A new type of aluminum wire and copper terminal welding device and welding method

Abstract

This invention relates to the field of aluminum-copper welding technology, specifically to a novel welding device and method for welding aluminum wires and copper terminals. The device includes a worktable, a lower welding plate, a controller, a telescopic rod, an upper welding plate, a positioning component, a mating component, and a locking component. The worktable is mounted on the ground, the lower welding plate is mounted on top of the worktable, the controller is mounted above the worktable, the telescopic rod is mounted below the controller, the upper welding plate is mounted below the telescopic rod, the positioning component is installed inside the upper and lower welding plates, the mating component is installed inside the lower welding plate, and the locking component is installed inside the upper welding plate. The mating and locking components are positioned correspondingly. After the locking component enters the mating component and rotates, it locks the upper and lower welding plates. The positioning component performs positioning and calibration of the workpiece.

Description

Technical Field

[0001] This invention relates to the field of aluminum-copper welding technology, specifically to a novel welding device and method for welding aluminum wires and copper terminals. Background Technology

[0002] Aluminum conductors are widely used in power and electronic equipment due to their light weight, low cost, and good conductivity, especially in large-scale power transmission and distribution systems. However, due to the significant differences in physical and chemical properties between aluminum and copper, particularly in their coefficients of thermal expansion and electrochemical corrosion susceptibility, directly welding aluminum conductors to copper terminals using traditional methods can easily lead to increased contact resistance, decreased mechanical strength, and interfacial corrosion, potentially causing equipment failure and even fire hazards. Therefore, developing a specialized welding device for connecting aluminum conductors to copper terminals has become a key technological direction for improving joint performance and service life.

[0003] Existing connection methods, such as bolt crimping, cold pressing joints, and explosive welding, while solving the problem of aluminum-copper connection to some extent, still suffer from drawbacks such as complex processes, unstable contact, and low operating efficiency. Furthermore, these methods have high requirements for environmental conditions, operating techniques, and material adaptability in practical applications, making it difficult to meet the comprehensive requirements of high efficiency, high reliability, and low cost in industrial settings. Therefore, there is an urgent need for a new type of welding device with a reasonable structure, simple operation, and strong adaptability to achieve efficient and stable connection between aluminum wires and copper terminals, thereby improving the overall system's safety and reliability.

[0004] In view of the above, in order to overcome the above technical problems, the present invention designs a novel welding device and welding method for aluminum wires and copper terminals, which solves the above technical problems. Summary of the Invention

[0005] The technical objective of this invention is to design a novel welding device and welding method for aluminum wires and copper terminals, so as to achieve an efficient and stable connection between aluminum wires and copper terminals.

[0006] To achieve the above-mentioned technical objectives, the present invention provides the following technical solution:

[0007] A novel welding device for aluminum wires and copper terminals features a rational structural design and comprehensive functions. It mainly includes a worktable, a lower welding plate, a controller, a telescopic rod, an upper welding plate, positioning components, mating components, and locking components. The worktable, serving as the supporting foundation for the entire device, is installed on the ground and possesses good stability and load-bearing capacity. The lower welding plate, mounted above the worktable, supports the workpiece and also serves as the lower support structure. The controller, fixed in the upper area of ​​the worktable, is responsible for the control and operation of the entire welding system, including temperature regulation, telescopic control, and the start and stop management of the welding program.

[0008] A telescopic rod is installed below the controller, with one end connected to the controller and the other end connected to the upper welding plate. The telescopic rod allows the upper welding plate to move up and down, facilitating workpiece clamping, positioning, and welding operations. The upper welding plate is installed below the telescopic rod and can be docked or separated from the lower welding plate during operation through its telescopic movement. Positioning components are installed inside both the upper and lower welding plates. These components are used to precisely position the aluminum wires and copper terminals, ensuring alignment of the two different metal materials during welding, which helps improve weld quality and joint strength.

[0009] In addition, the lower welding plate is equipped with a mating assembly, while the upper welding plate is equipped with a locking assembly. The mating and locking assemblies are positioned opposite each other and fit tightly. When the telescopic rod lowers the upper welding plate to the designated position, the locking assembly precisely inserts into the mating assembly, and through rotation or pressing, secures the two plates, effectively preventing misalignment due to vibration or thermal expansion and contraction during welding. Simultaneously, the positioning assembly calibrates the workpiece before the entire welding operation, ensuring accuracy and consistency throughout the welding process. This device enables efficient, stable, and safe welding of aluminum wires to copper terminals, and is widely applicable in the power, automotive, and electronics industries.

