Machining method for precise positioning of aluminum-nickel welding process

Abstract

The invention relates to the technical field of aluminum bar manufacturing, in particular to a machining method for precise positioning of an aluminum-nickel welding process, which is characterized in that a double-clamping-groove positioning structure is designed on an aluminum bar base body, and the structure replaces manual lineation through mechanical positioning, so that the problems of poor positioning precision and tedious procedures of a traditional process are effectively solved. The implementation process comprises the steps of machining the positioning clamping groove through laser cutting, precisely assembling the nickel sheet, welding aluminum and nickel, stacking and fixing, and carrying out batch linear cutting, so that a set of complete precise welding solution is formed. According to the method, the positioning precision and the production efficiency are remarkably improved, and a foundation is laid for automatic production.

Description

Technical Field

[0001] This invention relates to the field of aluminum busbar manufacturing technology, and more specifically, to a processing method for precise positioning in an aluminum-nickel welding process. Background Technology

[0002] Current aluminum-nickel welding processes primarily rely on manual operation, resulting in systemic technical deficiencies. Operators must first use a shearing machine to cut aluminum strips to the appropriate size, then use calipers to mark lines on the aluminum strips. Nickel sheets of a specific size are then spot-welded to the aluminum plate along the marked lines using a resistance spot welder for positioning, before aluminum-nickel welding is performed. This method suffers from three major technical bottlenecks:

[0003] (1) Low positioning accuracy and uncontrollable error: Shearing error reaches ±0.5mm, manual scribing error reaches ±0.5mm, spot welding fixing error reaches ±0.2mm, welding offset error reaches ±0.2mm, nickel sheet size reaches ±0.1mm, and the cumulative error is ≥1.5mm, resulting in low product qualification rate.

[0004] (2) Low production efficiency: The process is complicated and time-consuming. Each welding position requires separate marking, alignment and spot welding. There are many steps and the cycle is long. It is highly dependent on skilled workers. Operators need to concentrate their attention and the operation speed is limited. The process relies heavily on human eyes and manual positioning, which makes it difficult to mass-produce and prolongs the production cycle of products.

[0005] (3) High cost: High labor costs, requiring a large number of skilled workers for repetitive labor; High rework / scrap rate, with a high rate of welding defects due to poor positioning, resulting in rework or scrap costs; High inspection cost: To ensure quality, it is necessary to increase the size of the welding position for full inspection in subsequent processes, thereby increasing inspection costs and time; Quality risk cost: Due to quality hazards such as welding size deviation, products may enter the end market, resulting in high risk costs including after-sales maintenance, quality claims and compliance fines. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the purpose of this invention is to provide a processing method for precise positioning in aluminum-nickel welding, which solves the technical problems of poor positioning accuracy, cumbersome procedures, low efficiency, and insufficient quality stability caused by the reliance on manual positioning in traditional aluminum-nickel welding processes.

[0007] The above-mentioned technical objective of the present invention is achieved through the following technical solution:

[0008] A machining method for precise positioning in an aluminum-nickel welding process includes the following steps:

[0009] (1) Material preparation: Use a laser beam to cut the aluminum busbar to the specified size, and cut alignment holes and two slots for precise positioning of the nickel sheet on the aluminum busbar substrate. The length of the slot is L1 and the width is W1. At the same time, use a computer slicer to cut the nickel sheet to the specified size. The length of the nickel sheet is 2*(L2+H) and the width is W2. Wherein, L1=W2+(0.2mm*2), L2 is the distance between the two slots, and H is the thickness of the aluminum busbar substrate.

[0010] (2) Positioning the nickel sheet: Pass the nickel sheet through the slot on the aluminum busbar base and bend it along the edge to fix it so that the nickel sheet is stably fixed in the slot of the aluminum busbar;

[0011] (3) Aluminum-nickel welding: Use tongs to hold the aluminum busbar and feed it into the welding machine for aluminum-nickel welding;

[0012] (4) Stacking and welding: Align multiple aluminum bars that have been completed with aluminum-nickel welding through alignment holes using round pins, clamp them with pliers, and fix them at the four corners of the aluminum bars with argon arc welding to form a 10PCS / stack welding assembly.

[0013] (5) Wire cutting: The stacked aluminum bars are fixed on the machine table and wire cut using a fast wire cutting machine to obtain the final product.

[0014] Preferably, the slot includes a main positioning slot and an auxiliary positioning slot, and the two slots together form a rigid limiting system to constrain the movement and rotational degrees of freedom of the nickel sheet.

[0015] Preferably, the positional relationship between the main positioning slot and the auxiliary positioning slot is set such that the positioning error after the nickel sheet is assembled is controlled within ±0.2mm.

[0016] Preferably, the alignment holes on the aluminum busbar substrate serve as reference holes during stacking and welding, ensuring the alignment accuracy of multiple aluminum busbars during stacking.

[0017] Preferably, the laser cutting process in step (1) meets the accuracy requirements of the linear tolerance dimension table in GB / T1804-2000.

