A welding process and apparatus for an inductor coil

Abstract

The application relates to the field of welding devices, in particular to a welding process of an inductor coil, which comprises the following steps: step one: sleeving a wiring terminal on a bent section of the inductor coil; step two: placing the inductor coil on a positioning jig of a welding device for positioning; step three: starting the welding device to weld the wiring terminal and the bent section of the inductor coil; step four: taking the inductor coil finished product welded from the positioning jig, and meanwhile, placing the inductor coil to be welded on the jig, and repeating steps one to four. The application simultaneously improves the welding efficiency and welding quality of double-layer inductor coils.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of welding devices, in particular to a welding process of an inductor coil. BACKGROUND

[0002] Double-layer inductor coils are not only widely used in heat exchange fields (such as evaporators and condensers of air conditioners, heat exchangers in chemical equipment, etc.), but also gradually introduced into the field of inductive elements. In these applications, the welding of the terminal and the coil is a key step to ensure the reliability of electrical connection. Especially in some occasions with extremely high requirements for electrical connection stability, such as industrial control systems, power equipment, etc., welding can provide a firm and low-resistance connection, reduce contact resistance, reduce heat generation and energy loss, and thus ensure the normal operation and safety of the equipment.

[0003] A spiral pipe welding fixture is disclosed in the related art, which comprises a base and a rotating plate located above the base. The rotating plate and the base are connected by a plurality of vertically arranged columns. The bottom of the column is fixed on the base. The rotating plate, the base and the plurality of columns form a containing space for placing the spiral pipe workpiece. A through hole is formed on the rotating plate at a position corresponding to the containing space. A plurality of arc-shaped sliding grooves corresponding to the plurality of columns are formed on the rotating plate. The arc-shaped sliding grooves are uniformly distributed on the outer side of the through hole in the circumferential direction. The top of each column is slidingly connected in the corresponding arc-shaped sliding groove. An upper clamping groove is formed on the bottom of the rotating plate along the tangential direction of the through hole for clamping the upper lead-out end of the spiral pipe workpiece. A positioning hole is formed on the top of the base at a position corresponding to the containing space for positioning the bottom of the spiral pipe workpiece. A lower clamping groove is formed on the top of the base along the tangential direction of the positioning hole for clamping the lower lead-out end of the spiral pipe workpiece. A central tensioning rod is movably arranged in the containing space along the vertical direction for tensioning the spiral pipe workpiece. The central tensioning rod is inserted into the containing space through the through hole of the rotating plate, and the bottom of the central tensioning rod is inserted into the positioning hole of the base.

[0004] However, when this welding fixture designed for helical tube workpieces is applied to the welding of inductor coils, significant defects and shortcomings exist. Specifically, the structure of an inductor coil differs fundamentally from that of a helical tube workpiece. An inductor coil consists of an inner coil and an outer coil, forming a concentric circle structure connected by a connecting wire. The free ends of both the outer and inner coils are integrally formed with bent sections for fitting and welding terminals. This unique structure requires the welding fixture to possess a high degree of precision positioning capability to ensure that the terminals are accurately fitted onto the bent sections and welded reliably. However, the welding fixtures in related technologies do not address the positioning of this unique structure of inductor coils, lacking a precise positioning mechanism for the inner coil, outer coil, and their bent sections. This may lead to inductor coil wobbling or positional deviation during welding, affecting welding quality and even causing welding failure. Furthermore, because inductor coil welding requires extremely high positioning accuracy, the fixtures in related technologies may be more complex to operate and less efficient, failing to meet the production needs of inductor coil welding. Summary of the Invention

[0005] To improve the welding efficiency of double-layer inductor coils, this application provides a welding process for inductor coils.

[0006] The welding process for an inductor coil provided in this application adopts the following technical solution:

[0007] In a first aspect, this application discloses a welding process for an inductor coil, comprising the following steps:

[0008] Step 1: Place the first terminal block onto the first bent section of the inductor coil, and simultaneously place the second terminal block onto the second bent section of the inductor coil;

[0009] Step 2: Position the inductor coil on the positioning fixture of the positioning mechanism in the welding device when it is in an idle state. At this time, the inductor coil on the other positioning mechanism is in the welding state.

[0010] Step 3: Start the welding device to weld the terminals of the positioned inductor coil to the bent section of the inductor coil. During the welding process, the operator can repeat Step 1 on another idle positioning mechanism to perform the terminal setting operation of the inductor coil to be welded.

[0011] Step 4: After an inductor coil is soldered, remove the finished inductor coil from the corresponding positioning fixture. At the same time, place the inductor coil to be soldered, which has had its terminals fitted in Step 3, onto the positioning fixture. Then repeat Steps 1 to 4 to achieve simultaneous soldering and inductor coil replacement operations.

[0012] By adopting the technical scheme, the spiral tube welding fixture in the related art cannot meet the welding requirement of the special structure of the inductor coil, because it lacks a precise positioning mechanism for the inner coil, the outer coil and the bending section thereof, and is prone to cause the inductor coil to shake or deviate in position during welding, affecting the welding quality and even leading to failure, and the operation is complex and inefficient, the application provides a welding process of an inductor coil, by arranging two positioning mechanisms, when the inductor coil on one positioning mechanism is in a welding state, the worker can perform the sleeving operation of the wiring terminal of the to-be-welded inductor coil on the other idle positioning mechanism, when one inductor coil is welded, the welded inductor coil product is immediately taken down and replaced with the to-be-welded inductor coil with the sleeved wiring terminal, the welding and replacement of the inductor coil are simultaneously performed, the welding efficiency of the double-layer inductor coil is effectively improved, the precise positioning mechanism also guarantees the welding quality, and the production requirement of the inductor coil welding is met.

[0013] Optionally, the inner coil is placed in the annular positioning cavity formed between the inner positioning column and the positioning ring; the outer coil of the inductor coil is sleeved on the positioning ring, and the inner side wall of the outer coil abuts against the inner side wall of the positioning ring, and the end portions of the inner coil and the outer coil abut against the upper surface of the bearing block, and the connecting wire is placed in the positioning cavity.

[0014] By adopting the technical scheme, an annular positioning cavity is formed between the inner positioning column and the positioning ring in terms of structural layout. The annular positioning cavity serves to accommodate and position the inner coil of the inductor coil. The inner coil is placed in the annular positioning cavity, thereby ensuring the accuracy and stability of the position. Meanwhile, the outer coil of the inductor coil is sleeved on the positioning ring. The inner side wall of the outer coil abuts against the inner side wall of the positioning ring, which not only helps to fix the position of the outer coil, but also ensures the relative positional relationship between the outer coil and the inner coil, thereby ensuring the overall performance of the inductor coil. In terms of working principle, the end portions of the inner coil and the outer coil abut against the upper surface of the bearing block. The bearing block serves to support and position the inductor coil, thereby ensuring the stability of the inductor coil when subjected to external force. In addition, the connecting wire is also placed in the positioning cavity, which helps to arrange and protect the connecting wire, preventing it from being damaged or interfered.

[0015] Optionally, the positions of the inductor coil, the first wiring terminal and the second wiring terminal are adjusted, so that the first bending section of the inductor coil is located in the first positioning channel, the second bending section of the inductor coil is located in the second positioning channel, the bottom end of the first wiring terminal abuts against the top end of the terminal positioning column, and the second wiring terminal is located in the terminal positioning groove.

[0016] By adopting the technical scheme, the first bending section of the inductor coil is accurately placed in the first positioning channel, ensuring accurate and stable position; meanwhile, the second bending section of the inductor coil is placed in the second positioning channel, also ensuring accurate positioning. In this way, both bending sections of the inductor coil are properly positioned, laying a foundation for subsequent electrical connection and stable work. Next, the wiring terminal is positioned. The bottom end of the first wiring terminal is abutted against the top end of the terminal positioning column, and the stability of the first wiring terminal in the device is ensured through the support and positioning effect of the terminal positioning column. Meanwhile, the second wiring terminal is placed in the terminal positioning groove, and the second wiring terminal is kept in the correct position and direction by the shape and size limitation of the terminal positioning groove. The accurate positioning of the inductor coil and its wiring terminal is realized.