[0010] The structural design of the welding lower plate fully considers the stability and precision of welding aluminum wires and copper terminals. It mainly consists of four parts: placement slots, welding tables, mounting holes, and fixing holes. The placement slots are formed on the upper surface of the welding lower plate and are arranged in a linear array to facilitate continuous multi-station operation and improve overall welding efficiency. A welding table is set in the central area of ​​each placement slot. The welding table has a semi-circular cross-section, which helps to better fit the curved shape of the aluminum wire or copper terminal, improves positioning stability, and prevents the welding quality from deteriorating due to slippage or displacement during the welding process.

[0011] The welding table has symmetrical mounting holes on both sides for installing auxiliary clamps or limiting devices to further secure the workpiece, ensuring accurate welding position and improving welding reliability. Additionally, fixing holes are provided between adjacent placement slots to firmly secure the workpiece or other accessories to the lower plate, preventing workpiece displacement due to vibration or temperature changes during welding. Notably, the upper welding plate also has mirror images of the lower welding plate with identical placement slots, welding table, mounting holes, and fixing holes, enabling precise alignment and synchronous locking of the upper and lower plates during welding, providing a stable welding support environment for the aluminum-copper joint.

[0012] The bottom of the welding plate is carefully designed with a gas flow channel. This channel is used to deliver protective gas, such as argon or a mixed gas, during the welding process to prevent oxidation or the generation of harmful impurities in the welding area, ensuring the stability of weld quality and the reliability of electrical conductivity. Above this gas flow channel, a horizontally arranged branch channel is also provided. The branch channels are arranged in parallel to each other, which can evenly distribute the bottom gas to multiple points in the welding area, thereby forming a stable and balanced gas protective environment. Through the combined action of the gas flow channel and the branch channel, the weld formation effect can be effectively improved, and defects such as porosity and slag inclusions can be reduced, meeting the high requirements for atmosphere control in dissimilar metal welding of aluminum wires and copper terminals.

[0013] The welding station features a precisely machined mating groove, which is annular in shape and designed to fit tightly with corresponding components in the upper plate structure. This ensures excellent sealing and structural stability during operation. At the lower end of the groove, a welding port is provided for guiding the output of gas or welding medium. Its rational design effectively and precisely delivers the protective gas from below to the contact area of ​​the workpiece. The other end of the welding port connects to a flow channel, allowing gas from the flow channel to smoothly enter the welding interface area, creating a closed local atmosphere. This prevents oxygen from entering the welding point, effectively improving welding quality and reducing defects. This design is particularly suitable for welding dissimilar metals like aluminum and copper, where a high protective atmosphere is required.

[0014] The positioning component is used for precise positioning and stable fixation of aluminum wires and copper terminals during welding. Its structure comprises three parts: a return spring, a telescopic block, and a locking block. The return spring is installed in a mounting hole inside the welding station and has good elastic recovery capability, automatically returning the telescopic mechanism to its initial state after welding. The telescopic block is installed above the return spring and can move up and down under force or spring push to accommodate workpieces of different sizes or shapes. The locking block, as the uppermost positioning component, is installed on top of the telescopic block. Its upper surface is designed with an arc-shaped structure, which naturally conforms to the surface of the aluminum wire or copper terminal, thus achieving a more stable positioning effect. This arc-shaped surface not only increases the contact area, preventing workpiece slippage, but also avoids damage to the wires, improving the applicability and safety of the device and ensuring smooth welding operations.

[0015] The mating assembly is used to achieve precise docking and secure locking between the upper and lower plates of the welding device. Its structure includes three parts: a mating block, a limiting groove, and a snap-fit ​​groove. The mating block is a hollow structure installed in the fixing hole of the lower welding plate, serving as a connection and support. A limiting groove is provided on the side wall surface of the hollow part inside the mating block. This limiting groove cooperates with the limiting structure in the locking assembly to ensure precise control of the insertion angle and depth, preventing misalignment or shaking. Inside the lower part of the mating block, a snap-fit ​​groove is also provided. This snap-fit ​​groove is used to mechanically engage with the snap-fit ​​component in the locking assembly. When the upper plate descends to the working position, the locking assembly inserts into the mating block and snaps into the snap-fit ​​groove, thus firmly connecting the upper and lower structures, thereby improving the overall stability and safety during the welding process. This design is simple and efficient, facilitates quick assembly and disassembly, and improves operational convenience and reliability.

