Compressor heater terminal welding method

Abstract

The invention discloses a compressor heater terminal welding method, and belongs to the technical field of vehicle-mounted heat management. The key points of the technical scheme are as follows: any terminal is selected as a reference terminal, distance measurement is carried out on other terminals, the surface difference between the other terminals and the reference terminal is calculated, and the surface difference is compensated; preheating the terminal and the thick film heating plate to enable the temperature of the terminal to be welded and the temperature of the thick film heating plate to be consistent; the welding wire is conveyed to the welding area between the terminal and the thick film heating plate, the welding wire is melted through the temperature of the terminal and the temperature of the thick film heating plate, welding of the terminal and the thick film heating plate is completed, and efficient and high-quality welding operation is achieved through the welding scheme. Before welding, a uniform and flat working plane is provided for subsequent welding by accurately compensating the surface difference of the terminals, so that the problems of non-uniform welding, non-uniform solder distribution and the like caused by inconsistent heights of the terminals are effectively avoided. And the welding efficiency is improved through the preheating treatment link, and the adverse effect on the material performance caused by too long heating time is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle thermal management, and more particularly to a method for welding compressor heater terminals. Background Art

[0002] The welding of compressor heater terminals is a key step in electrical connection. The mainstream welding methods for thick film terminals are reflow soldering, laser soldering, and soldering iron.

[0003] Reflow soldering places high demands on the mating surface tolerances of terminals and thick film, and requires a series of process controls. Temperature zone control is complex, and due to batch monitoring, precise one-to-one control of soldering temperatures is impossible, which can easily lead to voiding issues. Stencil defects can also easily lead to poor solder printing. Furthermore, the solder joints are large and thin. During the reflow process, the vibration caused by tooling or track during the transportation of solder paste from the reflow zone to the cooling zone can easily cause cracks in the solder joints.

[0004] Laser welding has strict requirements on the matching of thick films and surface differences between terminals, and has a low fault tolerance. Due to the characteristics of the terminal material, the laser's high reflectivity makes it difficult to control the welding power, resulting in unstable welding strength consistency.

[0005] Soldering with a soldering iron may result in thermal shock due to incomplete preheating, which may easily cause the thick silver layer to fall off and the glass of the dielectric layer to break, leading to insulation failure.

[0006] Therefore, it is necessary to propose a new solution to solve the above problems. Summary of the Invention

[0007] In view of the shortcomings of the prior art, the present invention aims to provide a compressor heater terminal welding method.

[0008] The above technical objectives of the present invention are achieved through the following technical solutions: A compressor heater terminal welding method comprises the following steps:

[0009] S1. Select any terminal as the reference terminal, measure the distance of the remaining terminals, calculate the surface difference between them and the reference terminal, and compensate for the surface difference;

[0010] S2. Preheating the terminal and the thick film heating plate to make the terminal to be welded and the thick film heating plate have the same temperature;

[0011] S3, delivering the welding wire to the welding area between the terminal and the thick film heating plate, continuing to heat the terminal and the thick film heating plate, utilizing the temperature of the terminal and the thick film heating plate to melt the welding wire, and completing the welding of the terminal and the thick film heating plate;

[0012] In step S3 , the welding wire has no direct contact with the terminal and the thick film heating plate.

[0013] The present invention is further configured as follows: in step S3, the temperature of the terminal and the thick film heating plate is monitored in real time, and temperature compensation is performed so that the temperature difference between the terminal and the thick film heating plate is less than a set threshold.

[0014] The present invention is further configured as follows: in step S1, when the surface difference between the terminal and the reference terminal is lower than a set threshold, the height of the terminal is adjusted, and the lower surface of the terminal with the surface difference is adjusted to the same plane as the reference terminal; when the surface difference between the terminal and the reference terminal is higher than the set threshold, the terminal is discarded.

[0015] The present invention is further configured such that: in step S3, a servo motor is used in conjunction with meshing transmission of gears to perform segmented feeding, and the feeding length of each segment is the same.

[0016] The present invention is further configured as follows: in step S2, after preheating is completed, the thick film heating plate is lifted upward. After being lifted into place, the distance between the upper surface of the thick film heating plate welding position and the lower surface of the terminal welding position is 1.2 times to 3 times the diameter of the welding wire.

