Intelligent intermediate frequency welding machine for sliding rail connecting piece

Abstract

The invention relates to the technical field of medium-frequency inverter resistance welding, and discloses an intelligent medium-frequency welding machine for a sliding rail connecting piece and a differential welding tongs assembly which comprise a differential shell, a planetary bevel gear set and a driving bevel gear pair. The transmission chain comprises a half shaft which is connected with a first bevel gear set, a first intermediate transmission shaft, a second intermediate transmission shaft, a second bevel gear set, a second intermediate transmission shaft, a third bevel gear set and a third intermediate transmission shaft; the base pressure execution chain comprises a servo motor, and the output end of the servo motor is connected with a planet carrier input shaft through a first gear set and connected with a flywheel shaft through a second gear set; a phase coupling instantaneous pressurizing chain comprises a flywheel, a centrifugal swing block, a slope track and an electromagnetic clutch. The current detection and control system comprises a Hall current sensor and a controller; the bevel gear differential self-pressure-equalizing mechanism is used, the factor that two-channel force control coupling of a traditional double-execution-element system is complex is overcome, and the technical problem that double-point stress is uneven is solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of intermediate frequency inverter resistance welding, and more particularly to a slide rail connecting piece intelligent intermediate frequency welding machine. BACKGROUND

[0002] In the existing slide rail connecting piece intermediate frequency spot welding technology, due to the thickness difference of the workpiece, the manufacturing tolerance and the thermal deformation in the welding process, the traditional double-executing element welding tong or single-executing element cooperating with the electric control compensation system is difficult to achieve the ideal welding effect. The specific performance is that the insufficient basic pressure in the current rising and peak value stage causes the molten core to splash, the rebound of one side electrode in the pressure maintaining stage causes false welding, and the coupling of the two-channel force control system is complex and difficult to maintain. The existing technology has the problems of response time difference, poor force peak reproducibility and uneven force of double points by following the current peak value through software, which seriously affects the stability of the welding quality. SUMMARY

[0003] The present application provides a slide rail connecting piece intelligent intermediate frequency welding machine, which solves the technical problem of system maintenance difficulty in the related art.

[0004] The present application provides a slide rail connecting piece intelligent intermediate frequency welding machine, which includes: A rack provides support and motion guidance for the welding machine with a guide system; A differential welding tong assembly includes a differential case and a planetary carrier, a pair of driving bevel gears and a planetary bevel gear set are arranged in the differential case, the pair of driving bevel gears includes left and right driving bevel gears, the planetary bevel gear set includes a plurality of evenly distributed planetary bevel gears, the driving bevel gears are connected with bearings in the differential case, and the planetary bevel gears are connected with the planetary carrier through a pin shaft; A transmission chain includes a half shaft, a first bevel gear set, a second bevel gear set, a third bevel gear set, an upper electrode and a lower electrode, the half shaft extends out from the differential cases on both sides and is connected to the first bevel gear set, the first bevel gear set drives a third intermediate transmission shaft through a first intermediate transmission shaft, a second bevel gear set, a second intermediate transmission shaft and a third bevel gear set in turn, a pinion is fixedly arranged on the third intermediate transmission shaft, the pinion is meshingly connected with a rack, the rack is fixed to the slide table of the upper electrode and the lower electrode through bolts, and the third intermediate transmission shaft drives the slide table to move in the rack through the pinion and the rack; A phase coupling instantaneous pressure boosting chain includes a flywheel shaft, a centrifugal swing block, an inclined surface track and an electromagnetic clutch, a flywheel is installed on the flywheel shaft, the centrifugal swing block is hinged to the flywheel through an eccentric pin, a roller is arranged at the outer end of the centrifugal swing block, the roller is in contact with the inclined surface track, the driving end of the electromagnetic clutch is fixedly connected with the flywheel, and the driven end of the electromagnetic clutch is connected with the input shaft of the planetary carrier; The flywheel shaft is coaxial with the input shaft of the planet carrier but has different rotating speed, the vertical distance between the two ends of the inclined track and the axis of the flywheel shaft is different to form an inclined surface, the centrifugal pendulum block can swing outward under the action of centrifugal force, the roller slides along the inclined track to generate a tangential component, and the additional torque is superimposed on the input shaft of the planet carrier through the electromagnetic clutch. The base pressure execution chain includes a servo motor, the servo motor is fixed on the rack through a motor base, and an output end of the servo motor is connected to the input shaft of the planet carrier.