[0017] Optionally, the specific steps of starting the welding device in step three are as follows:

[0018] S1: The first moving seat is driven to move in the horizontal direction by the first driving assembly in the positioning mechanism, the positioning jig is moved to the lower side of the support seat, so that the inductor coil is in the welding position;

[0019] S2: The second moving seat is driven to move to the upper side of the positioning mechanism in the horizontal direction by the second driving assembly in the welding mechanism, so that the welding assembly is aligned with the to-be-welded part of the inductor coil;

[0020] S3: The lifting seat is driven to descend by the lifting driving assembly, and the welding assembly is driven to descend to an appropriate height, so that the electric iron of the welding assembly contacts the wiring terminal and the bending section of the inductor coil;

[0021] S4: The welding assembly is started to perform welding operation, the first wiring terminal is welded to the first bending section, and the second wiring terminal is welded to the second bending section, completing the welding of the inductor coil.

[0022] By adopting the technical scheme, when welding operation is needed, the first moving seat is first driven to move by the first driving assembly of the positioning mechanism, the inductor coil on the positioning jig is accurately moved to the lower side of the support seat, i.e. the welding position. At this time, the second driving assembly in the welding mechanism starts to work, drives the second moving seat to move to the upper side of the positioning mechanism, so that the welding assembly is aligned with the to-be-welded part of the inductor coil. Then, the lifting driving assembly drives the lifting seat to descend, and the welding assembly is driven to descend to an appropriate height, ensuring that the electric iron fully contacts the wiring terminal and the bending section of the inductor coil. Finally, the welding assembly is started to perform welding operation, the first wiring terminal is welded to the first bending section, and the second wiring terminal is welded to the second bending section, thereby completing the welding of the inductor coil. The accurate positioning and efficient welding of the inductor coil are realized.

[0023] Optionally, the tin wire on the winding mechanism passes through two guide wheels in sequence for guidance and turning; the third driving assembly of the feeding mechanism drives the first rotating shaft to rotate, thereby driving the first feeding wheel to rotate; the adjusting assembly drives the swing base to swing around the first mounting rod through the rotation of the eccentric wheel, so that the second rotating shaft drives the second feeding wheel to swing, thereby changing the distance between the first feeding wheel and the second feeding wheel, realizing the clamping and loosening of the tin wire, and accurately controlling the conveying speed and feeding amount of the tin wire; the tin wire is conveyed into the guide pipe of the guide assembly under the cooperation of the first feeding wheel and the second feeding wheel; the guide pipe conveys the tin wire to the electric iron, and the electric iron melts the tin wire, thereby completing the welding of the first connecting terminal and the first bent segment and the welding of the second connecting terminal and the second bent segment.

[0024] By adopting the above technical scheme, when welding operation is needed, the tin wire on the winding mechanism first passes through the guidance and turning of the two guide wheels, ensuring the accuracy of the tin wire conveying path. Subsequently, the third driving assembly of the feeding mechanism starts to work, drives the first rotating shaft to rotate, and drives the first feeding wheel to rotate. At the same time, the adjusting assembly adjusts the rotation angle of the eccentric wheel according to the welding requirement, drives the swing base to swing around the first mounting rod, so that the second rotating shaft drives the second feeding wheel to swing, thereby changing the distance between the first feeding wheel and the second feeding wheel. This adjustment of the distance realizes the clamping and loosening of the tin wire, and further accurately controls the conveying speed and feeding amount of the tin wire. The tin wire is stably and accurately conveyed into the guide pipe of the guide assembly under the close cooperation of the first feeding wheel and the second feeding wheel. The guide pipe further guides the tin wire to the electric iron, and the electric iron generates high temperature after being electrified, melts the tin wire, thereby completing the welding of the first connecting terminal and the first bent segment and the welding of the second connecting terminal and the second bent segment.

[0025] In the second aspect, the application discloses a welding device for the above welding process, which comprises a base, a positioning mechanism, a welding mechanism, a winding mechanism, a guide mechanism and a feeding mechanism; the base comprises a base and a supporting seat, and the supporting seat is fixed to the upper surface of the base; the positioning mechanism is arranged on the base and is used for positioning the inductor coil; the welding mechanism, the winding mechanism, the guide mechanism and the feeding mechanism are all arranged on the supporting seat, the welding mechanism is used for welding the connecting terminal to the inductor coil, the winding mechanism is used for winding the tin wire and conveying the tin wire to the feeding mechanism through the guide mechanism, and the feeding mechanism is used for conveying the tin wire to the welding mechanism.

[0026] By adopting the above technical scheme, the winding mechanism first plays a role, which is responsible for winding the tin wire and guiding the tin wire to the feeding mechanism through the guide mechanism. The guide mechanism plays a key role here, which ensures that the path of the tin wire during transmission is accurate and smooth, avoiding the winding or deviation of the tin wire. After receiving the tin wire, the feeding mechanism precisely controls the transmission speed and feeding amount of the tin wire through the third driving assembly and the adjusting assembly inside it. During this process, the feeding mechanism can timely clamp or release the tin wire according to the welding requirements, ensuring that the tin wire can be stably and accurately transmitted to the welding mechanism. At the same time, the positioning mechanism has accurately positioned the inductor coil at the welding position. When the feeding mechanism transmits the tin wire to the welding mechanism, the welding mechanism starts to work. It uses a soldering iron or other welding tools to melt the tin wire and accurately drop it between the terminal of the inductor coil and the bent segment, completing the welding operation.

[0027] Optionally, the positioning mechanism comprises a first moving seat, a first driving assembly and a positioning jig; the first moving seat is in sliding cooperation with the base, the first driving assembly is arranged on the base and is used to drive the first moving seat to move in the horizontal direction; the positioning jig is fixed on the first moving seat and is used to position the inductor coil; the positioning jig comprises a bottom plate, a bearing block, an inner positioning column and a positioning ring, the bearing block is fixed on the surface of the bottom plate, the inner positioning column and the positioning ring are both fixed on the surface of the bearing block, an annular positioning cavity for positioning the inner coil is formed between the inner positioning column and the positioning ring, and a clearance cavity for accommodating the connecting wire is formed on the positioning ring; a first positioning seat, a second positioning seat and a terminal positioning seat are further fixedly arranged on the upper surface of the bottom plate, a first positioning channel is formed on the first positioning seat, a second positioning channel is formed on the second positioning seat, and a terminal positioning groove is formed on the terminal positioning seat.

[0028] By adopting the above technical scheme, when it is necessary to position the inductor coil to the welding position, the first driving assembly is started to drive the first moving seat to move in the horizontal direction, driving the positioning jig to move together. When the positioning jig moves to the specified position, the worker places the inductor coil on the positioning jig, and through the precise positioning of the annular positioning cavity, the first positioning channel, the second positioning channel and the terminal positioning groove, it is ensured that the inductor coil and the terminal are in the correct welding position. At this time, the positioning mechanism has completed its positioning task and prepared for the subsequent welding operation. The precise positioning and stable fixation of the inductor coil are realized, which provides reliable guarantee for the welding operation.

[0029] Optionally, the welding mechanism comprises a second moving seat, a second driving assembly, a lifting seat, a lifting driving assembly and a welding assembly; the second moving seat is in sliding cooperation with the cross beam; the second driving assembly is arranged on the cross beam and is used to drive the second moving seat to move horizontally; the lifting seat is in sliding cooperation with the second moving seat; the lifting driving assembly is arranged on the second moving seat and is used to drive the lifting seat to lift; the welding assembly is arranged on the lifting seat; the welding assembly is used to weld the first connecting terminal to the first bending segment and is used to weld the second connecting terminal to the second bending segment.