[0017] The present invention is further configured as follows: in step S3, whether the welding wire is in contact with the terminal or the thick film heating plate is detected before welding. When it is detected that the welding wire is in contact with either the terminal or the thick film heating plate, welding is terminated. If the welding wire has melted, the terminal or thick film heating plate in contact with the welding wire is removed and scrapped or reworked.

[0018] The present invention is further configured to: use an electrical measuring module and / or a pressure sensing module to detect the contact between the welding wire and the terminal or thick film heating plate; when the electrical measuring module and / or the pressure sensing module detects that the welding wire is in contact with the terminal or the thick film heating plate, heating is stopped and the terminal or the thick film heating plate is removed.

[0019] The present invention is further configured to: use an electrical measuring module and / or a pressure sensing module to detect the contact between the welding wire and the terminal or thick film heating plate; when the electrical measuring module and / or the pressure sensing module detects that the welding wire is in contact with the terminal or the thick film heating plate, heating is stopped and the terminal or the thick film heating plate is removed.

[0020] The present invention is further configured to: start the electrical measurement module and the pressure sensing module before the welding wire is delivered to a certain position; after the electrical measurement module and the pressure sensing module are normally started, start supplying the terminal and the welding wire.

[0021] The present invention is further configured as follows: in the steps S2 and S3, the terminals, thick film heating plate and welding positions are monitored in real time, and when the temperature is higher than the set temperature, the heating power is reduced.

[0022] In summary, the present invention has the following beneficial effects:

[0023] This welding solution achieves efficient, high-quality welding operations. Precise compensation for terminal face differences before welding provides a uniform and flat working surface for subsequent welding, effectively avoiding issues such as uneven welding and uneven solder distribution caused by inconsistent terminal heights. The preheat treatment improves welding efficiency, reduces the adverse effects of prolonged heating on material properties, and promotes atomic diffusion within the material, enhancing the bonding strength of the weld joint.

[0024] During the soldering process, a real-time temperature monitoring and compensation system ensures that the temperature of the soldering area remains within the optimal range, ensuring that the solder fully melts and bonds well with the terminals and thick-film heating plate, significantly improving solder quality. The solder delivery mechanism, through the precise coordination of a servo motor and gears, accurately delivers the correct amount of solder for each weld, avoiding excessive or insufficient solder. The fixture that secures the product to the fixture maintains product stability during the soldering process, preventing solder leakage and short circuits caused by vibration or displacement, further improving solder reliability and stability.

[0025] The heating and monitoring module ensures stable electrical performance and temperature during the heating process. The pressure detection module also effectively prevents damage to the product caused by excessive pressure. An infrared camera monitors the temperature of the welding area in real time, providing a key basis for temperature control and enabling more precise temperature management throughout the welding process. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic structural diagram of the equipment used in the compressor heater terminal welding method of the present invention;

[0027] Figure 2 Schematic diagram of the working system of the equipment used in the compressor heater terminal welding method of the present invention.

[0028] In the figure: 1, lower floating mechanism; 101, lower heating module; 102, thick film heating plate; 103, pressure sensing module; 104, lower temperature detection module;

[0029] 2. Upper floating mechanism; 201. Upper heating module; 202. Internal electrical measurement module; 203. Terminals; 204. Pins; 205. Upper temperature detection module;

[0030] 3. Solder delivery channel;

[0031] 4. Infrared temperature detection camera. DETAILED DESCRIPTION

[0032] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention; it is obvious that the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0033] Example:

[0034] like Figure 1 and Figure 2 As shown, the compressor heater terminal welding method includes the following steps:

[0035] S1. Select any terminal 203 as a reference terminal, measure the distance of the remaining terminals 203, calculate the surface difference between them and the reference terminal, and compensate for the surface difference;

[0036] S2, preheating the terminal 203 and the thick film heating plate 102 so that the terminal 203 to be welded and the thick film heating plate 102 have the same temperature;

[0037] S3. Transport the welding wire to the welding area between the terminal 203 and the thick film heating plate 102, continue to heat the terminal 203 and the thick film heating plate 102, use the temperature of the terminal 203 and the thick film heating plate 102 to melt the welding wire, and complete the welding of the terminal 203 and the thick film heating plate 102.

[0038] In step S1, when the surface difference between the terminal 203 and the reference terminal is lower than the set threshold, the height of the terminal 203 is adjusted, and the lower surface of the terminal 203 with the surface difference is adjusted to the same plane as the reference terminal; when the surface difference between the terminal 203 and the reference terminal is higher than the set threshold, the terminal 203 is discarded.

