Warning lamp and preparation method thereof

Abstract

The invention discloses a warning lamp and a preparation method thereof, and relates to the technical field of electrical equipment.The preparation method of the warning lamp comprises the steps that a welding head of an ultrasonic welding device is controlled to move to make contact with a second shell; a first welding parameter is obtained, and the welding head is regulated and controlled to act based on the first welding parameter; a monitoring unit is controlled to obtain a machining signal in real time, and the melting state of the welding structure is confirmed based on the machining signal; and under the condition that the welding structure reaches the complete melting state, a second welding parameter is obtained, and the welding head is regulated and controlled to act based on the second welding parameter. According to the technical scheme, sufficient welding machining of the warning lamp shell is achieved, and the production qualification rate and reliability of the warning lamp are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical equipment, and in particular to a warning lamp and a preparation method thereof. Background Art

[0002] In related technologies, warning lights can usually be processed using ultrasonic welding. High-frequency vibration is used to make the protrusions between the upper shell and the lower shell rub against each other, causing the protrusions to melt to form a connecting layer connecting the upper shell and the lower shell, thereby achieving sealed production and assembly of the warning light.

[0003] However, most existing warning lights are produced using relatively fixed welding processing procedures, which leads to inconsistent welding effects of warning light shells made of different materials. It is easy for some warning light shells to be insufficiently welded, affecting the welding and assembly effect of the warning lights, resulting in poor sealing performance and anti-drop and anti-disassembly performance of some warning lights, and reducing the assembly and production reliability of the warning lights. Summary of the Invention

[0004] The main purpose of the present invention is to provide a warning light and a preparation method thereof, aiming to achieve sufficient welding processing of the warning light housing and improve the production qualification rate and reliability of the warning light.

[0005] To achieve the above objectives, the present invention provides a warning light comprising a first housing, a second housing, and a circuit assembly. The circuit assembly is disposed within the first housing. The second housing is stacked with the first housing and covers the first housing. A welding structure is provided around the edge of the surface of the second housing facing the first housing. The welding structure is configured to melt during ultrasonic welding to form a connecting layer connecting the first and second housings. A method for manufacturing the warning light comprises:

[0006] Controlling the welding head of the ultrasonic welding device to move to contact the second shell;

[0007] Acquiring a first welding parameter, and regulating the welding head movement based on the first welding parameter;

[0008] The control monitoring unit acquires the processing signal in real time and confirms the melting state of the welding structure based on the processing signal;

[0009] When the weld structure reaches a completely molten state, a second welding parameter is acquired, and the welding head movement is regulated based on the second welding parameter.

[0010] In one embodiment, the monitoring unit includes a pressure sensor, the processing signal includes a pressure signal, the control monitoring unit acquires the processing signal in real time, and the step of confirming the molten state of the weld structure based on the processing signal includes:

[0011] Controlling the pressure sensor to obtain the pressure signal of the welding head in real time, and comparing the pressure signal with the set pressure value;

[0012] When the pressure signal is greater than or equal to the set pressure value, it is determined that the welding structure is in a completely molten state.

[0013] In one embodiment, the monitoring unit includes a temperature sensor, the processing signal includes a temperature signal, the control monitoring unit acquires the processing signal in real time, and the step of confirming the melting state of the weld structure based on the processing signal includes:

[0014] Controlling a temperature sensor to obtain a temperature signal of the welding structure in real time, and comparing the temperature signal with a melting temperature value;

[0015] When the temperature signal is greater than or equal to the melting temperature value, it is determined that the welding structure is in a completely molten state.

[0016] In one embodiment, the monitoring unit includes an acoustic signal detection device, the processing signal includes an acoustic reflection signal, the control monitoring unit acquires the processing signal in real time, and the step of confirming the melting state of the weld structure based on the processing signal includes:

[0017] Controlling the acoustic signal detection device to obtain in real time the acoustic reflection signal when the welding structure is melted;

[0018] When the acoustic reflection signal meets the melting acoustic wave parameters, it is determined that the welding structure is in a completely molten state.

[0019] In one embodiment, the monitoring unit includes a distance measuring device, the distance measuring device is used to measure the total height of the first shell and the second shell in the first direction, and the processing signal includes a height size signal;

[0020] The control monitoring unit acquires the processing signal in real time, and the step of confirming the melting state of the welding structure based on the processing signal includes:

[0021] Controlling the distance measuring device to obtain the height dimension signal of the warning light in real time;

[0022] When the height signal is less than or equal to the set height value, it is determined that the welding structure is in a completely molten state.

[0023] In one embodiment, the first welding parameter includes at least one of welding power, welding pressure, and welding amplitude;

[0024] And / or, the second welding parameter includes at least one of welding power, welding pressure, and welding amplitude.

[0025] In one embodiment, before the welding structure is melted, the longitudinal cross-section of the welding structure is an inverted triangle, and the angle of the end of the welding structure facing the first shell is defined as α, 60°≤α≤90°; the height of the welding structure along the first direction is defined as H, 0.2mm≤H≤0.6mm.

