Air conditioner panel ultrasonic welding machine and welding method

Abstract

The air conditioner panel ultrasonic welding machine comprises a supporting table, the upper portion of the supporting table is connected with a support, the support is provided with a linear module, the linear module is in driving connection with a welding mechanism, the supporting table is provided with a linear sliding table, the linear sliding table is in driving connection with a fixing table, and the fixing table is provided with a tool. A welding part and an air conditioner panel are installed on the tool, the welding part is inserted into the tool, and the air conditioner panel is located above the welding part. The air conditioner panel welding device can effectively complete welding of an air conditioner panel.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and more specifically, to an ultrasonic welding machine and welding method for air conditioning panels. Background Technology

[0002] Currently, in the manufacturing process of air conditioner panels, adhesive films or tapes are widely used for connecting plastic parts, especially for connecting the front panel and the liner. While these tapes do reduce the amount of manual labor required for screw or snap fastener connections, this tape connection method does have the following drawbacks:

[0003] I. Film Quality Stability: Numerous domestic and international film manufacturers offer a wide variety of films, with inconsistent quality. Different components have different film requirements, making it impossible to guarantee product quality. II. Environmental Issues: VOCs are generated during film production and use, and odor issues may even exist at the end-user level. III. Aging Issues: Components such as air conditioners are typically used for several years. Depending on the application scenario, the film may undergo aging due to humidity, light, and salt spray, leading to performance degradation and, in severe cases, component failure. IV. Low Production Efficiency: While film can improve production efficiency in some situations, it's difficult to apply to curved or recessed areas, requiring significant manual labor and impacting efficiency. V. High Cost: The manufacturing process of film is relatively complex, resulting in high costs. Film costs typically account for one-third of panel costs, while its weight accounts for less than 5%.

[0004] Ultrasonic welding is a method that uses ultrasonic waves to induce relative friction and fusion at the material interface. Air conditioner panels can be curved or flat; traditional ultrasonic welding equipment cannot effectively weld curved panels. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide an ultrasonic welding machine for air conditioning panels.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] This invention discloses an ultrasonic welding machine for air conditioner panels, including a support platform, a bracket connected to the upper part of the support platform, a linear module mounted on the bracket, a welding mechanism driven by the linear module, a linear slide mounted on the support platform, a fixed platform driven by the linear slide, a fixture mounted on the fixed platform, a welding component and an air conditioner panel mounted on the fixture, the welding component being inserted into the fixture, and the air conditioner panel being located above the welding component.

[0008] Furthermore, the upper part of the tooling is provided with an installation groove, and an installation block is provided in the installation groove.

[0009] Furthermore, the welding mechanism includes a linear actuator that drives an ultrasonic welding head.

[0010] Furthermore, the welded component includes a welding plate, one side of which is connected to a snap-fit ​​connector, and the other side of which is provided with a welding wire, with the side of the welding plate provided with the welding wire facing the air conditioning panel.

[0011] Furthermore, the bonding wires include outer bonding wires, which are arranged according to the outline of the bonding plate, and inner bonding wires, which are located within the area enclosed by the outer bonding wires and are arranged in a grid pattern.

[0012] Furthermore, the mounting slots are arranged in three rows on the tooling, and three welding mechanisms are arranged accordingly, with the positions of the welding mechanisms corresponding to the positions of the mounting slots.

[0013] Furthermore, a fixing groove is provided on the outer periphery of the tooling, and a fixing block that mates with the fixing groove is provided on the fixing platform.

[0014] Furthermore, the tooling has a through hole, and a vacuum tube corresponding to the position of the through hole is set on the fixed platform.

[0015] A welding method for an air conditioner panel.