[0018] Preferably, after the nickel sheet passes through the slot, it is temporarily fixed by slight manual bending to avoid displacement before welding.

[0019] Preferably, W1 = 2.5-3.0 mm.

[0020] In summary, this invention offers the following advantages: Through innovative mechanical positioning structure design, it achieves a technological breakthrough in aluminum-nickel welding, yielding significant technical benefits. Regarding positioning accuracy, the integrated slot structure replaces traditional manual marking for positioning, and the rigid limit design eliminates random operational errors, establishing a self-contained positioning coordinate system for the workpiece, thus greatly improving positioning accuracy and consistency. In terms of process efficiency, the previously discrete multi-step process is integrated into a continuous flow, eliminating intermediate temporary fixing links and enabling batch synchronous processing, significantly shortening the production cycle. Regarding quality stability, the mechanical positioning structure effectively eliminates systematic errors caused by human factors, reducing the impact of thermal deformation during welding, and significantly improving product consistency and reliability. This technical solution fundamentally changes the reliance of traditional aluminum-nickel welding processes on manual operation, providing the industry with an innovative solution that is high-precision, high-efficiency, and highly stable. Attached Figure Description

[0021] Figure 1 This is a process flow diagram of the present invention.

[0022] Figure 2 yes Figure 1 Top view of section (C).

[0023] Figure 3 yes Figure 2 A sectional view of section FF.

[0024] Figure 4 This is the wire cutting path diagram in step (5) of the present invention.

[0025] In the diagram: 1. Aluminum strip base; 11. Alignment hole; 12. Main positioning slot; 13. Auxiliary positioning slot; 2. Nickel sheet. Detailed Implementation

[0026] To make the objectives, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Several embodiments of the present invention are shown in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein.

[0027] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0028] Example 1

[0029] A machining method for precise positioning in aluminum-nickel welding process, such as... Figure 1-4 As shown, it includes the following steps:

[0030] (1) Material preparation: such as Figure 1As shown in section (A), the operator uses a laser beam to cut the aluminum busbar to the specified size (the cutting accuracy meets the linear tolerance dimension table of GB / T1804-2000), and cuts alignment holes 11 and two slots (including a main positioning slot 12 and an auxiliary positioning slot 13) for precise positioning of the nickel sheet 2 on the aluminum busbar base 1. The length of the slot is L1 and the width is W1. At the same time, a computer slicer is used to cut the nickel sheet 2 to the specified size. The length of the nickel sheet is 2*(L2+H) and the width is W2. Wherein, L1=W2+(0.2mm*2), L2 is the distance between the two slots, and H is the thickness of the aluminum busbar base 1. The specific dimensions of L1, W1, L2 and W2 are as follows. Figure 4 As shown;

[0031] (2) Positioning the nickel sheet: Pass the nickel sheet 2 through the slot on the aluminum busbar base 1, and gently bend and fix the nickel sheet 2 along the edge with your fingernail to make the nickel sheet 2 stably fixed in the slot of the aluminum busbar. Figure 1 As shown in section (B);

[0032] (3) Aluminum-nickel welding: The aluminum busbar is held in place by tongs and fed into the welding machine for aluminum-nickel welding, such as... Figure 1 As shown in section (C);

[0033] (4) Stacking and Welding: Multiple aluminum busbars that have completed aluminum-nickel welding are aligned using round pins through alignment holes 11, clamped with pliers, and then fixed at the four corners of the aluminum busbars with argon arc welding to form a welded assembly of 10 pieces per stack, such as... Figure 1 As shown in part (D);

[0034] (5) Wire EDM: The stacked aluminum bars are fixed on the machine base, and a fast wire EDM machine is used to perform wire cutting to obtain the final product, such as... Figure 1 As shown in section (E).

[0035] In this embodiment, production such as Figure 1 The product shown in section (E) is first cut into an aluminum busbar base 1 (90mm in length, 50mm in width, and 2mm in thickness) using laser cutting technology, and then a precision positioning slot structure is processed, including a main positioning slot 12 (18+2*0.2=18.4mm in length and 2.5-3.0mm in width) and an auxiliary positioning slot 13 (18+2*0.2=18.4mm in length and 3.0mm in width). Then, a pre-cut nickel sheet 2 (2*(20+2)=44mm in length and 18mm in width) is precisely embedded into the slot and temporarily fixed by slight bending.

[0036] In this invention, if there is only a main positioning slot 12 for positioning, the nickel sheet 2 is easily unstable in fixing on the aluminum busbar base 1, causing the welding of the nickel sheet 2 on both sides to be tilted, resulting in the nickel sheet's positional dimensions exceeding tolerance. In addition, setting both the main positioning slot 12 and the auxiliary positioning slot 13 can reduce the material consumption of the nickel sheet 2, so that the length of the nickel sheet 2 does not need to completely cover the edge of the aluminum busbar base 1 as originally.