[0026] In one embodiment, after the step of obtaining a second welding parameter and regulating the action of the welding head based on the second welding parameter when the welding structure reaches a completely molten state, the method further includes:

[0027] First time information is acquired in real time, and when the first time information satisfies a set welding time, the welding head is controlled to stop vibrating.

[0028] In one embodiment, after the step of obtaining the first time information and controlling the welding head to stop vibrating when the first time information satisfies the set welding time, the method further includes:

[0029] Acquiring a pressure holding parameter, and controlling the welding head to press down the second shell based on the pressure holding parameter;

[0030] The second time information is acquired in real time, and when the second time information satisfies the set pressure holding time, the welding head is controlled to move away from the second shell.

[0031] The present invention further provides a warning light, which is manufactured using the above-mentioned method for manufacturing a warning light.

[0032] The technical solution of the present application can effectively achieve segmented amplitude control during the preparation process of the warning light by real-time monitoring of the ultrasonic welding process. In the initial stage of welding, the surface oxide layer of the welding structure of the second shell can be quickly destroyed under the action of a high amplitude, so that the welding structure can quickly melt and flow to fill the gap between the first shell and the second shell; then, the processing signal is obtained by the monitoring unit, and the pressure of the welding head, the temperature of the welding structure, the acoustic reflection signal, or the thickness of the warning light during the processing process can be monitored, and the melting state of the welding structure can be analyzed and determined from the processing signal; and then, when it is confirmed that the welding structure is in a completely molten state, the welding parameters of the ultrasonic welding device can be adjusted to a certain extent, so that the welding head can be adjusted to a lower amplitude for processing in the middle and late stages of welding, which is conducive to avoiding the overflow of molten material under the action of a high amplitude, effectively preventing insufficient welding between the first shell and the second shell, so that the molten material can fully flow and fill the welding interface between the first shell and the second shell, and at the same time, it can avoid residual stress caused by excessive cooling of the welding material, and prevent over-welding or flash. Therefore, through the responsive segmented welding process design, the ultrasonic welding device can better adapt to the assembly and preparation of warning lights with various shell materials, avoid the problems of insufficient welding or excessive melting of warning lights, and significantly improve the assembly reliability and durability of warning lights. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying any creative work.

[0034] Figure 1 A flow chart of a first embodiment of a method for preparing a warning light provided by the present invention;

[0035] Figure 2 A flow chart of a second embodiment of a method for preparing a warning light provided by the present invention;

[0036] Figure 3 A flowchart of a third embodiment of a method for preparing a warning light provided by the present invention;

[0037] Figure 4 A flowchart of a fourth embodiment of a method for preparing a warning light provided by the present invention;

[0038] Figure 5 A flowchart of a fifth embodiment of a method for preparing a warning light provided by the present invention;

[0039] Figure 6A flowchart of a sixth embodiment of a method for preparing a warning light provided by the present invention;

[0040] Figure 7 A flow chart of a seventh embodiment of a method for preparing a warning light provided by the present invention;

[0041] Figure 8 A schematic diagram of a welding head moving toward a warning light to be processed according to an embodiment of a method for manufacturing a warning light provided by the present invention;

[0042] Figure 9 A schematic diagram of a welding head performing welding processing on a warning light according to an embodiment of a method for manufacturing a warning light provided by the present invention;

[0043] Figure 10 A schematic structural diagram of an embodiment of a warning light provided by the present invention;

[0044] Figure 11 for Figure 10 A cross-sectional view of an embodiment of a warning light;

[0045] Figure 12 for Figure 11 A partial enlarged view of point A in the middle;

[0046] Figure 13 This is a partial cross-sectional view of the first shell and the second shell of an embodiment of the warning light provided by the present invention before welding.

[0047] Description of Figure Numbers:

[0048] 100. Warning light; 10. First shell; 30. Second shell; 31. Welding structure; 33. Connecting layer; 200. Welding head.

[0049] The purpose, features and advantages of the present invention will be further described with reference to the accompanying drawings and in conjunction with the embodiments. DETAILED DESCRIPTION

[0050] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0051] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0052] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or suggesting their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of such features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or solutions that satisfy both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0053] In related technologies, warning lights are typically processed using ultrasonic welding. High-frequency vibrations cause the protrusions between the upper and lower shells to rub against each other, melting the protrusions to form a connecting layer that connects the upper and lower shells, achieving a sealed assembly. However, existing warning lights are mostly produced using a relatively fixed welding process, resulting in inconsistent welding results for warning light shells made of different materials. This can easily lead to inadequate welding of some warning light shells, affecting the welding and assembly of the warning lights. This can lead to poor sealing performance and resistance to drop and disassembly, reducing the reliability of the warning light assembly.

[0054] It is understandable that during the ultrasonic welding process, a higher amplitude and other welding parameters are first used to control the welding head, so that the energy of the welding head acting on the shell is greater, and the welding structure between the shells is melted quickly. After a fixed time, the welding parameters such as lower amplitude are adjusted to control the welding head, so that the molten material can fully flow and fill the contact surface between the shells. That is, the current warning light welding process mostly includes a first welding stage with high amplitude and a second welding stage with low amplitude, and the duration of the first welding stage and the duration of the second welding stage are both fixed. However, the melting points of different shell materials have certain differences. Using a fixed process time for processing can easily lead to insufficient melting of the welding structure between some shells, resulting in poor assembly sealing performance and anti-drop and anti-disassembly performance between the shells, affecting the production qualification rate of warning lights. In response to the above problems, the present invention proposes a method for preparing a warning light.