[0016] Step 1: The linear module drives the welding mechanism to move to the origin, and the linear slide drives the fixed table to move forward;

[0017] Step 2: Insert the corresponding mounting block into the fixing groove of the tooling according to the shape of the welded part, then insert the welded part onto the mounting block, and place the air conditioner panel on the tooling;

[0018] Step 3: The linear slide table drives the fixed stage to move backward to the welding position, and the linear module drives the welding mechanism to move to the position on the air conditioning panel corresponding to the welding part;

[0019] Step 4: The linear actuator drives the ultrasonic welding head to move, so that the ultrasonic welding head presses on the air conditioner panel. The ultrasonic welding head starts welding. After welding is completed, the ultrasonic welding head stops, and the linear actuator drives the ultrasonic welding head to move back to its original position. The linear module drives the welding mechanism to move to the position on the air conditioner panel corresponding to the position of the next column of welded parts.

[0020] Step 5: Repeat step 4 until all welded parts are completed.

[0021] The beneficial effects of the present invention are: a fixing groove is provided on the tooling, and a fixing block for placing the welding parts can be installed in the fixing groove, so that the welding parts can be in close contact with the air conditioner panel placed on the work surface, thereby achieving good welding. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a structure of an ultrasonic welding machine for air conditioning panels in this embodiment;

[0023] Figure 2 This is a schematic diagram showing the positional relationship between the welding mechanism and the tooling in this embodiment;

[0024] Figure 3 for Figure 2 Enlarged view of point A in the middle;

[0025] Figure 4 This is a schematic diagram of one structure of the welded component in this embodiment;

[0026] Figure 5 This is a schematic diagram of one structure of the bonding wire in this embodiment;

[0027] Figure 6 This is a schematic diagram of one usage state of the tooling in this embodiment;

[0028] Figure 7 This is a schematic diagram of the buffer structure in this embodiment;

[0029] Figure 8 This is a schematic diagram of the buffer component from another perspective in this embodiment;

[0030] Figure 9 This is a schematic diagram of one structure of the synchronizing rod in this embodiment.

[0031] Reference numerals: Support platform 100; Bracket 110; Linear module 111; Fixed platform 112; Linear slide 113; Guide rail 114; Fixing block 115; Welding mechanism 200; Linear actuator 220; Control valve 221; Ultrasonic welding head 230; Tooling 300; Mounting block 310; Fixing groove 311; Through hole 312; Vacuum tube 313; Air conditioning panel 400; Welding plate 510; Clip connector 520; External welding wire 530; Internal welding wire 531; Buffer 600; First connector 610; First connecting cavity 610; First connecting plate 612; Slide groove 613; Second connector 620; Second connecting cavity 621; Second connecting plate 622; Connecting groove 622; Spring 630; Synchronizing rod 700; Rotating part 710; Connecting part 720; Sliding part 730. Detailed Implementation

[0032] 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 creative efforts are within the scope of protection of the present invention.

[0033] like Figures 1-6 As shown, an ultrasonic welding machine for air conditioning panels includes a support platform 100, a bracket 110 connected to the upper part of the support platform 100, a linear module 111 mounted on the bracket 110, a welding mechanism 200 driven by the linear module 111, a linear slide 113 mounted on the support platform 100, a fixed platform 112 driven by the linear slide 113, and several guide rails 114 provided on the support platform 100. The fixed platform 112 is slidably mounted on the guide rails 114. The moving direction of the welding mechanism 200 is perpendicular to the moving direction of the fixture 300, and the welding mechanism 200 can move along the length of the fixture 300, sequentially reaching the positions of each welding component on the fixture 300. The fixture 300 is mounted on the fixed platform 112, and welding components and air conditioning panels 400 are mounted on the fixture 300. The welding components are inserted into the fixture 300, and the air conditioning panels 400 are located above the welding components, covering them.

[0034] like Figure 4 As shown, the welded component includes a welding plate 510. A snap-fit ​​connector 520 is connected to one side of the welding plate 510, and a welding wire is provided on the other side of the welding plate 510. The side of the welding plate 510 with the welding wire faces the air conditioning panel 400. The shape of the side of the welding plate 510 away from the snap-fit ​​connector 520 is consistent with the inner shape of the air conditioning panel 400, so that the welding plate 510 and the air conditioning panel 400 can fit tightly together.