[0005] Further, the output shaft of the servo motor is connected to a speed reducer, the output shaft of the speed reducer is connected to a first gear set and a second gear set, the first gear set is connected to the input shaft of the planet carrier, the second gear set is connected to the flywheel shaft, the rotating speed of the flywheel shaft is designed to be greater than the rotating speed of the input shaft of the planet carrier, and a holding brake is mounted on the input shaft of the planet carrier and used to maintain the welding pressure during a stop period.

[0006] Further, the current detection and control system includes a Hall current sensor and a controller, the Hall current sensor is used to monitor the welding current in real time, and the controller is used to control the engagement and separation of the electromagnetic clutch according to a current threshold.

[0007] Further, two symmetrical T-shaped sliding rails are formed in the flywheel, the eccentric pin of the centrifugal pendulum block is mounted on the T-shaped sliding block, the T-shaped sliding block slides in the T-shaped sliding rail, and a compression spring is mounted on the inner side of each centrifugal pendulum block, so that the centrifugal pendulum block is ensured to be attached to the inner diameter position at low speed.

[0008] Further, the centrifugal pendulum block adopts a fan-shaped mass block structure, the centroid deviates from the hinged point, the centrifugal pendulum block is connected with the T-shaped sliding block through the eccentric pin, a roller is mounted at the outer end of each centrifugal pendulum block, the roller is rotationally connected with the centrifugal pendulum block through a roller shaft, and the inclined angle of the inclined track is 15° to 25°.

[0009] Further, the electrode seat is mounted on the sliding table, an annular cooling channel is formed in the electrode seat, the annular cooling channel is connected with a water inlet and a water outlet, and the water inlet and the water outlet penetrate the front and rear end faces of the electrode seat in the axial direction and are sealingly connected through O-shaped sealing rings, so that the electrode seat can be continuously cooled during the welding process.

[0010] Further, the electromagnetic clutch adopts an electromagnetic control coil, when the current reaches a set threshold, the controller supplies power to the coil of the electromagnetic clutch to make the electromagnetic clutch engage, and when the current drops below the threshold, the current of the coil is cut off to make the electromagnetic clutch separate.

[0011] Further, two groups of parallel linear guide rails are mounted on the rack, and the sliding tables of the upper electrode and the lower electrode move in opposite directions on the guide rails through sliding blocks.

[0012] Further, the first gear set transmission ratio is 1:3, the second gear set transmission ratio is 1:2, the transmission between the first gear set and the second gear set is realized by the flat key connection, and the rotating speed of the flywheel shaft is 1.5 times of the rotating speed of the planetary carrier input shaft.