[0055] See also Figure 1In one embodiment of the present invention, a warning light 100 includes a first housing 10, a second housing 30, and a circuit assembly. The circuit assembly is disposed within the first housing 10. The second housing 30 is stacked with the first housing 10 and covers the first housing 10. A welding structure 31 is provided around the edge of the surface of the second housing 30 facing the first housing 10. The welding structure 31 is configured to melt during ultrasonic welding to form a connecting layer 33 connecting the first housing 10 and the second housing 30. A method for manufacturing the warning light includes:

[0056] Step S10, controlling the welding head 200 of the ultrasonic welding device to move to contact the second housing 30;

[0057] Step S20, obtaining a first welding parameter, and regulating the movement of the welding head 200 based on the first welding parameter;

[0058] Step S30, the control monitoring unit acquires the processing signal in real time, and confirms the melting state of the welding structure 31 based on the processing signal;

[0059] Step S40 , when the welding structure 31 reaches a completely molten state, obtain a second welding parameter, and regulate the operation of the welding head 200 based on the second welding parameter.

[0060] The welding head 200 of the ultrasonic welding device refers to a metal component capable of transmitting high-frequency mechanical vibrations, and the shape of its end portion can be adapted to the outer surface contour of the second shell 30, for example, a flat or curved structure. The first welding parameter can refer to a combination of process parameters used to quickly induce melting in the initial stage, and the monitoring unit can refer to a sensor device integrated into the welding equipment, such as a pressure sensor or an infrared temperature measurement module embedded in the welding head 200. Confirmation of the melting state refers to real-time comparison of the sensor signal with a preset threshold, for example, when the pressure signal drops to a certain value or the temperature reaches a certain value, it is determined to be completely melted. The second welding parameter can refer to a process parameter used to control the flow and filling of the molten material.

[0061] Specifically, the ultrasonic welding device can generate heat and melt the protruding structure between the upper shell and the lower shell by using the high-frequency vibration of the welding head 200, and finally form a connecting layer 33 to achieve sealing. Figure 8 and Figure 9As shown, the welding head 200, driven by a servo motor, moves vertically, contacts the second housing 30, and applies initial pressure. Under the control of first welding parameters, the welding head 200 vibrates at a high frequency, generating frictional heat that softens the surface of the weld structure 31. A monitoring unit then acquires real-time processing signals during the welding process. These processing signals may include, but are not limited to, temperature, pressure, acoustic reflections, and dimensional information. These monitored processing signals can be used to determine the melting state of the weld structure 31. For example, the temperature at the interface between the first housing 10 and the second housing 30 can be used to determine whether the weld structure 31 has reached its melting point. Another example is determining whether the weld structure 31 has completely melted from a solid state to a liquid state by measuring the height of the housings. After the weld structure 31 is completely melted, the ultrasonic welding device can be controlled to switch to a second welding parameter. This reduces the vibration amplitude of the welding head 200 to a certain extent, while increasing static pressure to promote uniform distribution of the molten material. This helps ensure that the molten material fully flows and fills the interface, avoiding residual stress caused by excessive cooling and preventing over-welding or flash.

[0062] Compared to existing technologies, which use fixed timing to control welding phase switching, this approach is unable to adapt to fluctuations in material properties. This solution uses real-time feedback from the melting state to dynamically adapt welding parameters to the actual processing progress. For example, for low-melting-point materials, the high-power phase can be shortened, while for high-melting-point materials, energy input can be automatically extended. This closed-loop control method eliminates the need for time margin design in traditional open-loop control.

[0063] The technical solution of the present application can effectively implement segmented amplitude control during the preparation process of the warning light 100 by real-time monitoring of the ultrasonic welding process. In the initial stage of welding, the surface oxide layer of the weld structure 31 of the second shell 30 can be quickly destroyed under the action of a high amplitude, so that the weld structure 31 can quickly melt and flow to fill the gap between the first shell 10 and the second shell 30. Then, the monitoring unit obtains processing signals, and can monitor information such as the pressure of the welding head 200, the temperature of the weld structure 31, the acoustic reflection signal, or the thickness of the warning light 100 during the processing process. The melting state of the weld structure 31 can be analyzed and determined from the processing signals. When it is confirmed that the weld structure 31 is completely melted, the welding parameters of the ultrasonic welding device can be adjusted to a certain extent, so that the welding head 200 can be adjusted to a lower amplitude during the middle and late stages of welding. This helps to prevent the molten material from easily overflowing under the action of a high amplitude, effectively prevents insufficient welding between the first shell 10 and the second shell 30, and allows the molten material to fully flow and fill the welding interface between the first shell 10 and the second shell 30. At the same time, it can avoid residual stress caused by excessive cooling of the welding material, and prevent over-welding or flash. Therefore, through the responsive segmented welding process design, the ultrasonic welding device can better adapt to the assembly and preparation of warning lights 100 with various shell materials, avoid the problems of insufficient welding or excessive melting of the warning lights 100, and significantly improve the assembly reliability and durability of the warning lights 100.