[0016] The locking assembly is used to achieve automatic docking and secure locking between the upper and lower welding plates. Its overall structure includes multiple components such as a drive motor, a drive cylinder, a moving block, a locking block, and a mating locking block. The drive motor is installed inside the upper welding plate and serves as the power source for this assembly, enabling precise control of its movements via control signals. Below the drive motor, a drive cylinder converts rotational motion into linear displacement, achieving precise pushing of the lower component. The moving block is installed at the lower end of the drive cylinder, acting as a connecting intermediate component to effectively transmit the thrust output by the cylinder to the locking block. The locking block is installed at the bottom of the moving block, ultimately engaging with the mating assembly on the lower plate. The surface of the locking block is equipped with mating locking blocks that insert into the locking grooves in the mating assembly on the lower plate, achieving precise engagement and rotational locking. This ensures structural stability and prevents loosening of the welding device during operation, improving overall welding accuracy and safety. This locking structure is reliable, highly automated, and suitable for welding requirements under various complex working conditions.

[0017] A novel method for welding aluminum wires to copper terminals, the method being used in conjunction with the aforementioned novel welding device for aluminum wires to copper terminals; the steps of the method are as follows:

[0018] S1: The staff places the aluminum wires and copper terminals on the placement slot of the welding lower plate by means of machinery or manual means, starts the controller, and moves the welding upper plate downward by means of the telescopic rod so that the welding upper plate covers the welding lower plate.

[0019] S2: The aluminum wire and the copper terminal are contacted by two upper and lower locking blocks, and are positioned under the elastic force of the return spring, so that the welding part is located on the welding table.

[0020] S3: The drive cylinder moves the moving block down, and the locking block slides to the lowest end in the limit groove. The drive motor drives the drive to rotate, so that the locking block rotates and the locking block is locked in the locking groove.

[0021] S4: Gas is introduced into the interior through the gas flow channel. After passing through the diversion channel, the gas enters the mating ring groove and is ignited at the welding joint to achieve simultaneous welding of the upper and lower parts.

[0022] The beneficial effects of this invention are as follows:

[0023] (1) The present invention provides a novel welding device for aluminum wires and copper terminals. Its reasonable structural design effectively solves the technical problems of poor contact, inaccurate positioning, and unstable welding strength in traditional aluminum-copper welding processes. By setting an adjustable structure for the upper and lower welding plates, and coordinating the precise cooperation of the positioning and locking components, rapid workpiece positioning, stable clamping, and automatic locking are achieved, improving operational efficiency and joint consistency. In particular, the arc-shaped snap-fit ​​block design in the positioning component allows for adaptive fitting according to the surface characteristics of the aluminum wires and copper terminals, significantly improving the accuracy of the welding position, effectively reducing the welding defect rate, and providing strong support for stable operation in actual production.

[0024] (2) This invention innovatively introduces a gas flow channel and a branch flow channel structure, realizing atmosphere protection during the welding process, effectively avoiding oxidation or contamination of the weld joint, and improving welding quality and conductivity. The cooperating component and the locking component are controlled by the linkage between the drive motor and the cylinder to complete the automatic docking and locking of the upper and lower plates, which not only greatly improves the clamping efficiency and the convenience of worker operation, but also adapts to the welding requirements of aluminum and copper parts of different specifications, and has good versatility and automation adaptability. The overall device has a compact structure, intelligent operation, and stable welding quality, and is suitable for aluminum and copper welding needs in multiple fields such as power, electrical equipment, and automobile manufacturing, and has broad application value. Attached Figure Description

[0025] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0026] The above and other aspects of the invention will now be described by way of example only, with reference to the accompanying drawings, in which:

[0027] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0028] Figure 2 This is an enlarged schematic diagram of the positioning component and the mating component of the present invention;

[0029] Figure 3This is a schematic diagram of the locking component position of the present invention;

[0030] Figure 4 This is a schematic diagram of the welding lower plate structure of the present invention;

[0031] Figure 5 This is a cross-sectional view of the welding lower plate of the present invention;

[0032] Figure 6 This is a schematic diagram of the positioning component structure of the present invention;

[0033] Figure 7 This is a schematic diagram of the component structure of the present invention;

[0034] Figure 8 This is a schematic diagram of the locking component structure of the present invention.