[0013] The application also comprises an intelligent medium-frequency welding method for a slide rail connecting piece, comprising the following steps: a self-pressure equalizing distribution step: a servo motor outputs torque to a planetary carrier input shaft through a reducer, and the torque is distributed to upper and lower half shafts through a differential mechanism, and the slide table of the upper electrode and the lower electrode is driven to move oppositely through a composite bevel gear transmission chain, when one side first contacts the workpiece to generate a larger reaction force, the planetary bevel gear starts to rotate, and the other side continues to feed until the pressure of the two sides is automatically balanced; a peak phase transient pressure increasing step: in the welding power-on rising section, the flywheel shaft reaches the set angular speed under the driving of the second gear set, the centrifugal pendulum block generates centrifugal force, when the current reaches the set threshold value, the Hall current sensor triggers the electromagnetic clutch to engage, the centrifugal force drives the centrifugal pendulum block to swing outward, the roller slides along the inclined track to generate a tangential component, and the additional torque is superimposed on the planetary carrier input shaft through the electromagnetic clutch; a pressure maintaining and return step: after the current peak, the Hall current sensor detects a signal lower than the threshold value, the controller cuts off the current of the electromagnetic clutch coil to make the electromagnetic clutch separate, the system returns to the base pressure mode, the pressure is maintained by the holding brake, after the pressure maintaining is completed, the servo motor is reversed, the differential mechanism is reversely withdrawn by an equal amount, and the slide tables of the upper electrode and the lower electrode are oppositely separated.

[0014] The application has the following beneficial effects: The application overcomes the complex coupling factors of the traditional two-channel force control system of the double execution element system, and solves the technical problem of uneven force at two points, because the bevel gear differential self-pressure equalizing mechanism is used.

[0015] In addition, the application overcomes the factor of response time difference of the software following the current peak, and solves the technical problem of poor force peak reproducibility, because the flywheel-centrifugal pendulum block-inclined track transient pressure increasing mechanism is used in cooperation with the electromagnetic clutch controlled by the current detection.

[0016] In addition, the application avoids the cross talk of the upper and lower output channels, and solves the technical problem of difficult system maintenance, because the pressure increasing chain is only superimposed in parallel with the base pressure chain during the engagement of the electromagnetic clutch, the self-pressure equalizing mechanism of the differential is not changed, and the mechanical superposition of the two chains is located at the differential input end. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 is a perspective structure diagram of the intelligent medium-frequency welding machine for the slide rail connecting piece of the application. Figure 2 is the internal structure diagram of the slide rail connector intelligent medium frequency welding machine of the present application; Figure 3 is the perspective view of the differential welding tongs assembly of the present application; Figure 4 is the perspective view of the flywheel and its components of the present application; Figure 5 is the internal schematic diagram of the slide table of the present application; Figure 6 is the side view of the electromagnetic clutch and its components of the present application; Figure 7 is the Figure 6 cutaway view of the present application.

[0018] In the figure: 100, rack; 200, differential case; 201, driving bevel gear; 202, planetary bevel gear set; 203, planet carrier; 204, planet carrier input shaft; 300, half shaft; 301, first bevel gear set; 302, first intermediate transmission shaft; 303, second bevel gear set; 304, second intermediate transmission shaft; 305, third bevel gear set; 306, third intermediate transmission shaft; 307, pinion; 308, electrode holder; 309, linear guide pair; 310, servo motor; 311, slide table; 312, rack; 313, first gear set; 314, second gear set; 400, flywheel shaft; 401, flywheel; 402, centrifugal pendulum block; 403, inclined surface track; 404, eccentric pin; 405, compression spring; 406, T-shaped slide rail; 407, electromagnetic clutch; 408, Hall current sensor; 409, coil; 410, roller. DETAILED DESCRIPTION

[0019] The subject matter described herein will now be discussed with reference to example implementations. It should be understood that the discussion of these implementations is merely meant to provide a better understanding of the subject matter described herein and can be changed in function and arrangement without departing from the scope of the present description. Various examples can omit, substitute, or add various procedures or components as appropriate. Also, it should be understood that some features described with respect to one example can be combined with features described with respect to a different example.

[0020] In at least one embodiment of the present application, a slide rail connector intelligent medium frequency welding machine is disclosed, as shown in Figure 1 - Figure 7 The slide rail connector intelligent medium frequency welding machine includes a differential welding tongs assembly, a base pressure execution chain, a phase coupling transient pressure boost chain, and a rack 100 and a guide system. The parts are fixedly connected by bolts, key connections, etc. to form an overall structure.