[0064] See Figure 2 In one embodiment of the present invention, the monitoring unit includes a pressure sensor, the processing signal includes a pressure signal, and the step of controlling the monitoring unit to obtain the processing signal in real time and confirming the molten state of the welding structure 31 based on the processing signal includes:

[0065] Step S311, controlling the pressure sensor to obtain a pressure signal from the welding head 200 in real time, and comparing the pressure signal with a set pressure value;

[0066] Step S312 : When the pressure signal is greater than or equal to the set pressure value, it is determined that the welding structure 31 is in a completely molten state.

[0067] It is understood that during the welding process of the warning light 100, the welding head 200 needs to maintain a certain pressure on the surface of the second shell 30 to ensure sufficient contact welding between the second shell 30 and the first shell 10. Due to the interaction of forces, the welding head 200 will be subjected to a certain reaction force exerted by the second shell 30 during the welding process. However, as the weld structure 31 gradually melts during the welding process, the reaction force exerted on the welding head 200 is relatively small. When the weld structure 31 is completely melted, the gap between the first shell 10 and the second shell 30 reaches its minimum value, so that the welding head 200 is now subjected to a larger reaction force. Furthermore, by monitoring the reaction force exerted on the welding head 200 during the welding process, the melting state of the weld structure 31 can be clearly identified.

[0068] The pressure sensor may refer to a device for detecting the reaction force exerted on the welding head 200 by the second shell 30. Specifically, it may be implemented using a piezoelectric sensor or a resistive strain sensor, which converts mechanical pressure into an electrical signal for measurement. The pressure signal refers to the real-time pressure data generated after the welding head 200 contacts the second shell 30, which may be collected through voltage changes or resistance changes. The set pressure value refers to a standard threshold value determined in advance based on the material properties of the welding structure 31 and the parameters of the welding head 200. Specifically, it may be determined through experimental testing or empirical data, and is used to characterize the reaction force exerted on the welding head 200 when the welding structure 31 is completely melted.

[0069] Specifically, during ultrasonic welding, the welding head 200 continuously applies downward pressure to bring the second shell 30 into contact with the first shell 10. The pressure sensor collects real-time pressure data on the welding head 200 and compares the real-time pressure with a preset set pressure value. When the real-time pressure reaches or exceeds the set pressure value, it indicates that the weld structure 31 has completely melted under the action of ultrasonic vibration and pressure to form a connecting layer 33. At this time, the system automatically switches to the second welding parameter, reducing the welding power or amplitude to allow the molten material to fully fill the gap between the shells. Dynamically judging the melting state through the pressure signal can adapt to the melting point differences between shells of different materials.

[0070] Therefore, real-time monitoring of the pressure signal accurately captures the critical point at which welding structure 31 completes melting, eliminating the risk of misjudgment due to material differences. Compared to time-controlled methods, the pressure signal feedback mechanism precisely matches the melting characteristics of different welding materials, avoiding issues such as inadequate welding or over-melting. The dynamic pressure signal feedback mechanism ensures that the timing of parameter switching in welding head 200 precisely matches the material properties, effectively improving the density and uniformity of the shell connection layer 33, thereby enhancing the sealing performance and structural reliability of warning light 100.

[0071] See Figure 3In one embodiment of the present invention, the monitoring unit includes a temperature sensor, the processing signal includes a temperature signal, and the step of controlling the monitoring unit to obtain the processing signal in real time and confirming the molten state of the welding structure 31 based on the processing signal includes:

[0072] Step S321, controlling the temperature sensor to obtain a temperature signal of the welding structure 31 in real time, and comparing the temperature signal with the melting temperature value;

[0073] Step S322 : when the temperature signal is greater than or equal to the melting temperature value, it is determined that the welding structure 31 is in a completely molten state.

[0074] In this embodiment, the temperature sensor may refer to a device capable of detecting temperature changes in the weld structure 31. Specifically, it may be implemented as a thermocouple or infrared temperature measuring element, and is used to directly obtain real-time temperature data of the weld area. The temperature signal may refer to an electrical signal collected by the temperature sensor that reflects the temperature changes in the weld structure 31. Specifically, it may be converted into a digital signal by an analog-to-digital conversion circuit and processed to represent the actual temperature state of the melting process. The melting temperature value may refer to the critical temperature required for the material of the weld structure 31 to melt. Specifically, it can be determined through experimental testing based on material properties and used as a reference threshold for determining the melting state.

[0075] Specifically, during ultrasonic welding, a temperature sensor is positioned near the weld structure 31 to monitor temperature changes in the weld area in real time. When the welding head 200 applies vibration energy, the weld structure 31 heats up due to frictional heat generation. The temperature sensor continuously collects temperature signals and transmits them to the control system. By comparing these signals with the preset melting temperature, it can accurately determine whether the weld structure 31 has reached a fully molten state. For example, if the temperature signal consistently exceeds the melting temperature and remains stable, it indicates that the material has fully melted. At this point, the control system triggers a switch in welding parameters, transitioning to the next stage of processing.