[0035] The weld wires on welding plate 510 can assist in achieving better welding results. During the welding process, the weld wires melt first to ensure a full weld at the required welding points. For example... Figure 5 As shown, the welding wires include an outer welding wire 530, which is arranged according to the contour of the welding plate 510. The outer welding wire 530 is spaced 1-3 mm from the outer periphery of the welding plate 510 to ensure that the welding wires are not squeezed out of the welding plate 510 when the air conditioning panel 400 is pressed on the welding plate 510. The inner welding wire 531 is located within the area enclosed by the outer welding wire 530. The inner welding wire 531 is arranged in a grid pattern, which can effectively fill the area within the outer welding wire 530, thereby enhancing the welding effect.

[0036] The air conditioner panel 400 can be either curved or flat, and is made of ABS. The welded parts are also made of ABS. The upper surface of the fixture 300 is identical in shape to the inner side of the panel, i.e., the side of the panel closest to the fixture 300. This ensures that the installation position of the welded parts on the fixture 300 matches the position on the air conditioner panel 400, and that the fixture 300 effectively supports the air conditioner panel 400 while minimizing any gaps between them.

[0037] like Figure 6As shown, the upper part of the tooling 300 has an installation groove, and an installation block 310 is provided in the installation groove. The installation block 310 is provided with a cavity that mates with the snap-fit ​​connector 520 of the welded part. The installation block 310 is installed in the installation groove in a detachable manner. The appropriate installation block 310 is selected for installation according to different welded parts, so that different welded parts can be fixed and thus the welding of different welded parts can be completed.

[0038] The welding plate 510 is installed on the mounting block 310. The end face with the welding line is 2-5mm higher than the upper surface of the fixture 300 to ensure that the inner side of the air conditioner panel 400 does not contact the upper surface of the fixture 300, thus avoiding friction between the two during the welding process.

[0039] The welding mechanism 200 includes a linear actuator 220, which drives an ultrasonic welding head 230. The linear actuator 220 is a cylinder, and two control valves 221 are installed on the cylinder. The control valves 221 control the inlet and outlet of gas, thereby controlling the direction of piston movement.

[0040] The mounting slots are arranged in three rows on the tooling 300, and the welding mechanisms 200 are arranged in three corresponding rows, with the positions of the welding mechanisms 200 corresponding to the positions of the mounting slots.

[0041] The tooling 300 has a fixing groove 311 on its outer periphery, and the fixing platform 112 has a fixing block 115 that cooperates with the fixing groove 311. When the tooling 300 is installed on the fixing platform 112, the fixing block 115 is inserted into the fixing groove 311, thereby positioning and fixing the tooling 300 on the fixing platform 112.

[0042] The tooling 300 has a through hole 312, and the fixed platform 112 is provided with a vacuum tube 313 corresponding to the position of the through hole 312. The vacuum tube 313 can be used to adsorb the air conditioner panel 400, making the installation of the air conditioner panel 400 more stable.

[0043] like Figure 2 , Figures 7-9 As shown, a buffer 600 is provided between the linear actuator 220 and the ultrasonic welding head 230. The buffer 600 includes a first connector 610 fixedly connected to the output end of the linear actuator 220 and a second connector 620 fixedly connected to the ultrasonic welding head 230. The first connector 610 is provided with a first connecting cavity 610 opening towards the second connector 620, and the second connector 620 is provided with a second connecting cavity 621 opening towards the first connector 610. A spring 630 is installed between the first connecting cavity 610 and the second connector 620. The spring 630 can play a certain buffering role, preventing the ultrasonic welding head 230 from applying excessive pressure to the air conditioning panel 400, thereby effectively protecting the air conditioning panel 400.