[0030] By adopting the above technical scheme, firstly, the second driving assembly is started to drive the second moving seat to move horizontally along the cross beam, so as to quickly and accurately position the welding assembly above the to-be-welded area of the inductance coil. During this process, the sliding cooperation between the second moving seat and the cross beam ensures the stability of movement and the accuracy of positioning. Then, the lifting driving assembly starts to work to drive the lifting seat to descend, so as to gradually drive the welding assembly to approach the inductance coil. When the welding assembly is lowered to a suitable height, the welding head of the welding assembly is in close contact with the connecting terminal of the inductance coil, at which time the welding assembly is started to weld the first connecting terminal and the second connecting terminal on the inductance coil. After the welding is completed, the lifting driving assembly is started again to drive the lifting seat to ascend, so as to drive the welding assembly to leave the welding position and prepare for the next welding.

[0031] Optionally, the wire feeding mechanism comprises a first rotating assembly, a second rotating assembly, a third driving assembly, an adjusting assembly and a linkage assembly; the first rotating assembly comprises a first rotating shaft and a first wire feeding wheel; the first rotating shaft penetrates through the support and is rotationally connected with the support; the first wire feeding wheel is sleeved on the first rotating shaft and is fixedly connected with the first rotating shaft; the second rotating assembly comprises a second rotating shaft, a second wire feeding wheel and a second linkage gear; one end of the second rotating shaft penetrates through the bottom end of the swing seat and is rotationally connected with the swing seat; the other end of the second rotating shaft extends out of the support; the second wire feeding wheel is sleeved on the other end of the second rotating shaft extending out of the support; the second linkage gear is sleeved on the second rotating shaft and is fixedly connected with the second rotating shaft; the third driving assembly is used to drive the first rotating shaft to rotate; the adjusting assembly comprises a first mounting rod, a swing seat, a second mounting rod, an eccentric wheel and a driving rod; both ends of the first mounting rod penetrate through the support and are rotationally connected with the support; the swing seat is rotationally connected with the first mounting rod; both ends of the second mounting rod penetrate through the support and are fixedly connected with the support; an eccentric hole is formed in the eccentric position of the eccentric wheel; the second mounting rod penetrates through the eccentric hole of the eccentric wheel; the eccentric wheel is rotationally connected with the second mounting rod; the side wall of the eccentric wheel abuts against the side wall of the swing seat; the driving rod is fixedly arranged on the swing seat and the end of the driving rod away from the swing seat extends out of the support.

[0032] By adopting the technical scheme, the wire feeding mechanism comprises a first rotating assembly, a second rotating assembly, a third driving assembly, an adjusting assembly and a linkage assembly. The third driving assembly drives the first rotating shaft to rotate, thereby driving the first wire feeding wheel to rotate. The adjusting assembly drives the swing base to swing around the first mounting rod through the rotation of the eccentric wheel, thereby driving the second rotating shaft to drive the second wire feeding wheel to swing, and changing the distance between the first wire feeding wheel and the second wire feeding wheel. The wire feeding mechanism can timely clamp or release the solder wire according to the welding requirement, so as to ensure that the solder wire can be stably and accurately transmitted to the welding mechanism. The accurate control not only improves the accuracy and quality of welding, but also avoids welding defects caused by unstable transmission of the solder wire, such as incomplete welding points and virtual welding. At the same time, the automatic control of the wire feeding mechanism reduces the difficulty and error of manual operation, and improves the production efficiency.

[0033] Optionally, the guide assembly comprises a fixed seat and a guide pipe. The fixed seat passes through the clamping block and is fixedly connected with the clamping block. The guide pipe passes through the fixed seat and is fixedly connected with the fixed seat. Both ends of the guide pipe are provided with openings, and the guide pipe is inclined. The bottom end of the guide pipe faces the electric iron, and is used for accurately transmitting the solder wire to the electric iron.

[0034] By adopting the technical scheme, the guide assembly provides a stable and accurate guide path during the transmission of the solder wire from the wire feeding mechanism to the welding position. After the solder wire is fed out from the wire feeding mechanism, it enters the top opening of the guide pipe and slides down along the inside of the guide pipe. Since the guide pipe is inclined, the solder wire will naturally accelerate to slide down under the action of gravity until reaching the bottom opening of the guide pipe. At this time, since the bottom end of the guide pipe faces the electric iron, the solder wire will be accurately transmitted to the welding position of the electric iron, providing necessary welding material for subsequent welding operation, and improving the welding quality and production efficiency.

[0035] In summary, the present application has at least one of the following beneficial technical effects:

[0036] 1. By arranging two positioning mechanisms, the present application realizes parallel operation of welding and replacing the inductor coil. When the inductor coil on one positioning mechanism is in the welding state, the worker can perform the sleeving operation of the wiring terminal of the to-be-welded inductor coil on the other idle positioning mechanism. When one inductor coil is welded, the welded inductor coil product is immediately taken off and replaced with the to-be-welded inductor coil with the sleeved wiring terminal. This parallel operation mode greatly improves the overall welding efficiency, reduces the production cycle, and meets the demand of large-scale production.

[0037] 2. The positioning mechanism realizes precise positioning of the inductor coil and its terminal through structures such as the annular positioning cavity, the first positioning channel, the second positioning channel, and the terminal positioning groove. This precise positioning mechanism ensures the stability and accuracy of the inductor coil during welding, avoiding welding quality problems caused by inductor coil shaking or position deviation. At the same time, the welding mechanism realizes precise positioning and operation of the welding assembly in three-dimensional space through the cooperative work of the second driving assembly and the lifting driving assembly, further improving the accuracy and quality of welding;

[0038] 3. The winding mechanism is responsible for winding the tin wire and guiding the tin wire to the feeding mechanism through the guide mechanism; the feeding mechanism precisely controls the conveying speed and feeding amount of the tin wire through the third driving assembly and the adjusting assembly; the welding mechanism automatically adjusts the position and height of the welding assembly according to the welding requirements and performs welding operation. This automatic and intelligent control method not only improves production efficiency and quality, but also reduces the difficulty and error of manual operation. BRIEF DESCRIPTION OF DRAWINGS

[0039] Figure 1 is a flowchart of an inductor coil welding process in an embodiment of the present application.

[0040] Figure 2 is a structural schematic diagram of an inductor coil in an embodiment of the present application.

[0041] Figure 3 is a structural schematic diagram of a welding device in an embodiment of the present application.

[0042] Figure 4 is a structural schematic diagram of a positioning mechanism in an embodiment of the present application.

[0043] Figure 5 is a structural schematic diagram of a positioning jig in an embodiment of the present application.

[0044] Figure 6 is a structural schematic diagram of a welding mechanism in an embodiment of the present application.

[0045] Figure 7 is a structural schematic diagram of a feeding mechanism and a guide mechanism in an embodiment of the present application.

[0046] Figure 8 is a structural schematic diagram of a third driving assembly in an embodiment of the present application.

[0047] BRIEF DESCRIPTION OF DRAWINGS:

[0048] 1, Inductor; 11, inner coil; 12, outer coil; 13, first bending section; 14, second bending section; 15, first terminal; 16, second terminal; 2, base; 21, base; 22, support seat; 221, crossbeam; 222, support rod; 23, first guide rail; 3, positioning mechanism; 31, first moving seat; 32, first driving assembly; 321, first driving wheel; 322, first driven wheel; 323, first belt; 324, first motor; 33, positioning jig; 331, bottom plate; 332, bearing block; 333, inner positioning column; 334, positioning ring; 335, annular positioning cavity; 336, avoidance cavity; 337, first positioning seat; 3371, first positioning block; 3372, terminal positioning column; 3373, first positioning channel; 338, second positioning seat; 3381, second positioning channel; 339, terminal positioning seat; 3391, terminal positioning groove; 34, protective cover; 341, avoidance groove; 4, welding mechanism; 41, second moving seat; 42, second driving assembly; 43, lifting seat; 44, lifting driving assembly; 45, welding assembly; 451, adjusting block; 452, clamping block; 453, electric soldering iron; 454, adjusting groove; 46, guide assembly; 461, fixed seat; 462, guide pipe; 47, support; 471, avoidance hole; 5, wire feeding mechanism; 51, first rotating assembly; 511, first rotating shaft; 512, first wire feeding wheel; 52, second rotating assembly; 521, second rotating shaft; 522, second wire feeding wheel; 523, second linkage gear; 53, third driving assembly; 531, driving gear; 532, driven gear; 533, first linkage gear; 534, second motor; 54, adjusting assembly; 541, first mounting rod; 542, swinging seat; 543, second mounting rod; 544, eccentric wheel; 545, driving rod; 546, eccentric hole; 6, wire winding mechanism; 7, guide mechanism. DETAILED DESCRIPTION

[0049] The accompanying drawings are included to provide a further understanding of the present application, and are incorporated herein and constitute a part of this application. Figures 1-8 The present application will be further described in detail.