[0076] Therefore, by directly judging the melting state through real-time temperature monitoring, it is possible to effectively avoid the problem of insufficient melting or energy waste, and dynamically adapt to the welding processing requirements of the warning light 100 shell of different materials, ensuring that the welding structure 31 is fully melted, thereby improving the sealing and structural strength of the connection between the shells, and effectively reducing the welding defect rate caused by misjudgment of the melting state.

[0077] See Figure 4 In one embodiment of the present invention, the monitoring unit includes an acoustic signal detection device, the processing signal includes an acoustic reflection signal, and the step of controlling the monitoring unit to obtain the processing signal in real time and confirming the molten state of the weld structure 31 based on the processing signal includes:

[0078] Step S331, controlling the acoustic signal detection device to obtain in real time the acoustic reflection signal when the welding structure 31 is melted;

[0079] Step S332 : When the acoustic reflection signal satisfies the melting acoustic wave parameters, it is determined that the welding structure 31 is in a completely molten state.

[0080] In this embodiment, the acoustic signal detection device may refer to a device capable of transmitting and receiving acoustic wave signals, and may be implemented using an ultrasonic probe. By transmitting high-frequency acoustic waves and receiving reflected signals, the propagation characteristics of the acoustic waves in the weld structure 31 are analyzed. The molten acoustic wave parameter may refer to a pre-set acoustic characteristic value reflecting the molten state of the welding material. Specifically, this parameter may be achieved by experimentally calibrating the acoustic wave reflection intensity or frequency variation range at different melting stages, and is used to determine whether the weld structure 31 has reached complete melting.

[0081] Specifically, during the ultrasonic welding process, the acoustic signal detection device emits high-frequency sound waves to the welding structure 31. When the sound waves encounter an unmelted solid structure, the reflected signal has higher energy and a specific frequency distribution. As the welding structure 31 gradually melts into a liquid state, the material density and acoustic impedance change, and the intensity or frequency characteristics of the reflected signal change accordingly. By collecting the reflected signal in real time and comparing it with the melting sound wave parameters, it is possible to accurately identify whether the welding structure 31 is completely melted. For example, when the reflected signal intensity is lower than the set threshold or the frequency characteristics are within the parameter range under the molten state, it is determined that the welding structure 31 has reached complete melting, and the welding parameter switching is triggered immediately.

[0082] Therefore, by dynamically monitoring the melting state through the acoustic reflection signal, the actual melting progress of the welding structure 31 of different materials can be accurately identified, avoiding the problem of insufficient melting or excessive melting due to fixed time, and realizing real-time dynamic monitoring of the melting state of the welding structure 31, ensuring that the welding structure 31 is fully melted to fill the gap between the first shell 10 and the second shell 30, thereby improving the sealing and structural strength of the warning light 100 shell welding, and thereby improving the production qualification rate of the warning light 100.

[0083] See Figure 5 In one embodiment of the present invention, the monitoring unit includes a distance measuring device for measuring the total height of the first shell 10 and the second shell 30 in the first direction, and the processing signal includes a height size signal;

[0084] The control monitoring unit acquires the processing signal in real time, and the steps of confirming the melting state of the welding structure 31 based on the processing signal include:

[0085] Step S341, controlling the distance measuring device to obtain the height dimension signal of the warning light 100 in real time;

[0086] Step S342 : When the height signal is less than or equal to the set height value, it is determined that the welding structure 31 is in a completely molten state.

[0087] In this embodiment, the first direction can refer to the direction shown in the figure, that is, the direction in which the first shell 10 and the second shell 30 are stacked and assembled. The distance measuring device can refer to a measuring device for detecting the thickness of the shell stack, which can be implemented by a laser distance measuring sensor or an ultrasonic distance measuring module, and the vertical dimensions of the shell assembly are collected in real time by a non-contact measurement method. The height dimension signal can refer to the total shell thickness data output by the distance measuring device, which can be transmitted to the control system in the form of a voltage signal or a digital signal, and is used to characterize the change in the shell spacing of the welding structure 31 during the melting process. The set height value can refer to a critical threshold value calculated based on the initial thickness of the shell and the expected thickness of the connecting layer 33, for example, it can be the value of the initial total thickness minus the theoretical shrinkage of the connecting layer 33.

[0088] Specifically, during the welding process, the melting of the welding structure 31 causes the gap between the shells to gradually decrease, and the distance measuring device continuously monitors the height changes of the shell components. When the real-time height value is detected to be equal to or below a preset threshold, it indicates that the molten material has fully filled the gap and completed the shell connection. Compared to existing technologies that rely on fixed time control, this method directly determines the melting completion status based on physical dimensional changes, avoiding welding time errors caused by material differences and ensuring that the welding device fully melts and fills the gap between the first shell 10 and the second shell 30.