[0039] In step S2, after preheating is completed, the thick film heating plate 102 is lifted upward. After being lifted into place, the distance between the upper surface of the welding position of the thick film heating plate 102 and the lower surface of the welding position of the terminal 203 is 1.2 times to 3 times the diameter of the welding wire.

[0040] In step S3, whether the welding wire is in contact with the terminal 203 or the thick film heating plate 102 is detected before welding. When it is detected that the welding wire is in contact with either the terminal 203 or the thick film heating plate 102, welding is terminated. If the welding wire has melted, the terminal 203 or the thick film heating plate 102 in contact with the welding wire is removed and scrapped or reworked.

[0041] This compressor heater terminal welding method uses an electrical measurement module 202 and / or a pressure sensing module 103 to detect contact between the welding wire and the terminal 203 or the thick-film heating plate 102. When the electrical measurement module 202 and / or the pressure sensing module detect contact between the welding wire and the terminal 203 or the thick-film heating plate 102, heating is stopped and the terminal 203 or the thick-film heating plate 102 is removed. Before the welding wire is delivered to the desired position, the electrical measurement module 202 and the pressure sensing module 103 are activated. After the electrical measurement module 202 and the pressure sensing module 103 have activated normally, the supply of the terminal 203 and welding wire begins.

[0042] In step S2 and step S3, the terminals, thick film heating plate and welding position are monitored in real time, and when the temperature is higher than the set temperature, the heating power is reduced.

[0043] like Figure 1As shown, in at least one embodiment, the equipment used in the method includes an upper floating mechanism 2 and a lower floating mechanism 1, the upper floating mechanism 2 is arranged above the lower floating mechanism 1, and the solder delivery channel 3 is arranged between the lower floating mechanism 1 and the upper floating mechanism 2. By adjusting the upper floating mechanism 2, the face difference compensation is performed on the terminal 203 whose face difference is less than the set deviation, ensuring that all terminals 203 are in the same height plane before welding, providing good conditions for subsequent welding operations and ensuring the consistency of welding quality. The bottom end of the upper floating mechanism 2 is provided with an upper heating module 201, which provides a stable heat source for the terminal 203 during the welding process, ensuring that the terminal 203 and the solder are fully melted and fused, and the distance measuring instrument inside the upper heating module 201 checks the face difference of the terminal 203 After data processing, the upper floating mechanism 2 adjusts the spacing according to the face difference data. The upper heating module 201 is provided with an internal electric measuring module 202. The terminal 203 is provided at the bottom of the upper heating module 201. The bottom of the terminal 203 has a pin 204. The side of the internal electric measuring module 202 is provided with an upper temperature detection module 205, which can timely and accurately detect the temperature changes of the upper heating module 201 and its surrounding areas. When the temperature is higher than the set value, the feedback information can be used to reduce the temperature of the upper heating module 201 to prevent damage to the terminal 203 and the welding part due to excessive temperature, thereby ensuring the safety and stability of the welding process. The lower heating module 101 is provided in the lower floating mechanism 1. After the upper heating module 201 reaches the working position, it will contact the lower heating module 10 1 issues a preheating instruction. After the instruction is issued, the upper heating module 201 and the lower heating module 101 coordinate actions according to the program instructions to ensure real-time linkage between the upper and lower temperature zones, ensure that the temperatures of the two are uniform, achieve precise control of the temperature of the entire welding area, ensure that the welding process is carried out under appropriate temperature conditions, improve welding quality and efficiency, and the thick film heating plate 102 is placed in the fixture of the lower floating mechanism 1, which is conducive to achieving effective heating of the thick film heating plate 102 during the welding process, so that it can quickly reach the appropriate welding temperature and work in conjunction with the upper heating module 201 to ensure temperature uniformity of the entire welding area. The bottom end of the thick film heating plate 102 is fixed with a pressure sensing module 103, and one end of the lower floating mechanism 1 is provided with a lower temperature detection module 104. The temperature of the lower heating module 101 is monitored and fed back in real time. In cooperation with the upper temperature detection module 205, after the upper and lower temperature sensing modules detect that the upper heating module 201 and the lower heating module 101 are preheated to the required temperature, the internal electric measurement module 202 and the pressure sensing module 103 are started to start anti-contact protection. After the internal electric measurement module 202 and the pressure sensing module 103 are started, the terminals 203 and solder are supplied. After the solder is in place signal arrives, the upper temperature detection module 205 sends an energy replenishment signal to the upper heating module 201 to ensure normal temperature fluctuations. After monitoring is in place, welding is started. When the internal electric measurement module 202 or the pressure sensing module 103 detects a signal, it proves that the welding wire is in contact with the terminal 203 or the thick film heating plate 102.At this point, the control module shuts down the welding equipment, stopping at least the upper heating module 201, the lower heating module 101, and the lower floating mechanism 1. The upper floating mechanism 2 then removes the terminal 203 and disposes it as scrap. An infrared temperature detection camera 4 is installed on the exterior of the lower floating mechanism 1 and the upper floating mechanism 2 in the same direction. This camera monitors temperature changes in the welding area in real time, providing comprehensive and accurate temperature information, facilitating timely adjustment of welding parameters and ensuring stable and consistent welding quality.