[0021] The core of the differential welding clamp assembly is the differential housing 200, which is bolted to the frame 100. Inside the differential housing 200 are arranged a drive bevel gear pair and a planetary bevel gear set 202. The drive bevel gear pair includes two drive bevel gears 201 (left and right), and the planetary bevel gear set 202 includes several evenly distributed planetary bevel gears. The planetary carrier 203 serves as the sole input to receive external driving force. The drive bevel gear pair is connected to the differential housing 200 via deep groove ball bearings, and the planetary bevel gears are connected to the planetary carrier 203 via heat-treated pins. The pins are positioned at both ends by open retaining rings. The upper and lower half-shafts 300 drive their respective rack-and-pinion pairs via compound bevel gear transmission chains. The transmission link includes: a half-shaft 300 connected via a spline to the driving bevel gear of the first bevel gear set 301; the driven bevel gear of the first bevel gear set 301 and the first intermediate transmission shaft 302 are fixedly connected via a key; the first intermediate transmission shaft 302 is connected via a key to the driving bevel gear of the second bevel gear set 303, which drives the driven bevel gear; the driven bevel gear and the second intermediate transmission shaft 304 are fixedly connected via a key; the second intermediate transmission shaft 304 drives the driven bevel gear via the driving bevel gear of the third bevel gear set 305, which is connected via a key; the driven bevel gear and the third intermediate transmission shaft 306 are fixedly connected via a key. All bevel gears are supported by tapered bearings, which are preloaded with nuts.

[0022] The transmission link is a multi-stage bevel gear transmission system. Through the cascading transmission of three-stage bevel gear sets, the rotational motion output by the differential is ultimately converted into the linear motion of the electrode slide 311. The transmission ratio of each bevel gear set can be designed according to actual needs to achieve ideal speed and torque transmission. Each stage of the bevel gear set is connected by an intermediate shaft and bearing housings, which are fixed to the frame 100 by bolts.

[0023] To ensure transmission accuracy and eliminate backlash, each stage of the bevel gear set uses precision-machined bevel gear pairs with ground tooth surfaces. The tooth profile adopts Gleason spiral bevel gears with a module of 3-5 and a gear ratio of 1:1 to 1:2, ensuring smooth and precise transmission. All drive shafts are supported by high-precision bearings, which are mounted in bearing housings with an interference fit (H7 / p6). The bearing housings adopt an integral design to improve rigidity and are connected to the frame 100 by M12 high-strength bolts.

[0024] The upper electrode slide 311 and the lower electrode slide 311 are guided and moved on the frame 100 via linear guide pairs 309. Each slide 311 is equipped with two sets of linear guides, which are ball-bearing linear guides with a rated dynamic load of not less than 2000N. They are fixed to the frame 100 with M8 bolts. The rack 312 is fixed to the connecting slide 311 with M10 bolts. It is a precision-grade rack 312 with a module of 4-6 and a tooth surface hardness of not less than HRC55. The pinion 307 fixed on the third intermediate drive shaft 306 meshes with the rack 312 via a flat key connection, converting the rotary motion into linear motion. The electrode holder 308 is fixed to the slide table 311 by M8 bolts. An annular cooling channel is opened inside the electrode holder 308. The annular cooling channel has an annular cross-section with an inner diameter of 20mm and an outer diameter of 30mm. It connects the water inlet and the water outlet and passes through the front and rear end faces of the electrode holder 308 in the axial direction. The sealing connection is achieved by O-rings to achieve continuous cooling during the welding process.

[0025] The base pressure actuator chain includes a servo motor 310, which has a rated power of not less than 2kW and a rated speed of 1500rpm. The servo motor 310 is connected to a reducer via a cross coupling. The servo motor 310 is fixed to the frame 100 via a motor mount. Its output end is connected to the planetary carrier input shaft 204 and the flywheel shaft 400 via a first gear set 313 and a second gear set 314, respectively. The first gear set 313 has a transmission ratio of 1:3, and the second gear set 314 has a transmission ratio of 1:2. The gears are connected by a flat key for transmission, with the keyway using an N7 fit. It should be understood that the speed of the flywheel shaft 400 is designed to be greater than the speed of the planetary carrier input shaft 204, specifically 1.5 times, to allow sufficient space for the subsequent installation of the electromagnetic clutch 407.