[0089] Therefore, by detecting the physical changes in the shell spacing in real time, it is possible to accurately identify the point where melting is complete, eliminating the impact of material property differences on weld quality. For example, for shell materials with lower melting points, weld structure 31 may reach a fully molten state prematurely. Immediately adjusting the welding parameters can prevent overmelting. For materials with higher melting points, energy is continuously applied until the predetermined height is reached to ensure complete melting.

[0090] Through the above technical solution, the present application can dynamically adapt to the welding characteristics of different materials, accurately determine the melting state of the welding structure 31, and avoid problems such as insufficient welding or over-melting. This improves the uniformity and density of the shell connection and ensures the sealing performance and structural strength of the warning light 100.

[0091] In one embodiment of the present invention, the first welding parameter includes at least one of welding power, welding pressure, and welding amplitude;

[0092] And / or, the second welding parameter includes at least one of welding power, welding pressure, and welding amplitude.

[0093] In this embodiment, welding power refers to the energy input to the welding head 200 per unit time. This can be achieved by adjusting the output power of the power module. By controlling the welding power, the energy input rate during the melting of the welded structure 31 can be adjusted. Welding pressure refers to the vertical force applied by the welding head 200 to the surface of the second shell 30. This can be achieved by using a pneumatic or hydraulic drive device. By adjusting the welding pressure, the contact tightness between the welded structure 31 and the first shell 10 can be controlled. Welding amplitude refers to the displacement amplitude generated by the welding head 200 during vibration. This can be achieved by adjusting the output frequency of the ultrasonic generator or the amplitude regulator. By changing the amplitude, the intensity of the vibration energy transmitted to the welded structure 31 can be adjusted.

[0094] Specifically, during the melting phase of the weld structure 31, by adjusting at least one of the first welding parameters, the energy input conditions can be matched to the shell material characteristics. For example, during the initial melting phase, a combination of high welding power and large amplitude is used to rapidly heat the weld structure 31 to a molten state. When the molten state reaches a preset threshold, the weld structure 31 is switched to a lower power or smaller amplitude in the second welding parameters, allowing the molten material to fully flow and fill the contact surface between the first shell 10 and the second shell 30. Thus, dynamic adjustment of welding parameters can adapt to the differences in melting characteristics of shells of different materials, avoiding problems such as insufficient or excessive melting caused by fixed parameters.

[0095] By introducing an adjustable welding parameter combination, the energy input requirements can be matched in real time during the melting process. For example, welding power or amplitude can be increased when melting lag is detected, or pressure parameters can be reduced when the melting rate is too fast, thereby optimizing the welding adaptability of housings of different materials. This allows for dynamic adjustment of welding energy input parameters for warning light 100 housings of different materials, ensuring that the weld structure 31 achieves full melting and uniform filling under different material conditions, effectively improving the sealing and structural strength of the connection between the housings, and further enhancing the production qualification rate and reliability of warning lights 100.

[0096] See Figure 13 In one embodiment of the present invention, before the welding structure 31 is melted, the longitudinal cross-section of the welding structure 31 is an inverted triangle, and the angle of the end of the welding structure 31 facing the first shell 10 is defined as α, 60°≤α≤90°; the height of the welding structure 31 along the first direction is defined as H, 0.2mm≤H≤0.6mm.

[0097] In this embodiment, the inverted triangular longitudinal cross-sectional shape may refer to the welding structure 31 presenting a triangular geometric shape with the vertex facing downward in a cross-section perpendicular to the stacking direction of the first shell 10 and the second shell 30. Specifically, it can be achieved by mold injection molding or mechanical processing molding process. This shape can form a stress concentration area during ultrasonic vibration. The end angle α may refer to the geometric angle formed by the two inclined surfaces at the end of the welding structure 31. Specifically, it can be detected by a three-dimensional measuring instrument or an optical profilometer. This angle range can balance the relationship between the material melting rate and the fluidity of the melt. The height H may refer to the vertical dimension of the welding structure 31 along the shell stacking direction. Specifically, it can be measured by a laser ranging device or a contact displacement sensor. This size range can ensure that the molten material fully fills the gap between the shells.

[0098] Specifically, during the ultrasonic welding process, the vibration energy of the welding head 200 is transmitted to the end of the inverted triangle welding structure 31, which helps to form stress concentration at the tip of the inverted triangle welding structure 31, so that the welding structure 31 can enter a molten state more quickly. Because the angle α is limited to between 60° and 90°, such as 60°, 65°, 70°, 75°, 80°, 85°, and 90°, the efficiency of generating localized high temperatures in the end area during vibration friction can be improved within this angle range. When the height H of the welding structure 31 is within the range of 0.2mm to 0.6mm, the height of the welding structure 31 can be kept neither too small nor too large, which helps ensure that the volume of molten material can completely cover the contact surface of the shell, while also avoiding glue overflow caused by excessive material. By controlling the synergistic effect of the end angle and the structure height, the melting process of the welding structure 31 is precisely confined to a predetermined area, allowing the ultrasonic energy to form an effective heat accumulation area at the welding end. At the same time, the flow path of the molten material is guided by the geometric shape, which effectively overcomes the problem of insufficient melting caused by differences in shell materials.