[0035] In the diagram: 1. Workbench; 2. Lower welding plate; 21. Placement slot; 22. Welding table; 221. Mating ring groove; 222. Welding joint; 23. Mounting hole; 24. Fixing hole; 25. Gas flow channel; 26. Diverting flow channel; 3. Controller; 4. Telescopic rod; 5. Upper welding plate; 6. Positioning assembly; 61. Return spring; 62. Telescopic block; 63. Snap-fit ​​block; 7. Mating assembly; 71. Mating block; 72. Limiting groove; 73. Snap-fit ​​groove; 8. Locking assembly; 81. Drive motor; 82. Drive cylinder; 83. Moving block; 84. Lowering block; 85. Mating snap-fit ​​block. Detailed Implementation

[0036] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0037] like Figure 1-8 As shown, a novel welding device for aluminum wires and copper terminals features a rational structural design and comprehensive functions. It mainly includes a workbench 1, a lower welding plate 2, a controller 3, a telescopic rod 4, an upper welding plate 5, a positioning assembly 6, a mating assembly 7, and a locking assembly 8, among other key components. The workbench 1 serves as the supporting foundation for the entire device, installed on the ground, and possesses good stability and load-bearing capacity. The lower welding plate 2 is installed above the workbench 1 to support the welding workpiece and also serves as the lower support structure. The controller 3 is fixed to the upper area of ​​the workbench 1 and is responsible for the control and operation of the entire welding system, including temperature regulation, telescopic control, and the start and stop management of the welding program.

[0038] A telescopic rod 4 is installed below the controller 3, with one end connected to the controller 3 and the other end connected to the upper welding plate. The telescopic rod 4 enables the upper welding plate 5 to move up and down, facilitating workpiece clamping, positioning, and welding operations. The upper welding plate 5 is installed below the telescopic rod 4 and can be docked or separated from the lower welding plate 2 during operation through telescopic movement. Positioning components 6 are installed inside both the upper welding plate 5 and the lower welding plate 2. These components are used to precisely position the aluminum wire and copper terminal, ensuring alignment of the two different metal materials during welding, which helps improve welding quality and joint strength.

[0039] In addition, the lower welding plate 2 is equipped with a mating component 7, and correspondingly, the upper welding plate 5 is equipped with a locking component 8. The mating component 7 and the locking component 8 are positioned opposite each other and fit tightly. When the telescopic rod 4 lowers the upper welding plate 5 to the designated position, the locking component 8 can accurately insert into the mating component 7, and complete the fixing and locking between the two plates through rotation or pressing, effectively preventing component misalignment due to vibration or thermal expansion and contraction during the welding process. At the same time, the positioning component 6 calibrates the workpiece before the entire welding operation to ensure the accuracy and consistency of the welding process. This device enables efficient, stable, and safe welding of aluminum wires and copper terminals, and is widely applicable to power, automotive, and electronics industries.

[0040] like Figure 4 As shown, the structural design of the welding lower plate 2 fully considers the stability and precision of welding aluminum wires and copper terminals. It mainly consists of four parts: placement slots 21, welding tables 22, mounting holes 23, and fixing holes 24. The placement slots 21 are formed on the upper surface of the welding lower plate 2 and are arranged in a linear array to facilitate continuous multi-station operation and improve overall welding efficiency. A welding table 22 is set in the central area of ​​each placement slot 21. The cross-section of the welding table 22 is semi-circular, which helps to better fit the arc shape of the aluminum wire or copper terminal, improves the stability of positioning, and prevents the welding quality from deteriorating due to slippage or displacement during the welding process.

[0041] The welding table 22 has symmetrical mounting holes 23 on both sides for mounting auxiliary clamps or limiting devices to further fix the welding workpiece, ensure accurate welding position, and improve welding reliability. In addition, fixing holes 24 are provided between two adjacent placement slots 21 to firmly fix the welding workpiece or other accessories to the lower plate, thereby preventing workpiece displacement due to vibration or temperature changes during welding. It is worth mentioning that the upper welding plate 5 also has mirror images of the placement slots 21, welding table 22, mounting holes 23, and fixing holes 24 at positions corresponding to the lower welding plate 2, thereby achieving precise alignment and synchronous locking of the upper and lower plates during welding, providing a stable welding support environment for the aluminum-copper joint.