[0044] like Figure 1 and Figure 2 In step 1, the surface difference of the terminal 203 is compensated by adjusting the height of the upper floating mechanism 2. By accurately measuring and screening the surface difference of the terminal 203, it is ensured that the multiple terminals 203 are in the best welding position, which can ensure the height consistency of the terminals 203 entering the welding process, lay the foundation for subsequent high-quality welding, reduce welding defects caused by height differences of the terminals 203, such as cold solder joints and leaking solder, and improve the accuracy and reliability of welding. The lower surfaces of the multiple terminals 203 are at the same height, which helps to achieve uniform heat transfer and solder distribution during the welding process, thereby ensuring the flatness and smoothness of the welding surface, improving the welding appearance quality, improving the welding consistency, and reducing the occurrence of welding defects.

[0045] like Figure 1 and Figure 2 As shown, the equipment used in step 2 includes an upper temperature detection module 205, a lower temperature detection module 104 and an infrared temperature detection camera 4 for real-time monitoring of the temperature of the welding position. When the temperature is higher than the set temperature, the temperature of the upper heating module 201 and / or the lower heating module 101 is reduced to prevent overheating during the welding process from causing excessive growth of the solder joint alloy layer and resulting in a decrease in the strength of the solder joint. The preheating treatment can enable the terminal 203 and the thick film heating plate 102 to reach a certain temperature in advance, reduce the heating time required for formal welding, speed up the welding process, improve the overall production efficiency, and prevent Because the temperature difference between the solder and the terminal 203 or the thick film heating plate 102 is too large, the heating time of the terminal 203 or the thick film heating plate 102 is too long. After the preheating is completed, the thick film heating plate 102 is lifted upward by the lower floating mechanism 1. After being lifted into place, the distance between the upper surface of the welding position of the thick film heating plate 102 and the lower surface of the welding position of the terminal 203 is 1.2 times to 3 times the diameter of the welding wire, which enhances the bonding force of the welding part, improves the strength and stability of the welding joint, and reduces the risk of loosening or breaking of the welding joint during use, thereby ensuring welding efficiency and welding quality.

[0046] like Figure 1 and Figure 2As shown, during the welding process, the soldering piece of the terminal 203 and the thick film of the thick film heating plate 102 are 100% monitored in real time and temperature compensation is performed. Solder is applied after the welding temperature is reached. Before the welding temperature is reached, solder is not applied to prevent cold welding. Real-time temperature monitoring and compensation can ensure that the temperature during the welding process is always within the appropriate range, avoiding problems such as poor solder flow, insufficient welding or overheating damage caused by excessively high or low temperature, thereby ensuring the stability and consistency of welding quality.

[0047] like Figure 1 and Figure 2 As shown, during the welding process, a servo motor is used in conjunction with the meshing transmission of the gears to perform segmented feeding. The feeding length of each segment is the same, and the solder in the solder delivery channel 3 is accurately transferred. The corresponding rate is controlled, and segmented feeding is used to improve the accuracy of the solder application amount. High-precision and stable solder delivery can be achieved, ensuring the accuracy and consistency of the amount of solder used in each welding, which helps to control welding costs and reduce welding defects caused by too much or too little solder.

[0048] like Figure 1 and Figure 2 As shown, during the welding process, the product and the jig remain fixed, and the welding assembly extends the solder into the gap between the terminal 203 and the thick film heating plate 102. The terminal 203 and the thick film heating plate 102 are not transported or vibrated during the welding process, and the welding assembly does not contact the solder joint, ensuring that the tin liquid does not crack due to vibration when solidifying, reducing the problems of welding position deviation and uneven solder distribution caused by product movement during the welding process, improving the accuracy and repeatability of welding, and helping to improve the product yield.

