the length of the bare wire segment (111) is equal to the sum of the lengths of the welding head accommodating area (320), the gap, and the retaining edge (311) along the second direction; Stacking the wiring harness (110): stacking two or more wiring harnesses (110), with the rubber-coated section (112) pressing against two ribs (311) arranged on the same side along the second direction, and being located on a side of the ribs (311) facing away from the welding head accommodating area (320); Welding the wire harness (110): the four retaining edges (311) are used to clamp two or more overlapping bare wire segments (111), and the welding head (400) is extended into the welding head accommodating area (320) to press against all the bare wire segments (111).

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