[0037] The reason for setting the tolerance to +0.2mm((L1-W2) / 2) in this invention is that it was derived from practical experience in considering the width tolerance of the nickel sheet cut by the computer and the ease with which the operator can pass the nickel sheet through the slot. If the tolerance is too small, it will be inconvenient for the operator to pass the sheet through the slot; if the tolerance is too large, it will not be conducive to achieving a precise positioning effect.

[0038] To verify the technical effect of Example 1, the following comparative examples were designed for verification.

[0039] Comparative Example 1

[0040] Aluminum busbars are manufactured using existing processes (marking, spot welding, aluminum-nickel welding, stacking welding, wire cutting).

[0041] Comparative Example 2

[0042] The aluminum strip is manufactured using a process that only has the main positioning slot 12 and omits the auxiliary positioning slot 13. The other steps are the same as in Example 1.

[0043] Comparative Example 3

[0044] The aluminum busbar is manufactured using a process where the alignment holes 11 are not cut into the aluminum busbar substrate 1. The other steps are the same as in Example 1.

[0045] The following data are statistics on the dimensional inspection and welding time (before stacking and welding) of the aluminum busbars produced by the above four methods:

[0046] Table 1. Statistical Table

[0047]

[0048] The existing process in Comparative Example 1, after aluminum-nickel welding, also involves stacking and welding followed by centralized wire cutting, similar to this invention. However, due to the cumulative error ≥1.5mm, and the lack of alignment holes on the aluminum busbar substrate for fixing, the existing process can only align the edges of the aluminum busbar and clamp it with pliers for welding. This results in a larger error in the nickel sheets after stacking and welding the aluminum busbar. After wire cutting, approximately only 2-3 pieces out of a stack of aluminum busbars (10 pieces) pass full inspection and are dimensionally acceptable. In Example 1, the aluminum busbar with added slots maintains a product pass rate of over 96% after wire cutting (with a 4% defect rate due to surface damage), and the full inspection is changed to random sampling of 3 pieces per batch, significantly reducing inspection costs. In Comparative Examples 1-2, the positioning accuracy significantly deteriorates after omitting the auxiliary positioning slots 13 or alignment holes 11.

[0049] Regarding the welding production time: the production time for manufacturing 1 piece of aluminum busbar is between 130-150 seconds using the existing process (scribing-spot welding-welding) in Comparative Example 1, and between 30-50 seconds using the added slot in Example 1. The welding production time of Comparative Examples 1-2 is comparable to that of Example 1.

[0050] In summary, this invention solves the technical problems of poor positioning accuracy, cumbersome procedures, low efficiency, and insufficient quality stability caused by the reliance on manual positioning in traditional aluminum-nickel welding processes, and its technical effect meets expectations.

[0051] 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 embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A machining method for precise positioning in aluminum-nickel welding process, characterized in that: Includes the following steps: (1) Material preparation: Use a laser beam to cut the aluminum busbar to the specified size, and cut alignment holes and two slots for precise positioning of the nickel sheet on the aluminum busbar substrate. The length of the slot is L1 and the width is W1. At the same time, use a computer slicer to cut the nickel sheet to the specified size. The length of the nickel sheet is 2*(L2+H) and the width is W2. Wherein, L1=W2+(0.2mm*2), L2 is the distance between the two slots, and H is the thickness of the aluminum busbar substrate. (2) Positioning the nickel sheet: Pass the nickel sheet through the slot on the aluminum busbar base and bend it along the edge to fix it so that the nickel sheet is stably fixed in the slot of the aluminum busbar; (3) Aluminum-nickel welding: Use tongs to hold the aluminum busbar and feed it into the welding machine for aluminum-nickel welding; (4) Stacking and welding: Align multiple aluminum bars that have been completed with aluminum-nickel welding through alignment holes using round pins, clamp them with pliers, and fix them at the four corners of the aluminum bars with argon arc welding to form a 10PCS / stack welding assembly. (5) Wire cutting: The stacked aluminum bars are fixed on the machine table and wire cut using a fast wire cutting machine to obtain the final product.

2. The processing method according to claim 1, characterized in that: The slot includes a main positioning slot and an auxiliary positioning slot. The two slots together form a rigid limiting system to constrain the movement and rotational degrees of freedom of the nickel sheet.

3. The processing method according to claim 2, characterized in that: The positional relationship between the main positioning slot and the auxiliary positioning slot is set to control the positioning error of the nickel sheet after assembly within ±0.2mm.

4. The processing method according to claim 1, characterized in that: The alignment holes on the aluminum busbar substrate serve as reference holes during stacking and welding, ensuring the alignment accuracy of multiple aluminum busbars during stacking.

5. The processing method according to claim 1, characterized in that: The laser cutting process in step (1) meets the accuracy requirements of the linear tolerance dimension table in GB / T1804-2000.

6. The processing method according to claim 1, characterized in that: After the nickel sheet passes through the slot, it is temporarily fixed by slight manual bending to prevent displacement before welding.

7. The processing method according to claim 1, characterized in that: W1 = 2.5-3.0 mm.

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