[0044] Simultaneously, a first connecting plate 612 is provided in the first connecting cavity 610, and a second connecting plate 622 is provided in the second connecting cavity 621. Two first connecting plates 612 and two second connecting plates 622 are provided on the same side of both the first connecting cavity 610 and the second connecting cavity 621. The two first connecting plates 612 and the two second connecting plates 622 are connected by a synchronizing rod 700. The synchronizing rod 700 includes a rotating part 710, with connecting parts 720 perpendicular to it at both ends. The connecting parts 720 are connected to sliding parts 730 parallel to the rotating part 710. The first connecting plate 612 is provided with a sliding groove 613, and the sliding part 730 is embedded in the sliding groove 613. The second connecting plate 622 is provided with a connecting groove 623, and the rotating part 710 is rotatably embedded in the connecting groove 623. Two first connecting plates 612 and two second connecting plates 622, along with corresponding synchronizing rods 700, are provided on each corresponding side of the first connecting cavity 610 and the second connecting cavity 621. When the first connector 610 and the second connector 620 approach each other, the sliding part 730 slides within the groove 613, simultaneously causing the rotating part 710 to rotate. This ensures that all parts of the first connector 610 and the second connector 620 approach each other synchronously, preventing uneven force on the second connector 620 due to uneven force applied to the spring 630 by the first connecting cavity 610. This allows the pressure of the first connecting cavity 610 to be synchronously transmitted to the second connector 620, ensuring stable pressure on the welded part by the second connector 620 and the ultrasonic welding head 230, especially the stable pressure of the ultrasonic welding head 230 on the corresponding welded part when the welding head 201 is tilted on both sides.

[0045] A welding method for an air conditioner panel includes the following steps:

[0046] Step 1: The linear module 111 drives the welding mechanism 200 to move to the origin, that is, the welding mechanism 200 moves away from above the tooling 300. The linear slide 113 drives the fixed table 112 to move forward and reach the position above the support table 100.

[0047] Step 2: According to the shape of the welded part, insert the corresponding mounting block 310 into the fixing groove 311 of the tooling 300, and then insert the welded part into the mounting block 310. The side of the welding plate 510 with the welding line is set upward. Place the air conditioner panel 400 on the tooling 300. The air conditioner panel 400 can also be adsorbed onto the tooling 300 through the additionally set vacuum tube 313 to enhance the fixation of the air conditioner panel 400.

[0048] Step 3: The linear slide 113 drives the fixed stage 112 to move backward to the welding position, and the linear module 111 drives the welding mechanism 200 to move to the position on the air conditioning panel 400 corresponding to the welding part.

[0049] Step 4: The linear actuator 220 drives the ultrasonic welding head 230 to move, so that the ultrasonic welding head 230 presses on the air conditioner panel 400, making the air conditioner panel 400 and the welding plate 510 of the welded part fit tightly together.

[0050] The ultrasonic welding head 230 is activated to begin welding. The welding process parameters are: ultrasonic power 2-2.2 kW, ultrasonic frequency 18-22 kHz, welding time 0.5-1 second, and welding pressure 0.4-0.5 atmospheres. After welding is completed, the ultrasonic welding head 230 stops, and the linear actuator 220 drives the ultrasonic welding head 230 to move back to its original position. The linear module 111 drives the welding mechanism 200 to move to the position on the air conditioning panel 400 corresponding to the next column of welded parts.

[0051] Step 5: Repeat step 4 until all welded parts are completed.

[0052] Step 6: The linear module 111 drives the welding mechanism 200 to move to the origin, and the linear slide 113 drives the fixed table 112 to move forward, so as to remove the air conditioner panel 400 with the welded part from the tooling 300.

[0053] For the curved air conditioner panel 400, the welding process parameters are as follows: ultrasonic power of 2 kW, ultrasonic frequency of 20 kHz, welding time of 0.8 seconds, and welding pressure of 0.4 standard atmospheres.

[0054] For the flat air conditioner panel 400, the welding process parameters are as follows: ultrasonic power is 2 kW, ultrasonic frequency is 20 kHz, welding time is 0.5 seconds, and welding pressure is 0.4 standard atmospheres.