[0050] The terminology used in the present application is for the purpose of describing particular embodiments only and is not intended to be limiting of the present application. Unless otherwise defined, technical or scientific terms used in the present application are intended to have the meanings commonly understood by one of ordinary skill in the art in the field of the present application. The terminology used in the present application, and not specifically defined herein, is intended to have the commonly understood meanings as construed by those skilled in the pertinent technical and scientific fields contained therein. The use herein of "first", "second" and like designations is not intended to restrict the number and / or the order of the components.

[0051] For the convenience of understanding, in the horizontal direction in the present embodiment, the length direction of the crossbeam 221 is defined as the first direction, and the length direction of the first moving seat 31 is defined as the second direction, and based on this, the welding process of an inductor is described.

[0052] Embodiment 1

[0053] The embodiment of the present application discloses a welding process of an inductor coil. Referring to Figure 1 and Figure 2 , the welding process of the inductor coil comprises the following steps:

[0054] Step one: terminal sleeve

[0055] The worker sleeves the first terminal 15 on the first bending section 13 of the inductor coil 1, and sleeves the second terminal 16 on the second bending section 14 of the inductor coil 1. This step prepares for subsequent welding, ensuring that the terminal can be accurately placed in the welding position. Specifically, the inductor coil 1 comprises an inner coil 11 and an outer coil 12 located outside the inner coil 11, the outer coil 12 and the inner coil 11 are formed by winding the same enameled wire, the outer coil 12 and the inner coil 11 form a concentric circle structure, and the outer coil 12 and the inner coil 11 are connected by a connecting wire. The free end of the outer coil 12 is integrally formed with the first bending section 13 after bending, the free end of the inner coil 11 is integrally formed with the second bending section 14, the first terminal 15 is sleeved on the first bending section 13, and the second terminal 16 is sleeved on the second bending section 14.

[0056] Step two: inductor coil 1 positioning

[0057] Referring to Figure 3 、 Figure 4 and Figure 5 , the inductor coil 1 is placed on the positioning jig 33 of the welding device for positioning. Specifically, the number of positioning mechanisms 3 in the welding device is two, and the two positioning mechanisms 3 are arranged at intervals along the first direction. The worker places the inductor coil 1 on the positioning jig 33 of one of the positioning mechanisms 3, and the annular positioning cavity 335 in the positioning jig 33 tightly fits the inner coil 11, ensuring that the inner coil 11 does not shake during positioning. The avoidance cavity 336 on the positioning ring 334 provides a suitable accommodation space for the connecting wire, avoiding the connecting wire from being squeezed or interfered during positioning. The first positioning channel 3373 of the first positioning seat 337 is shaped to fit the first bending section 13, and the terminal positioning groove 3391 of the terminal positioning seat 339 is used to position the second terminal 16. Through these structures, the inductor coil 1 is accurately fixed on the positioning jig 33, and the first terminal 15 and the second terminal 16 are accurately positioned in the welding position respectively.

[0058] Referring to Figure 5Specifically, the inner coil 11 is placed in the annular positioning cavity 335 formed between the inner positioning column 333 and the positioning ring 334; the outer coil 12 of the inductor coil 1 is sleeved on the positioning ring 334, and the inner side wall of the outer coil 12 abuts against the inner side wall of the positioning ring 334, and the end portions of the inner coil 11 and the outer coil 12 abut against the upper surface of the bearing block 332, and the connecting wire is placed in the positioning cavity. Further, the positions of the inductor coil 1, the first connecting terminal 15 and the second connecting terminal 16 are adjusted, so that the first bending section 13 of the inductor coil 1 is located in the first positioning channel 3373, the second bending section 14 of the inductor coil 1 is located in the second positioning channel 3381, the bottom end of the first connecting terminal 15 abuts against the top end of the inner positioning column 333, and the second connecting terminal 16 is located in the terminal positioning groove 3391.

[0059] Step three: start the welding device

[0060] Referring to Figure 4 When the inductor coil 1 in one positioning mechanism 3 is positioned, the first driving assembly 32 in each positioning mechanism 3 starts to work. In the working process, the first motor 324 drives the first driving wheel 321 to rotate, and the rotation of the first driving wheel 321 drives the first belt 323 to move, because one side of the first belt 323 is fixedly connected with the driving seat, and the driving seat is fixed on the lower surface of the first moving seat 31. Therefore, the movement of the first belt 323 drives the driving seat to move, and further drives the first moving seat 31 and the positioning jig 33 to move along the second direction, so as to move the positioning jig 33 on the first moving seat 31 to the lower side of the support seat 22, so as to facilitate the operation of the welding mechanism 4. Through the cooperation of the first guide rail 23 and the first sliding block, the shaking and deviation of the first moving seat 31 in the moving process can be effectively reduced, so as to ensure that the positioning jig 33 always maintains a stable movement track, and further improve the positioning precision of the inductor coil 1.

[0061] Referring to Figure 3 and Figure 6 At the same time, the welding mechanism 4 starts to work. The second driving assembly 42 is arranged in the horizontal beam 221, and the structure of the second driving assembly 42 is completely same as that of the first driving assembly 32, which is used to drive the second moving seat 41 to reciprocate along the first direction, so as to move the second moving seat 41 to the upper side of the positioning mechanism 3. The lifting driving assembly 44 is a cylinder, which is arranged on the second moving seat 41, and is used to drive the lifting seat 43 to lift, so as to drive the welding assembly 45 to descend to a suitable height.

[0062] Referring to Figure 6 and Figure 7During the welding process, the wire winding mechanism 6 continuously winds the tin wire. The tin wire on the winding drum is first guided and turned by the two guide wheels, and then transmitted to the wire feeding mechanism 5. The third driving assembly 53 of the wire feeding mechanism 5 drives the first rotating shaft 511 to rotate, thereby driving the first wire feeding wheel 512 to rotate. At the same time, the adjusting assembly 54 drives the swing seat 542 to swing around the first mounting rod 541 through the rotation of the eccentric wheel 544, so that the second rotating shaft 521 drives the second wire feeding wheel 522 to swing, thereby changing the distance between the first wire feeding wheel 512 and the second wire feeding wheel 522, so as to realize the clamping and releasing of the tin wire and accurately control the transmission speed and the wire feeding amount of the tin wire. The tin wire is transmitted to the guide pipe 462 of the guide assembly 46 under the cooperation of the first wire feeding wheel 512 and the second wire feeding wheel 522. The guide pipe 462 is inclined and arranged with the bottom end facing the electric soldering iron 453, so as to ensure that the tin wire can be accurately transmitted to the electric soldering iron 453, thereby providing necessary welding materials for the welding process. Finally, the electric soldering iron 453 melts the tin wire, thereby welding the first connecting terminal 15 to the first bent section 13 and welding the second connecting terminal 16 to the second bent section 14.

[0063] With reference to Figure 3 Since the welding device is provided with two positioning mechanisms 3, when the inductor coil 1 in one of the positioning mechanisms 3 is being welded, the staff can simultaneously place and position the to-be-welded inductor coil 1 on the other positioning mechanism 3. After the welding of one inductor coil 1 is completed, the welding mechanism 4 can immediately move to the other positioned inductor coil 1 to perform welding, without the need to wait for the staff to place and position the inductor coil 1 again. This parallel operation mode greatly improves the overall welding efficiency and reduces the production cycle.