[0042] like Figure 5 As shown, the bottom of the welding lower plate 2 is carefully designed with a gas flow channel 25. This gas flow channel 25 is used to transport protective gas, such as argon or a mixed gas, during the welding process to prevent oxidation or the generation of harmful impurities in the welding area, ensuring the stability of welding quality and the reliability of electrical conductivity. Above the gas flow channel 25, a horizontally arranged diversion channel 26 is also provided. The diversion channel 26 is arranged in parallel, which can evenly distribute the bottom gas to multiple points in the welding area, thereby forming a stable and balanced gas protective environment. Through the combined action of the gas flow channel 25 and the diversion channel 26, the weld formation effect can be effectively improved, defects such as porosity and slag inclusions can be reduced, and the high requirements for atmosphere control in the welding of dissimilar metals such as aluminum wires and copper terminals can be met.

[0043] like Figure 5 As shown, the welding station 22 has a precisely formed mating groove 221 inside. This groove 221 has a ring-shaped structure and is used to tightly fit with the corresponding component in the upper plate structure, ensuring good sealing and structural stability of the welding station 22 during operation. At the lower end of the groove 221, a welding port 222 is further formed. This port is used to guide the output of gas or welding medium. Its reasonable design effectively and accurately delivers the protective gas from below to the contact area of ​​the workpiece. The other end of the welding port 222 communicates with the diversion channel 26. This connection allows the gas in the diversion channel 26 to smoothly enter the welding interface area, forming a closed local atmosphere environment. This prevents oxygen from entering the welding point, effectively improving welding quality and reducing welding defects. It is particularly suitable for welding dissimilar metals such as aluminum and copper, where a high protective atmosphere is required.

[0044] like Figure 6 As shown, the positioning component 6 is used for precise positioning and stable fixing of aluminum wires and copper terminals during the welding process. Its structure includes three parts: a return spring 61, a telescopic block 62, and a locking block 63. The return spring 61 is installed in the mounting hole 23 inside the welding table 22, possessing good elastic recovery capability, and can automatically return the telescopic mechanism to its initial state after the welding operation is completed. The telescopic block 62 is installed above the return spring 61, and can move up and down under force or spring push to adapt to the clamping needs of workpieces of different specifications or shapes. The locking block 63, as the uppermost positioning component, is installed on top of the telescopic block 62. Its upper surface is designed with an arc-shaped structure, which can naturally fit with the surface of the aluminum wire or copper terminal, thereby achieving a more stable positioning effect. This arc-shaped surface not only increases the contact area and prevents workpiece slippage, but also avoids damage to the wires, improving the applicability and safety of the device and ensuring smooth welding operations.

[0045] like Figure 7As shown, the mating assembly 7 is used to achieve precise docking and stable locking between the upper and lower plates of the welding device. Its structure includes three parts: a mating block 71, a limiting groove 72, and a snap-fit ​​groove 73. The mating block 71 is a hollow structure, installed in the fixing hole 24 of the lower welding plate 2, serving as a connection and support. A limiting groove 72 is provided on the side wall surface of the hollow part inside the mating block 71. This limiting groove 72 is used to cooperate with the limiting structure in the locking assembly 8 to ensure precise control of the insertion angle and depth, preventing misalignment or shaking. Inside the lower part of the mating block 71, a snap-fit ​​groove 73 is also provided. This snap-fit ​​groove 73 is used to mechanically engage with the snap-fit ​​component in the locking assembly 8. When the upper plate descends to the working position, the locking assembly 8 inserts into the mating block 71 and snaps into the snap-fit ​​groove 73, thus firmly connecting the upper and lower structures, thereby improving the overall stability and safety during the welding process. This design is simple and efficient, facilitates quick assembly and disassembly, and improves operational convenience and reliability.