[0049] like Figure 1 and Figure 2 As shown, during the welding process, the terminal 203 and the thick film of the thick film heating plate 102 are preheated to the solder melting point at the same time, which enables the two to better interact with the solder during welding to form a firm welding joint, improve the reliability and durability of welding, and solve the problem of thermal shock during welding. After the welding is completed, the lower floating mechanism 1 moves at a variable speed according to the program, and the product is placed in the jig. The upper heating module 201 and the lower heating module 101 stop heating to complete the corresponding welding.

[0050] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiment. All technical solutions based on the concept of the present invention are within the scope of protection of the present invention. It should be noted that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should also be considered within the scope of protection of the present invention.

[0051] Finally, it should be noted that in the description of the present invention, it should be noted that the terms "vertical", "up", "down", "horizontal", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limitations on the present invention.

[0052] In the description of the present invention, it should also be noted that, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to internal connections between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

Claims

1. A method for welding compressor heater terminals, characterized in that: The following steps are involved: S1, selecting any terminal (203) as a reference terminal, measuring the distance of the remaining terminals (203), calculating the surface difference between the remaining terminals (203) and the reference terminal, and compensating for the surface difference; S2, preheating the terminal (203) and the thick film heating plate (102) to make the terminal (203) to be welded and the thick film heating plate (102) have the same temperature; S3, conveying the welding wire to the welding area between the terminal (203) and the thick film heating plate (102), continuing to heat the terminal (203) and the thick film heating plate (102), utilizing the temperature of the terminal (203) and the thick film heating plate (102) to melt the welding wire, and completing the welding of the terminal (203) and the thick film heating plate (102); In step S3, the welding wire has no direct contact with the terminal (203) and the thick film heating plate (102).

2. The compressor heater terminal welding method according to claim 1, characterized in that: In step S3, the temperature of the terminal (203) and the thick film heating plate (102) is monitored in real time, and temperature compensation is performed so that the temperature difference between the terminal (203) and the thick film heating plate (102) is less than a set threshold.

3. The compressor heater terminal welding method according to claim 1, characterized in that: In step S1, when the face difference between the terminal (203) and the reference terminal is lower than a set threshold, the height of the terminal (203) is adjusted, and the lower surface of the terminal (203) with the face difference is adjusted to the same plane as the reference terminal; when the face difference between the terminal (203) and the reference terminal is higher than a set threshold, the terminal (203) is removed.

4. The compressor heater terminal welding method according to claim 1, characterized in that: In step S3, a servo motor is used in conjunction with gear meshing transmission to perform segmented feeding, and the feeding length of each segment is the same.

5. The compressor heater terminal welding method according to claim 1, characterized in that: In step S2, after preheating is completed, the thick film heating plate (102) is lifted upward. After being lifted into place, the distance between the upper surface of the welding position of the thick film heating plate (102) and the lower surface of the welding position of the terminal (203) is 1.2 times to 3 times the diameter of the welding wire.

6. The compressor heater terminal welding method according to claim 1, characterized in that: In step S3, whether the welding wire is in contact with the terminal (203) or the thick film heating plate (102) is detected during welding. When it is detected that the welding wire is in contact with either the terminal (203) or the thick film heating plate (102), welding is terminated. If the welding wire has melted, the terminal (203) or the thick film heating plate (102) in contact with the welding wire is removed and scrapped or reworked.

7. The compressor heater terminal welding method according to claim 1, characterized in that: An electric measuring module (202) and / or a pressure sensing module (103) is used to detect the contact between the welding wire and the terminal (203) or the thick film heating plate (102); when the electric measuring module (202) and / or the pressure sensing module detects that the welding wire is in contact with the terminal (203) or the thick film heating plate (102), heating is stopped and the terminal (203) or the thick film heating plate (102) is removed.

8. The compressor heater terminal welding method according to claim 7, characterized in that: The method further includes starting the electric measuring module (202) and the pressure sensing module (103) before the welding wire is delivered to a certain position, and starting to supply the terminal (203) and the welding wire after the electric measuring module (202) and the pressure sensing module (103) are normally started.

9. The compressor heater terminal welding method according to claim 1, characterized in that: The steps S2 and S3 include real-time monitoring of the terminal (203), the thick film heating plate (102) and the welding position, and reducing the heating power when the temperature is higher than the set temperature.

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