[0099] Through the above-mentioned technical solution, the present application can improve the melting efficiency of the welding structure 31, ensuring that the connecting layer 33 forms a continuous and uniform sealing structure on the contact surface of the shell. The inverted triangle structure design allows the melting process to have a controllable starting position and expansion direction, effectively avoiding the occurrence of unmelted residue or excessive melting penetration, thereby significantly improving the assembly accuracy and structural reliability of the warning light 100 shell welding.

[0100] See Figure 6 In one embodiment of the present invention, after the welding structure 31 reaches a completely molten state, obtaining the second welding parameter and regulating the operation of the welding head 200 based on the second welding parameter, the method further includes:

[0101] Step S50 , obtaining first time information in real time, and controlling the welding head 200 to stop vibrating when the first time information meets the set welding time.

[0102] In this embodiment, the first time information may refer to the length of time from the start of vibration of the welding head 200 to the current moment. This may be implemented using a timer module to monitor the duration of vibration of the welding head 200. The welding time may be a pre-set empirical value or experimental data based on material properties to ensure sufficient flow of the molten material without excessive heating. Stopping vibration of the welding head 200 may mean terminating the high-frequency mechanical vibration by turning off the ultrasonic generator to prevent structural deformation caused by excessive melting.

[0103] Specifically, once the weld structure 31 has fully melted, the welding head 200 maintains vibration under the control of the second welding parameter until the set welding time is reached, then stops vibrating to prevent excessive energy input and thermal damage to the material. During this stage, the vibration duration is monitored in real time by a timer. When the preset time threshold is reached, the power to the ultrasonic generator is immediately cut off, causing the welding head 200 to stop vibrating. By monitoring the welding time in real time, the vibration duration can be dynamically adjusted to adapt to the melting characteristics of different shell materials. For example, the vibration time can be extended for high-melting-point materials, while shortened for low-melting-point materials, thereby ensuring the quality of the connecting layer 33 while avoiding thermal damage.

[0104] Through the above-mentioned technical solution, this application solves the problem of unstable sealing performance caused by fixed process time in the existing warning light 100 welding process, and realizes adaptive control of the welding process. Precise management of the melting time effectively improves the uniformity and density of the connecting layer 33, prevents excessive vibration of the molten material and causes overflow and leakage, enhances the sealing effect and impact resistance between the shells, and thus improves the assembly qualification rate and long-term reliability of the warning light 100.

[0105] See Figure 7 In one embodiment of the present invention, after obtaining the first time information and controlling the welding head 200 to stop vibrating when the first time information meets the set welding time, the method further includes:

[0106] Step S61 , obtaining a pressure holding parameter, and controlling the welding head 200 to press down the second housing 30 based on the pressure holding parameter;

[0107] Step S62 , obtaining the second time information in real time, and controlling the welding head 200 to move away from the second housing 30 when the second time information satisfies the set pressure holding time.

[0108] In this embodiment, during the welding process of the warning light 100, after the welding structure 31 is melted and fills the gap between the first shell 10 and the second shell 30 through ultrasonic vibration for a certain period of time, the welding head 200 can maintain a certain pressure on the second shell 30 and the first shell 10, and keep the molten material in contact with the first shell 10 and the second shell 30 during the process of cooling to form the connecting layer 33, thereby better improving the connection stability and reliability of the warning light 100 shell.

[0109] The holding pressure parameter refers to the force and duration of the downward pressure applied by the welding head 200 to the second shell 30 after the welding head 200 ceases vibrating. This parameter is achieved through the coordination of a pressure sensor and a timing device. This parameter ensures uniform distribution of the molten material during the solidification phase, preventing shrinkage due to cooling and resulting in a decrease in sealing performance. The second time information refers to the duration of the downward pressure of the welding head 200. This can be set using a time relay or programmable logic controller to precisely control the duration of the holding pressure phase.

[0110] Specifically, after the weld structure 31 is completely melted and the welding head 200 stops vibrating, the welding head 200 is controlled to continuously press down on the second shell 30. At this point, the molten material is in a critical state of transition from liquid to solid. By applying constant pressure, the material fluidity and filling effect can be optimized, and the gap between the shell contact surfaces is fully filled. During this process, the pressure holding parameters are monitored and adjusted in real time. When the preset pressure holding time is reached, the welding head 200 is controlled to retract to prevent the formation of pores or cracks within the connecting layer 33 due to premature pressure release.

[0111] By adding a pressure-holding stage, interfacial separation caused by material shrinkage is effectively suppressed, while simultaneously promoting microscopic bonding between the molten material and the shell surface. This solves the existing problem of reduced sealing performance due to material cooling shrinkage, significantly improving the structural integrity of the shell connection layer 33.

[0112] Through the above-described technical solution, the present application achieves precise control of the material solidification stage during the welding process, effectively eliminating internal defects in the connecting layer 33. The sealing performance and mechanical connection strength between the shells are simultaneously optimized, and the structural stability of the warning light 100 is improved when subjected to external impact or disassembly, further improving the production qualification rate and reliability of the warning light 100.