[0046] like Figure 8 As shown, the locking component 8 is used to achieve automatic docking and secure locking between the upper welding plate 5 and the lower plate. Its overall structure includes multiple components such as a drive motor 81, a drive cylinder 82, a moving block 83, a lower moving block 84, and a mating block 85. The drive motor 81 is installed inside the upper welding plate 5 and serves as the power source for this component, enabling precise control of its movements via control signals. Below the drive motor 81, the drive cylinder 82 is located to convert rotational motion into linear displacement, achieving precise pushing of the lower component. The moving block 83 is installed at the lower end of the drive cylinder 82, acting as a connecting intermediate component to effectively transmit the thrust output by the cylinder to the lower moving block 84. The lower moving block 84 is installed at the bottom of the moving block 83, ultimately engaging with the lower plate mating component 7. The surface of the lower moving block 84 is provided with a mating block 85, which is used to insert into the locking groove 73 in the lower plate mating component 7, achieving precise engagement and rotational locking. This ensures the welding device is structurally stable and not easily loosened during operation, improving overall welding accuracy and safety performance. This locking structure is reliable and highly automated, making it suitable for welding needs under various complex working conditions.

[0047] A novel method for welding aluminum wires to copper terminals, the method being used in conjunction with the aforementioned novel welding device for aluminum wires to copper terminals; the steps of the method are as follows:

[0048] S1: The staff places the aluminum wire and copper terminal on the placement slot 21 of the welding lower plate 2 by means of machinery or manual means, and starts the controller 3 to move the welding upper plate 5 downward by means of the telescopic rod 4 so that the welding upper plate 5 covers the welding lower plate 2.

[0049] S2: The aluminum wire and the copper terminal are contacted by two upper and lower locking blocks 63, and are positioned under the elastic force of the return spring 61, so that the welding part is located on the welding table 22.

[0050] S3: Drive cylinder 82 drives moving block 83 to move down, and cooperates with locking block 85 to slide to the bottom in limiting groove 72. Drive motor 81 drives drive cylinder 82 to rotate, causing moving block 84 to rotate, and locking block 85 is locked in locking groove 73.

[0051] S4: Gas is introduced into the interior through the gas flow channel 25. After passing through the diversion channel 26, the gas enters the mating ring groove 221 and is ignited at the welding joint 222 to achieve simultaneous welding of the upper and lower parts.

[0052] During operation, the worker places the aluminum wire and copper terminal in the placement groove 21 of the lower welding plate 2 mechanically or manually. Then, the controller 3 is activated, controlling the telescopic rod 4 to move the upper welding plate 5 downward, covering the lower welding plate 2 and forming a closed welding space. The locking block 63 inside the upper and lower plates clamps and positions the aluminum wire and copper terminal under the elastic action of the return spring 61, ensuring that the part to be welded falls precisely in the center area of ​​the welding table 22. The drive cylinder 82 moves the moving block 83 downward, causing the mating locking block 85 to slide to the bottom in the limiting groove 72. Then, the drive motor 81 controls the downward moving block 84 to rotate, firmly locking the mating locking block 85 into the locking groove 73 of the lower plate, thereby achieving stable locking of the upper and lower welding plates. The system injects protective gas through the gas flow channel 25. The gas is evenly guided to the mating ring groove 221 through the diversion channel 26 and ignited at the welding port 222, completing the high-temperature connection of the aluminum wire and copper terminal, and achieving fast and stable double-sided welding.

[0053] Various modifications to this disclosure will be readily apparent to those skilled in the art, and the general principles defined herein can be applied to other variations without departing from the scope of this disclosure. Therefore, this disclosure is not limited to the examples and designs described herein, but should be given the broadest scope consistent with the principles and novel features disclosed herein. Although one or more exemplary embodiments of this disclosure have been described with reference to the accompanying drawings, those skilled in the art will understand that various changes in form and detail may be made therein without departing from the spirit and scope of this disclosure as defined by the appended claims.