[0064] Embodiment 2

[0065] The embodiment discloses a welding device, with reference to Figure 3 and Figure 4 The welding device comprises a base 2, a positioning mechanism 3, a welding mechanism 4, a wire winding mechanism 6, a guide mechanism 7 and a wire feeding mechanism 5. The base 2 comprises a base plate 21 and a support seat 22, the support seat 22 is fixed to the upper surface of the base plate 21, the positioning mechanism 3 is arranged on the base plate 21, and the positioning mechanism 3 is used for positioning the inductor coil 1. The support seat 22 comprises a cross beam 221 and two support rods 222, the two support rods 222 each extend in the vertical direction, the bottom end of each support rod 222 is fixedly connected with the upper surface of the base plate 21, and the top end of each support rod 222 is fixedly connected with the lower surface of the cross beam 221. The welding mechanism 4, the wire winding mechanism 6, the guide mechanism 7 and the wire feeding mechanism 5 are arranged on the cross beam 221, the welding mechanism 4 is used for welding the connecting terminal to the inductor coil 1, the wire winding mechanism 6 is used for winding the tin wire and transmitting the tin wire to the wire feeding mechanism 5 through the guide mechanism 7, and the wire feeding mechanism 5 is used for transmitting the tin wire to the welding mechanism 4, thereby providing necessary welding materials for the welding process.

[0066] Referring to Figure 3 and Figure 4 In the embodiment, the number of positioning mechanisms 3 is two, and the two positioning mechanisms 3 are arranged along the first direction at intervals. Each positioning mechanism 3 comprises a first moving seat 31, a first driving assembly 32, and a positioning jig 33. The first moving seat 31 is in sliding fit with the base 21, the first driving assembly 32 is arranged on the base 21, and the first driving assembly 32 is used to drive the first moving seat 31 to move along the second direction. The positioning jig 33 is fixed on the first moving seat 31, and the positioning jig 33 is used to position the inductor coil 1.

[0067] Referring to Figure 4 Specifically, the first driving assembly 32 comprises a first driving wheel 321, a first driven wheel 322, a first belt 323, and a first motor 324. The first motor 324 is fixed on the lower surface of the base 21, the output shaft of the first motor 324 penetrates through the base 21 and is in rotational connection with the base 21, the first driving wheel 321 is sleeved on the output shaft of the first motor 324 and is fixedly connected with the output shaft of the first motor 324, the first driven wheel 322 is in rotational connection with the base 21, and the first belt 323 is arranged around the first driving wheel 321 and the first driven wheel 322. The lower surface of the first moving seat 31 is fixedly provided with a driving seat, and one side of the first belt 323 penetrates through the driving seat and is fixedly connected with the driving seat. In the working process, the first motor 324 drives the first driving wheel 321 to rotate. Since the first belt 323 is arranged around the first driving wheel 321 and the first driven wheel 322, the rotation of the first driving wheel 321 will drive the first belt 323 to move. Since one side of the first belt 323 is fixedly connected with the driving seat, and the driving seat is fixed on the lower surface of the first moving seat 31, the movement of the first belt 323 will drive the driving seat to move, thereby driving the first moving seat 31 and the positioning jig 33 to move along the second direction. This driving mode has simple structure, stable transmission, and can accurately control the moving distance and speed of the first moving seat 31, thereby realizing accurate positioning of the inductor coil 1, ensuring the accuracy of the welding position, and improving the welding quality.

[0068] Referring to Figure 4 For each positioning mechanism 3, the upper surface of the base 21 is fixedly provided with two first guide rails 23, and the two first guide rails 23 extend along the second direction. The lower surface of each first moving seat 31 is correspondingly fixedly provided with a first sliding block, the first guide rail 23 and the first sliding block are in one-to-one correspondence, the first guide rail 23 penetrates through the first sliding block, and the first sliding block is in sliding fit with the first guide rail 23. Through the cooperation of the first guide rail 23 and the first sliding block, the shaking and deviation of the first moving seat 31 in the moving process can be effectively reduced, the stable movement track of the positioning jig 33 can be ensured, and the positioning accuracy of the inductor coil 1 is further improved, thereby providing reliable guarantee for the subsequent welding operation.

[0069] With reference to Figure 3 , the positioning mechanism 3 further comprises a protective cover 34 fixed to the upper surface of the base 21, the first driving wheel 321, the first driven wheel 322, the first belt 323, the first guide rail 23 and the first sliding block are all located inside the protective cover 34, the protective cover 34 provides effective physical protection for these internal structures, which can prevent dust, sundries and other external impurities from entering, avoid the interference or damage of these impurities to the normal operation of the components, thereby ensuring the stability and reliability of the function of the first driving assembly 32 driving the first moving base 31 to move in the second direction, and prolonging the service life of the related components.

[0070] With reference to Figure 3 , the upper surface of the protective cover 34 is also provided with two position-avoiding grooves 341, each of which extends in the second direction. The first moving base 31 simultaneously passes through the two position-avoiding grooves 341, and the first moving base 31 and the position-avoiding grooves 341 are in sliding fit and clearance fit, the two position-avoiding grooves 341 avoid interference between the first moving base 31 and the protective cover 34 during the movement of the first moving base 31 in the second direction, and have a protective effect on the first moving base 31 and the protective cover 34. The arrangement of the protective cover 34 not only protects the internal parts, but also ensures the normal movement of the first moving base 31 through the position-avoiding grooves 341, so that the structure of the entire positioning mechanism 3 is more compact and reasonable, and the overall performance and reliability of the device are improved.

[0071] With reference to Figure 2 , Figure 4 and Figure 5The positioning jig 33 comprises a bottom plate 331, a bearing block 332, an inner positioning column 333 and a positioning ring 334. The bearing block 332 is fixed to the surface of the first bottom plate 331 by a plurality of bolts, the inner positioning column 333 and the positioning ring 334 are both fixed to the surface of the bearing block 332 by bolts, and the annular positioning cavity 335 for positioning the inner coil 11 is formed between the inner positioning column 333 and the positioning ring 334. The positioning ring 334 is further provided with an avoidance cavity 336 for accommodating the connecting wire, the length direction of the avoidance cavity 336 is the same as the length direction of the positioning ring 334, and both ends of the avoidance cavity 336 are provided in an open manner. The avoidance cavity 336 can effectively avoid the connecting wire from being squeezed or interfered during the bending process. The avoidance cavity 336 enables the connecting wire to stretch freely during the bending operation, and prevents the connecting wire from being damaged due to squeezing, thereby ensuring the integrity and conductivity of the connecting wire, improving the assembly quality and production efficiency of the inductor coil 1. The inner positioning column 333 is located inside the positioning ring 334, the axis of the inner positioning column 333 coincides with the axis of the positioning ring 334, the diameter of the inner positioning column 333 is smaller than the diameter of the inner diameter of the positioning ring 334, and when the worker places the inductor coil 1 on the first positioning seat 337, the inner coil 11 is located in the annular positioning cavity 335, the outer coil 12 is sleeved on the positioning ring 334, the inner side wall of the outer coil 12 abuts against the inner side wall of the positioning ring 334, the end portions of the inner coil 11 and the outer coil 12 abut against the upper surface of the bearing block 332, and the connecting wire is located in the avoidance cavity 336. This positioning method can accurately fix the inductor coil 1 on the positioning jig 33, ensure the position stability of the inductor coil 1 during the welding process, and avoid the problems of welding failure or poor welding quality caused by the movement of the inductor coil 1.

[0072] Referring to Figure 5The upper surface of the bottom plate 331 is further fixedly provided with a first positioning seat 337, the first positioning seat 337 comprising a first positioning block 3371 and a terminal positioning column 3372, the first positioning block 3371 being fixed to the upper surface of the bearing block 332, and the terminal positioning column 3372 being fixed to the upper surface of the first positioning block 3371. The first positioning seat is provided with a first positioning channel 3373, the shape of the first positioning channel 3373 being matched with the shape of the first bent section 13. When the inductor coil 1 is placed in the annular positioning cavity 335, the first bent section 13 is just located in the first positioning channel 3373, and the top end of the first bent section 13 extends in the vertical direction. When the staff sets the first terminal 15 on the top end of the first bent section 13, the first terminal 15 is lowered under the action of its own gravity, and when the bottom end of the first terminal 15 is connected to the top end of the terminal positioning column 3372, the first terminal 15 is just located at the position to be welded. The first positioning channel 3373 can accurately position the first bent section 13, ensure that the first terminal 15 can be accurately set on the first bent section 13 and be located at the correct position to be welded, and improve the welding precision and efficiency.