[0113] The present invention also provides a warning light 100, see Figures 10 to 13The warning light 100 includes a first housing 10, a second housing 30, and a circuit assembly. The circuit assembly is disposed within the first housing 10. The second housing 30 is stacked with the first housing 10 and covers the first housing 10. A welding structure 31 is provided around the edge of the surface of the second housing 30 facing the first housing 10. The welding structure 31 is configured to melt during ultrasonic welding to form a connecting layer 33 connecting the first housing 10 and the second housing 30. The warning light 100 is manufactured using the warning light manufacturing method described above. Because the warning light 100 utilizes all the technical solutions of all the above-mentioned embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above-mentioned embodiments, which will not be detailed here.

[0114] The above description is merely an exemplary embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformation made by utilizing the contents of the present invention's description and drawings under the technical concept of the present invention, or directly / indirectly applied in other related technical fields, is included in the patent protection scope of the present invention.

Claims

1. A method for preparing a warning light, characterized in that: The warning light includes a first shell, a second shell, and a circuit assembly. The circuit assembly is disposed within the first shell. The second shell is stacked with the first shell and covers the first shell. A welding structure is provided around the edge of the surface of the second shell facing the first shell. The welding structure is configured to melt during ultrasonic welding to form a connecting layer connecting the first shell and the second shell. The preparation method of the warning light includes: Controlling the welding head of the ultrasonic welding device to move to contact the second shell; Acquiring a first welding parameter, and regulating the welding head movement based on the first welding parameter; The control monitoring unit acquires the processing signal in real time and confirms the melting state of the welding structure based on the processing signal; When the weld structure reaches a completely molten state, a second welding parameter is acquired, and the welding head movement is regulated based on the second welding parameter.

2. The method for preparing a warning light according to claim 1, wherein: The monitoring unit includes a pressure sensor, the processing signal includes a pressure signal, the control monitoring unit acquires the processing signal in real time, and the step of confirming the melting state of the welding structure based on the processing signal includes: Controlling the pressure sensor to obtain the pressure signal of the welding head in real time, and comparing the pressure signal with the set pressure value; When the pressure signal is greater than or equal to the set pressure value, it is determined that the welding structure is in a completely molten state.

3. The method for preparing a warning light according to claim 1, wherein: The monitoring unit includes a temperature sensor, the processing signal includes a temperature signal, the control monitoring unit acquires the processing signal in real time, and the step of confirming the melting state of the welding structure based on the processing signal includes: Controlling a temperature sensor to obtain a temperature signal of the welding structure in real time, and comparing the temperature signal with a melting temperature value; When the temperature signal is greater than or equal to the melting temperature value, it is determined that the welding structure is in a completely molten state.

4. The method for preparing a warning light according to claim 1, wherein: The monitoring unit includes an acoustic signal detection device, the processing signal includes an acoustic reflection signal, the control monitoring unit acquires the processing signal in real time, and the step of confirming the melting state of the welding structure based on the processing signal includes: Controlling the acoustic signal detection device to obtain in real time the acoustic reflection signal when the welding structure is melted; When the acoustic reflection signal meets the melting acoustic wave parameters, it is determined that the welding structure is in a completely molten state.

5. The method for preparing a warning light according to claim 1, wherein: The monitoring unit includes a distance measuring device, the distance measuring device is used to measure the total height of the first shell and the second shell in a first direction, and the processing signal includes a height size signal; The control monitoring unit acquires the processing signal in real time, and the step of confirming the melting state of the welding structure based on the processing signal includes: Controlling the distance measuring device to obtain the height dimension signal of the warning light in real time; When the height signal is less than or equal to the set height value, it is determined that the welding structure is in a completely molten state.

6. The method for preparing a warning light according to any one of claims 1 to 5, characterized in that: The first welding parameter includes at least one of welding power, welding pressure, and welding amplitude; And / or, the second welding parameter includes at least one of welding power, welding pressure, and welding amplitude.

7. The method for preparing a warning light according to any one of claims 1 to 5, characterized in that: Before the welding structure is melted, the longitudinal cross-section of the welding structure is an inverted triangle, and the angle of the end of the welding structure facing the first shell is defined as α, 60°≤α≤90°; the height of the welding structure along the first direction is defined as H, 0.2mm≤H≤0.6mm.

8. The method for preparing a warning light according to any one of claims 1 to 5, characterized in that: When the weld structure reaches a completely molten state, after the step of obtaining a second welding parameter and regulating the movement of the welding head based on the second welding parameter, the method further includes: First time information is acquired in real time, and when the first time information satisfies a set welding time, the welding head is controlled to stop vibrating.

9. The method for preparing a warning light according to claim 8, wherein: After the step of obtaining the first time information and controlling the welding head to stop vibrating when the first time information satisfies the set welding time, the method further includes: Acquiring a pressure holding parameter, and controlling the welding head to press down the second shell based on the pressure holding parameter; The second time information is acquired in real time, and when the second time information satisfies the set pressure holding time, the welding head is controlled to move away from the second shell.

10. A warning light, characterized in that: The warning light is manufactured by the preparation method of the warning light according to any one of claims 1 to 9.

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