Claims

1. A novel welding device for aluminum wires and copper terminals, characterized in that, The system includes a workbench (1), a lower welding plate (2), a controller (3), a telescopic rod (4), an upper welding plate (5), a positioning component (6), a mating component (7), and a locking component (8). The workbench (1) is installed on the ground, the lower welding plate (2) is installed on top of the workbench (1), the controller (3) is installed above the workbench (1), the telescopic rod (4) is installed below the controller (3), the upper welding plate (5) is installed below the telescopic rod (4), the positioning component (6) is installed inside the upper welding plate (5) and the lower welding plate (2), the mating component (7) is installed inside the lower welding plate (2), and the locking component (8) is installed inside the upper welding plate (5). The positions of the mating component (7) and the locking component (8) are correspondingly set. After the locking component (8) enters the mating component (7) and rotates, it locks the upper welding plate (5) and the lower welding plate (2). The positioning component (6) locks the welding workpiece. For positioning and calibration, a gas flow channel (25) is provided at the bottom of the welding lower plate (2), and a horizontally arranged diversion channel (26) is provided above the gas flow channel (25). The welding lower plate (2) includes a placement groove (21), a welding table (22), a mounting hole (23), and a fixing hole (24). A mating ring groove (221) is provided inside the welding table (22), and a welding port (222) is provided at the lower end of the mating ring groove (221). The other end of the welding port (222) is connected to the diversion channel (26). The gas flow channel (25) is used to transport protective gas during the welding process to prevent oxidation or harmful impurities in the welding area, and to ensure the stability of welding quality and the reliability of electrical conductivity. Protective gas is injected through the gas flow channel (25), and the gas is evenly guided to the mating ring groove (221) through the diversion channel (26) and ignited at the welding port (222) to complete the high-temperature connection between the aluminum wire and the copper terminal.

2. The novel welding device for aluminum wires and copper terminals according to claim 1, characterized in that: The placement slot (21) is opened on the upper surface of the welding lower plate (2). The placement slot (21) is arranged in a linear array. The welding table (22) is arranged in the middle of the placement slot (21). The cross-section of the welding table (22) is set as a semi-circle. The mounting hole (23) is opened on both sides of the welding table (22). The fixing hole (24) is opened in the middle of the adjacent placement slot (21).

3. The novel welding device for aluminum wires and copper terminals according to claim 2, characterized in that: The welding plate (5) is mirror-imagely provided with a placement groove (21), a welding table (22), a mounting hole (23), and a fixing hole (24) in the same position.

4. The novel welding device for aluminum wires and copper terminals according to claim 3, characterized in that: The positioning component (6) includes a return spring (61), a telescopic block (62), and a snap-fit ​​block (63); the return spring (61) is installed inside the mounting hole (23), the telescopic block (62) is installed on top of the return spring (61), and the snap-fit ​​block (63) is installed on top of the telescopic block (62).

5. The novel welding device for aluminum wires and copper terminals according to claim 4, characterized in that: The top of the snap-fit ​​block (63) is set as an arc surface.

6. The novel welding device for aluminum wires and copper terminals according to claim 5, characterized in that: The mating component (7) includes a mating block (71), a limiting groove (72), and a snap-fit ​​groove (73); the mating block (71) is installed in the fixing hole (24), the limiting groove (72) is opened on the surface of the hollow part inside the mating block (71), and the snap-fit ​​groove (73) is opened on the bottom of the hollow part inside the mating block (71).

7. The novel welding device for aluminum wires and copper terminals according to claim 6, characterized in that: The locking assembly (8) includes a drive motor (81), a drive cylinder (82), a moving block (83), a lowering block (84), and a mating block (85); the drive motor (81) is installed inside the welding upper plate (5), the drive cylinder (82) is installed below the drive motor (81), the moving block (83) is installed below the drive cylinder (82), the lowering block (84) is installed below the moving block (83), and the mating block (85) is disposed on the surface of the lowering block (84).

8. A novel method for welding aluminum wires to copper terminals, the method being used in conjunction with the novel welding apparatus for aluminum wires to copper terminals as described in claim 7; characterized in that: The steps of the method are as follows: S1: The worker places the aluminum wire and copper terminal on the placement slot (21) of the welding lower plate (2) by means of machinery or manual means, starts the controller (3), and moves the welding upper plate (5) downward by means of the telescopic rod (4) so ​​that the welding upper plate (5) covers the welding lower plate (2); S2: The aluminum wire and copper terminal are contacted by the two upper and lower locking blocks (63), and are positioned under the elastic force of the return spring (61) so that the welding part is located on the welding table (22). S3: The drive cylinder (82) drives the moving block (83) to move down, and the locking block (85) slides to the bottom in the limiting groove (72). The drive motor (81) drives the drive cylinder (82) to rotate, so that the moving block (84) rotates and the locking block (85) is locked in the locking groove (73). S4: Gas is introduced into the interior through the gas flow channel (25). After the gas passes through the diversion channel (26), it enters the mating ring groove (221) and is ignited at the welding joint (222) to achieve simultaneous welding of the upper and lower parts.

Images