[0073] With reference to Figure 1 and Figure 5 The upper surface of the bottom plate 331 is further fixedly provided with a second positioning seat 338 and a terminal positioning seat 339, the second positioning seat 338 being provided with a second positioning channel 3381, and the terminal positioning seat 339 being provided with a terminal positioning groove 3391. When the inductor coil 1 is placed in the annular positioning cavity 335, the second bent section 14 is just located in the second positioning channel 3381. At the same time, when the staff sets the second terminal 16 on the second bent section 14 and moves to the position of the terminal positioning groove 3391, the outer side wall of the second terminal just abuts against the inner side wall of the terminal positioning groove 3391, and at this time, the second terminal 16 is just located at the position to be welded. The second positioning seat 338 and the terminal positioning seat 339 further ensure the positioning accuracy of the second terminal 16, so that the second terminal 16 can be accurately located at the position to be welded, and the first terminal 15 and the second terminal 16 jointly complete the welding operation, improving the positioning accuracy and welding quality of the whole welding device.

[0074] With reference to Figure 6The welding mechanism 4 comprises a second moving seat 41, a second driving assembly 42, a lifting seat 43, a lifting driving assembly 44 and a welding assembly 45. The second moving seat 41 is in sliding cooperation with the cross beam 221, the second driving assembly 42 is arranged inside the cross beam 221, and the second driving assembly 42 is used to drive the second moving seat 41 to reciprocate in the first direction. The structure of the second driving assembly 42 is exactly the same as that of the first driving assembly 32, and details are not repeated here. The lifting seat 43 is in sliding cooperation with the second moving seat 41, the lifting driving assembly 44 is arranged on the second moving seat 41, and the lifting driving assembly 44 is used to drive the lifting seat 43 to lift. The lifting driving assembly 44 is a pneumatic cylinder. As the lifting driving assembly 44, the pneumatic cylinder has the advantages of fast response speed, high control precision and simple structure, and can quickly and accurately drive the lifting seat 43 to lift, so as to meet the demand for height adjustment of the welding assembly 45 in the welding process, improve the welding efficiency and quality. The welding assembly 45 is arranged on the lifting seat 43, and the welding assembly 45 is used to weld the first terminal 15 to the first bending section 13, and simultaneously used to weld the second terminal 16 to the second bending section 14.

[0075] With reference to Figure 6 In this embodiment, the welding assembly 45 comprises an adjusting block 451, a clamping block 452 and an electric soldering iron 453. The adjusting block 451 is fixed on the lifting seat 43, and a through adjusting groove 454 is formed in the adjusting block 451. The adjusting groove 454 is in strip shape or arc shape. The surface of the clamping block 452 abuts against the surface of the clamping block 452. A bolt is arranged in the adjusting groove 454, and the bolt is in screw cooperation with the clamping block 452. The electric soldering iron 453 is fixedly connected to the clamping block 452. The bolt can freely slide along the length direction of the adjusting groove 454, so as to drive the clamping block 452 to adjust the angle or position within a certain range. When the position of the electric soldering iron 453 needs to be adjusted, the bolt is loosened, the clamping block 452 is moved to the desired position, and then the bolt is tightened again. Not only does this make the position adjustment of the electric soldering iron 453 simple and convenient, but also ensures the stability of the clamping block 452 after adjustment, and further ensures the position accuracy of the electric soldering iron 453 during work. The adjusting block 451 and the clamping block 452 can flexibly adjust the position and angle of the electric soldering iron 453 according to different welding requirements, improve the versatility and adaptability of the welding device, and ensure the consistency and stability of the welding quality.

[0076] With reference to Figure 6 The lifting seat 43 is further provided with a support 47. The winding mechanism 6 is a winding drum, and the winding drum is rotatably connected to the support 47. The winding drum is used to wind the tin wire. The guide mechanism 7 comprises two guide wheels, and the two guide wheels are rotatably connected to the support 47. The wire feeding mechanism 5 is arranged on the support 47, and the wire feeding mechanism 5 is used to deliver the tin wire to the welding assembly 45.

[0077] With reference to Figure 7 and Figure 5 The wire feeding mechanism 5 comprises a first rotating assembly 51, a second rotating assembly 52, a third driving assembly 53, an adjusting assembly 54 and a linkage assembly. The first rotating assembly 51 comprises a first rotating shaft 511 and a first wire feeding wheel 512, the first rotating shaft 511 extends along the second direction, the first rotating shaft 511 penetrates through the support 47 and is rotationally connected with the support 47, the first wire feeding wheel 512 is sleeved on the first rotating shaft 511 and is fixedly connected with the first rotating shaft 511, and the third driving assembly 53 is used for driving the first rotating shaft 511 to rotate. Specifically, the third driving assembly 53 comprises a driving gear 531, a driven gear 532, a first linkage gear 533 and a second motor 534, the second motor 534 is fixed in the cavity of the support 47, the output shaft of the second motor 534 penetrates through the support 47 and is rotationally connected with the support 47, the driving gear 531 is sleeved on the output shaft of the second motor 534 and is fixedly connected with the output shaft of the second motor 534, the driven gear 532 is rotationally connected with the support 47, the first linkage gear 533 is sleeved on the first rotating shaft 511 and is fixedly connected with the first rotating shaft 511, and the driven gear 532 is located between the driving gear 531 and the first linkage gear 533. The third driving assembly 53 in the gear transmission mode has the advantages of high transmission efficiency, accurate transmission ratio and compact structure, and through the mutual cooperation of multiple gears, the first rotating shaft 511 and the second rotating shaft 521 can be more stably and reliably driven to rotate, thereby driving the first wire feeding wheel 512 and the second wire feeding wheel 522 to rotate, providing power for the transmission of the solder wire, and better controlling the wire feeding speed and the wire feeding amount, thereby ensuring the stable supply of the solder wire in the welding process and improving the welding quality.

[0078] With reference to Figure 7The adjusting assembly 54 comprises a first mounting rod 541, a swing seat 542, a second mounting rod 543, an eccentric wheel 544 and a driving rod 545. The first mounting rod 541 extends along the first direction, and both ends of the first mounting rod 541 are arranged through the support 47 and are rotationally connected with the support 47. The first mounting rod 541 passes through the top end of the swing seat 542, and the swing seat 542 is rotationally connected with the first mounting rod 541. The second rotating assembly 52 comprises a second rotating shaft 521, a second wire feeding wheel 522 and a second linkage gear 523. The second rotating shaft 521 extends along the first direction, one end of the second rotating shaft 521 is arranged through the bottom end of the swing seat 542 and is rotationally connected with the swing seat 542, and the other end of the second rotating shaft 521 extends out of the support 47. An oval avoiding hole 471 is formed in the side wall of the support 47, and the width of the avoiding hole 471 is much larger than the diameter of the second rotating shaft 521. The second wire feeding wheel 522 is sleeved on the end of the second rotating shaft 521 extending out of the support 47, and the second wire feeding wheel 522 is fixedly connected with the second rotating shaft 521. The second linkage gear 523 is sleeved on the second rotating shaft 521 and is fixedly connected with the second rotating shaft 521. The first linkage gear 533 and the second linkage gear 523 are meshed with each other. The second mounting rod 543 extends along the first direction, and both ends of the second mounting rod 543 are arranged through the support 47 and are fixedly connected with the support 47. The eccentric hole 546 is formed in the eccentric position of the eccentric wheel 544, the second mounting rod 543 passes through the eccentric hole 546 of the eccentric wheel 544, the eccentric wheel 544 is rotationally connected with the second mounting rod 543, and the eccentric wheel 544 abuts against the side wall of the bottom end of the swing seat 542. Meanwhile, the driving rod 545 is fixedly arranged on the swing seat 542, and one end of the driving rod 545 away from the swing seat 542 extends out of the support 47. The adjusting assembly 54 drives the swing seat 542 to swing around the first mounting rod 541 through the rotation of the eccentric wheel 544, so that the second rotating shaft 521 drives the second wire feeding wheel 522 to swing, the distance between the first wire feeding wheel 512 and the second wire feeding wheel 522 is changed, and the clamping and releasing of the tin wire are realized. The conveying speed and the wire feeding amount of the tin wire can be accurately controlled, the stable supply of the tin wire in the welding process is ensured, and the welding quality is improved.