[0055] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiment. All technical solutions based on the concept of the present invention are within the scope of protection of the present invention. It should be noted that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An ultrasonic welding machine for air conditioner panels, characterized in that, The device includes a support platform (100), a bracket (110) connected to the upper part of the support platform (100), a linear module (111) mounted on the bracket (110), a welding mechanism (200) driven and connected to the linear module (111), a linear slide (113) mounted on the support platform (100), a fixed platform (112) driven and connected to the linear slide (113), a fixture (300) mounted on the fixed platform (112), a welded component and an air conditioning panel (400) mounted on the fixture (300), the welded component being inserted into the fixture (300), and the air conditioning panel (400) being located above the welded component.

2. The ultrasonic welding machine for air conditioner panels according to claim 1, characterized in that, The tooling (300) has an installation groove on its upper part, and an installation block (310) is provided in the installation groove.

3. The ultrasonic welding machine for air conditioner panels according to claim 1, characterized in that, The welding mechanism (200) includes a linear actuator (220) that drives an ultrasonic welding head (230) connected to it.

4. The ultrasonic welding machine for air conditioner panels according to claim 1, characterized in that, The welded component includes a welding plate (510), one side of which is connected to a snap connector (520), and the other side of which is provided with a welding wire. The side of the welding plate (510) with the welding wire faces the air conditioning panel (400).

5. The ultrasonic welding machine for air conditioner panels according to claim 4, characterized in that, The welding lines include an outer welding line (530) which is arranged according to the outline of the welding plate (510), and an inner welding line located within the area enclosed by the outer welding line (530) which is arranged in a grid pattern.

6. The ultrasonic welding machine for air conditioner panels according to claim 2, characterized in that, The mounting slots are arranged in three rows on the tooling (300), and the welding mechanisms (200) are arranged in three corresponding rows. The positions of the welding mechanisms (200) correspond to the positions of the mounting slots.

7. The ultrasonic welding machine for air conditioner panels according to claim 1, characterized in that, The tooling (300) has a fixing groove (311) on its outer periphery, and the fixing platform (112) has a fixing block (115) that cooperates with the fixing groove (311).

8. An ultrasonic welding machine for air conditioner panels according to claim 1, characterized in that, The tooling (300) has a through hole (312), and the fixed platform (112) is provided with a vacuum tube (313) corresponding to the position of the through hole (312).

9. A welding method for an air conditioner panel, using an ultrasonic welding machine for an air conditioner panel as described in any one of claims 1-8, characterized in that, Includes the following steps: Step 1: The linear module (111) drives the welding mechanism (200) to move to the origin, and the linear slide (113) drives the fixed stage (112) to move forward; Step 2: According to the shape of the welded part, insert the corresponding mounting block (310) into the fixing groove (311) of the fixture (300), then insert the welded part into the mounting block (310), and place the air conditioner panel (400) on the fixture (300); Step 3: The linear slide (113) drives the fixed stage (112) to move backward to the welding position, and the linear module (111) drives the welding mechanism (200) to move to the position on the air conditioning panel (400) corresponding to the welding part; Step 4: The linear actuator (220) drives the ultrasonic welding head (230) to move, so that the ultrasonic welding head (230) presses on the air conditioning panel (400). The ultrasonic welding head (230) starts welding. After welding is completed, the ultrasonic welding head (230) stops, and the linear actuator (220) drives the ultrasonic welding head (230) to move back to its original position. The linear module (111) drives the welding mechanism (200) to move to the position on the air conditioning panel (400) corresponding to the position of the next column of welded parts. Step 5: Repeat step 4 until all welded parts are completed.

10. The welding method for an air conditioner panel according to claim 9, characterized in that, The welding process parameters are as follows: ultrasonic power 2-2.2 kW, ultrasonic frequency 18-22 kHz, welding time 0.5-1 second, and welding pressure 0.4-0.5 atmospheres.

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