[0079] With reference to Figure 6 and Figure 7The guide assembly 46 is further fixed on the clamping block 452, and includes a fixed seat 461 and a guide pipe 462. The fixed seat 461 penetrates through the clamping block 452 and is fixedly connected with the clamping block 452. The guide pipe 462 penetrates through the fixed seat 461 and is fixedly connected with the fixed seat 461. Both ends of the guide pipe 462 are in an open arrangement, and the guide pipe 462 is in an inclined arrangement. The bottom end of the guide pipe 462 faces the electric soldering iron 453. The tin wire wound on the winding drum first passes through two guide wheels. The guide wheels guide and turn the tin wire, so that the tin wire is transmitted according to a predetermined path. Then, the tin wire is transmitted to the wire feeding mechanism 5. In the wire feeding mechanism 5, the third driving assembly 53 drives the first rotating shaft 511 to rotate, and then drives the first wire feeding wheel 512 to rotate. At the same time, the adjusting assembly 54 drives the swing seat 542 to swing around the first mounting rod 541 through the rotation of the eccentric wheel 544, so that the second rotating shaft 521 drives the second wire feeding wheel 522 to swing, and the distance between the first wire feeding wheel 512 and the second wire feeding wheel 522 is changed, so that the clamping and releasing of the tin wire are realized. Under the cooperation of the first wire feeding wheel 512 and the second wire feeding wheel 522, the tin wire is transmitted into the guide pipe 462 of the guide assembly 46. The guide pipe 462 is in an inclined arrangement and the bottom end faces the electric soldering iron 453. After the tin wire is guided by the guide pipe 462, the tin wire is finally transmitted to the electric soldering iron 453 of the welding assembly 45, so as to provide necessary welding material for the welding process. The arrangement of the guide assembly 46 can ensure that the tin wire is accurately transmitted to the electric soldering iron 453, avoid the tin wire from being deviated or wound during the transmission process, ensure the smooth progress of the welding process, and improve the welding quality and efficiency.

[0080] The implementation principle of the above embodiment is as follows: first, the worker places the inductor coil 1 to be welded on the positioning jig 33 of one of the positioning mechanisms 3. The annular positioning cavity 335 in the positioning jig 33 closely fits the inner coil 11, ensuring that the inner coil 11 does not shake during positioning, and the avoidance cavity 336 on the positioning ring 334 provides a suitable accommodation space for the connecting wire, avoiding extrusion or interference of the connecting wire during positioning. The first positioning channel 3373 of the first positioning seat 337 is adapted to the shape of the first bent section 13, and the terminal positioning groove 3391 of the terminal positioning seat 339 is used to position the second connecting terminal 16. Through these structures, the inductor coil 1 is accurately fixed on the positioning jig 33, and the first connecting terminal 15 and the second connecting terminal 16 are accurately positioned at the welding position respectively. When the positioning of the inductor coil 1 in one positioning mechanism 3 is completed, the welding preparation is ready. At this time, the first drive assembly 32 in each positioning mechanism 3 starts to work, the first motor 324 drives the first driving wheel 321 to rotate, and through the transmission of the first belt 323, the first moving seat 31 is driven to move in the second direction, so that the positioning jig 33 on the first moving seat 31 is moved to the lower side of the support seat 22, so that the welding mechanism 4 can operate. At the same time, the welding mechanism 4 starts to work. The second drive assembly 42 drives the second moving seat 41 to move in the first direction to the upper side of the positioning mechanism 3, the lifting drive assembly 44 drives the lifting seat 43 to descend, and the welding assembly 45 is lowered to the appropriate height. The electric iron 453 in the welding assembly 45 is in the best welding position under the adjustment of the adjusting block 451 and the clamping block 452. The adjustment groove 454 on the adjusting block 451 and the bolt cooperate with the clamping block 452, so that the position and angle of the electric iron 453 can be flexibly adjusted to adapt to the welding requirements of inductor coils 1 of different specifications and shapes. During the welding process, the wire winding mechanism 6 continuously winds the tin wire. The tin wire on the winding drum is first guided and turned by two guide wheels, and then transmitted to the wire feeding mechanism 5. The third drive assembly 53 of the wire feeding mechanism 5 drives the first rotating shaft 511 to rotate, and the first wire feeding wheel 512 rotates. At the same time, the adjusting assembly 54 drives the swing seat 542 to swing around the first mounting rod 541 through the rotation of the eccentric wheel 544, so that the second rotating shaft 521 drives the second wire feeding wheel 522 to swing, changes the distance between the first wire feeding wheel 512 and the second wire feeding wheel 522, and realizes the clamping and releasing of the tin wire, accurately controls the transmission speed and wire feeding amount of the tin wire. The tin wire is transmitted to the guide pipe 462 of the guide assembly 46 under the cooperation of the first wire feeding wheel 512 and the second wire feeding wheel 522. The guide pipe 462 is inclined and the bottom end faces the electric iron 453, which ensures that the tin wire can be accurately transmitted to the electric iron 453, providing necessary welding materials for the welding process.Since the welding device is provided with two positioning mechanisms 3, when the inductor coil 1 in one of the positioning mechanisms 3 is being welded, the staff can simultaneously perform the placing and positioning operation of the to-be-welded inductor coil 1 on the other positioning mechanism 3. After the welding of one inductor coil 1 is completed, the welding mechanism 4 can immediately move to the position above the other positioned inductor coil 1 to perform welding, without waiting for the staff to re-place and position the inductor coil 1. This parallel operation mode greatly improves the overall welding efficiency and reduces the production cycle.

[0081] The above are preferred embodiments of the present application, which do not limit the protection scope of the present application, and therefore: any equivalent changes made on the basis of the structure, shape and principle of the present application should be covered within the protection scope of the present application.

Claims

1. A welding process for an inductor coil, characterized by: The method comprises the following steps: Step one: the first terminal (15) is sleeved on the first bending section (13) of the inductor coil (1), and the second terminal (16) is sleeved on the second bending section (14) of the inductor coil (1); Step two: the inductor coil (1) is placed on the positioning jig (33) of the positioning mechanism (3) in the idle state of the welding device, and the inductor coil (1) on the other positioning mechanism (3) is in the welding state at this time; Step three: the welding device is started, and the terminals of the inductor coil (1) which has been positioned are welded with the bending sections of the inductor coil (1); during the welding process, the staff can repeat step one to sleeve the terminals of the inductor coil (1) to be welded on the other idle positioning mechanism (3); The specific steps of starting the welding device in step three are as follows: S1: the first moving seat (31) is driven to move along the horizontal direction by the first driving assembly (32) in the positioning mechanism (3), so that the positioning jig (33) is moved to the lower side of the support seat (22), so that the inductor coil (1) is in the welding position; S2: the second moving seat (41) is driven to move along the horizontal direction to the upper side of the positioning mechanism (3) by the second driving assembly (42) in the welding mechanism (4), so that the welding assembly (45) is aligned with the welding position of the inductor coil (1); S3: the lifting seat (43) is driven to descend by the lifting driving assembly (44), and the welding assembly (45) is driven to descend to an appropriate height, so that the electric iron (453) of the welding assembly (45) contacts the terminals and bending sections of the inductor coil (1); S4: the welding assembly (45) is started to perform welding operation, the first terminal (15) is welded on the first bending section (13), and the second terminal (16) is welded on the second bending section (14), and the welding of the inductor coil (1) is completed; Step four: when one inductor coil (1) is welded, the finished inductor coil (1) is taken off from the corresponding positioning jig (33), and the inductor coil (1) to be welded which has sleeved the terminal in step three is placed on the positioning jig (33), and then steps one to four are repeated, so that the welding and replacement of the inductor coil (1) are simultaneously performed.

2. A process for soldering an inductor coil as defined in claim 1, characterized in that: The inner coil (11) is placed in the annular positioning cavity (335) formed between the inner positioning column (333) and the positioning ring (334); the outer coil (12) of the inductor coil (1) is sleeved on the positioning ring (334), and the inner side wall of the outer coil (12) abuts against the inner side wall of the positioning ring (334); the end portions of the inner coil (11) and the outer coil (12) abut against the upper surface of the bearing block (332), and the connecting wire is placed in the positioning cavity.

3. A process for soldering an inductor coil as defined in claim 2, characterized in that: The positions of the inductor coil (1), the first connecting terminal (15) and the second connecting terminal (16) are adjusted, so that the first bending section (13) of the inductor coil (1) is located in the first positioning channel (3373), the second bending section (14) of the inductor coil (1) is located in the second positioning channel (3381), the bottom end of the first connecting terminal (15) abuts against the top end of the terminal positioning column (3372), and the second connecting terminal (16) is located in the terminal positioning groove (3391).

4. A process for welding an inductor coil as defined in claim 1, characterized in that: The tin wire on the winding mechanism (6) is guided and turned in sequence through two guide wheels; the third driving assembly (53) of the feeding mechanism (5) drives the first rotating shaft (511) to rotate, and drives the first feeding wheel (512) to rotate; the adjusting assembly (54) drives the swing seat (542) to swing around the first mounting rod (541) through the rotation of the eccentric wheel (544), so that the second rotating shaft (521) drives the second feeding wheel (522) to swing, changes the distance between the first feeding wheel (512) and the second feeding wheel (522), realizes the clamping and loosening of the tin wire, and accurately controls the conveying speed and feeding amount of the tin wire; the tin wire is conveyed into the guide pipe (462) of the guide assembly (46) under the cooperation of the first feeding wheel (512) and the second feeding wheel (522); the guide pipe (462) conveys the tin wire to the electric iron (453), the electric iron (453) melts the tin wire, and the welding of the first connecting terminal (15) and the first bending section (13) and the welding of the second connecting terminal (16) and the second bending section (14) are completed.

5. A welding device for use in the welding process according to any one of claims 1-4, characterized in that: The machine base (2), the positioning mechanism (3), the welding mechanism (4), the winding mechanism (6), the guide mechanism (7) and the feeding mechanism (5) are included; the machine base (2) includes a base (21) and a support seat (22), and the support seat (22) is fixed to the upper surface of the base (21); the positioning mechanism (3) is arranged on the base (21) and is used for positioning the inductor coil (1); the welding mechanism (4), the winding mechanism (6), the guide mechanism (7) and the feeding mechanism (5) are arranged on the support seat (22), the welding mechanism (4) is used for welding the connecting terminal to the inductor coil (1), the winding mechanism (6) is used for winding the tin wire and conveying the tin wire to the feeding mechanism (5) through the guide mechanism (7), and the feeding mechanism (5) is used for conveying the tin wire to the welding mechanism (4); The positioning mechanism (3) comprises a first moving seat (31), a first driving assembly (32) and a positioning jig (33); the first moving seat (31) is in sliding cooperation with the base (21), the first driving assembly (32) is arranged on the base (21) and is used for driving the first moving seat (31) to move in the horizontal direction; the positioning jig (33) is fixed on the first moving seat (31) and is used for positioning the inductance coil (1); the positioning jig (33) comprises a bottom plate (331), a bearing block (332), an inner positioning column (333) and a positioning ring (334), the bearing block (332) is fixed on the surface of the bottom plate (331), the inner positioning column (333) and the positioning ring (334) are both fixed on the surface of the bearing block (332), the annular positioning cavity (335) for positioning the inner coil (11) is formed between the inner positioning column (333) and the positioning ring (334), the avoidance cavity (336) for accommodating the connecting wire is arranged on the positioning ring (334); the upper surface of the bottom plate (331) is further provided with a first positioning seat (337), a second positioning seat (338) and a terminal positioning seat (339), the first positioning seat (337) is provided with the first positioning channel (3373), the second positioning seat (338) is provided with the second positioning channel (3381), and the terminal positioning seat (339) is provided with the terminal positioning groove (3391).

6. The welding device of claim 5, wherein: The welding mechanism (4) comprises a second moving seat (41), a second driving assembly (42), a lifting seat (43), a lifting driving assembly (44) and a welding assembly (45); the second moving seat (41) is in sliding cooperation with the cross beam (221), the second driving assembly (42) is arranged on the cross beam (221) and is used for driving the second moving seat (41) to move in the horizontal direction; the lifting seat (43) is in sliding cooperation with the second moving seat (41), the lifting driving assembly (44) is arranged on the second moving seat (41) and is used for driving the lifting seat (43) to lift and fall; the welding assembly (45) is arranged on the lifting seat (43), and the welding assembly (45) is used for welding the first connecting terminal (15) to the first bending section (13) and simultaneously used for welding the second connecting terminal (16) to the second bending section (14).

7. The welding device of claim 6, wherein: The wire feeding mechanism (5) comprises a first rotating assembly (51), a second rotating assembly (52), a third driving assembly (53), an adjusting assembly (54) and a linkage assembly; the first rotating assembly (51) comprises a first rotating shaft (511) and a first wire feeding wheel (512), the first rotating shaft (511) passes through the support (47) and is rotationally connected with the support (47), and the first wire feeding wheel (512) is sleeved on the first rotating shaft (511) and is fixedly connected with the first rotating shaft (511); the second rotating assembly (52) comprises a second rotating shaft (521), a second wire feeding wheel (522) and a second linkage gear (523), the second rotating shaft (521) extends in the horizontal direction, one end of the second rotating shaft (521) is arranged in the bottom end of the swing seat (542) and is rotationally connected with the swing seat (542), the other end of the second rotating shaft (521) extends out of the support (47), the second wire feeding wheel (522) is sleeved on the end of the second rotating shaft (521) extending out of the support (47), and the second linkage gear (523) is sleeved on the second rotating shaft (521) and is fixedly connected with the second rotating shaft (521); the third driving assembly (53) is used for driving the first rotating shaft (511) to rotate; the adjusting assembly (54) comprises a first mounting rod (541), a swing seat (542), a second mounting rod (543), an eccentric wheel (544) and a driving rod (545), both ends of the first mounting rod (541) pass through the support (47) and are rotationally connected with the support (47), the swing seat (542) is rotationally connected with the first mounting rod (541), both ends of the second mounting rod (543) pass through the support (47) and are fixedly connected with the support (47), an eccentric hole (546) is arranged at the eccentric position of the eccentric wheel (544), the second mounting rod (543) passes through the eccentric hole (546) of the eccentric wheel (544), the eccentric wheel (544) is rotationally connected with the second mounting rod (543), the side wall of the eccentric wheel (544) abuts against the side wall of the swing seat (542), and one end of the driving rod (545) fixedly arranged on the swing seat (542) and away from the swing seat (542) extends out of the support (47).

8. The welding device of claim 5, wherein: The guiding assembly (46) comprises a fixed seat (461) and a guiding pipe (462), the fixed seat (461) passes through the clamping block (452) and is fixedly connected with the clamping block (452), the guiding pipe (462) passes through the fixed seat (461) and is fixedly connected with the fixed seat (461), both ends of the guiding pipe (462) are in an open arrangement, and the guiding pipe (462) is arranged in an inclined manner, and the bottom end of the guiding pipe (462) faces the electric soldering iron (453) and is used for accurately conveying the tin wire to the electric soldering iron (453).

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