[0026] The output shaft of the servo motor 310 is connected to the reducer via a cross coupling. The reducer is a planetary gear reducer with a reduction ratio of 5:1 to 10:1. The output shaft of the reducer is connected to the first gear set 313 and the second gear set 314 via splines. The reducer is connected to the motor via a flange and is fixed to the frame 100 via a base and M12 bolts.

[0027] A normally closed electromagnetic brake is installed on the planetary carrier input shaft 204 via a keyway as a holding brake, with a braking torque of not less than 20 N·m, used to maintain welding pressure during the dwell period. The brake is fixed to the frame 100 by an L-shaped bracket and M8 bolts.

[0028] The phase-coupled instantaneous booster chain is the key innovative structure of this embodiment. The flywheel 401 is mounted on the flywheel shaft 400 via a key connection. The flywheel 401 is made of 45# steel, with a diameter of 300mm, a thickness of 40mm, and a weight of not less than 15kg. The flywheel shaft 400 is coaxially arranged with the planetary carrier input shaft 204 but at different speeds, supported by deep groove ball bearings. Six centrifugal pendulum blocks 402 are hinged to the flywheel 401 by eccentric pins 404, evenly distributed at 60° intervals along the circumference, allowing for radial outward swing. An inclined track 403 is fixed to the surface of the flywheel 401 by M8 countersunk bolts. The vertical distance difference between the two ends of the inclined track 403 and the axis of the flywheel shaft 400 is 30mm, forming an inclined surface with an angle of 15° to 25°. The surface is hardened to a hardness of not less than HRC58.

[0029] The centrifugal pendulum 402 adopts a fan-shaped mass block structure, with its center of mass offset from the hinge point by 25mm. The centrifugal pendulum 402 is hinged to a T-shaped slider via an eccentric pin 404. The eccentric pin 404 has a diameter of 12mm, is made of 40Cr, and can swing within a 30° range. Each centrifugal pendulum 402 has a roller 410 mounted on its outer end. The roller 410 is made of bearing steel, has a diameter of 40mm, and is rotatably connected to the centrifugal pendulum 402 via a shaft connected to a deep groove ball bearing. The bearing is positioned by a retaining ring. The roller 410 contacts the inclined track 403. When the electromagnetic clutch 407 disengages, due to centrifugal force, the roller 410 of the centrifugal pendulum 402 moves closer to the end of the inclined track 403 furthest from the flywheel shaft 400 axis. When the electromagnetic clutch 407 engages, the centrifugal pendulum 402 swings, and the roller 410 slides along the inclined track 403.

[0030] The centrifugal pendulum 402 is a sector-shaped mass block with a specific mass distribution. Each pendulum weighs 1.5 kg. Through precise design of the center of mass position, the generation and transmission efficiency of centrifugal force are optimized. The pendulum material is made of 40Cr with a tempered hardness of HRC32-36. The pendulum blocks are assembled into a whole using M6 bolts.

[0031] To provide radial movement constraint and guidance, six equally spaced T-shaped slide rails 406 are provided on the flywheel 401, each 25 mm wide and 30 mm deep, with a surface roughness of Ra1.6. The eccentric pins 404 of the centrifugal pendulum 402 are mounted on the T-shaped sliders via an interference fit H7 / s6. The T-shaped sliders slide within the T-shaped slide rails 406, and a polytetrafluoroethylene coating is used between the sliders and the slide rails to reduce friction. Each centrifugal pendulum 402 has a compression spring 405 installed inside. One end of the spring is fixed to the pendulum by a spring seat, and the other end abuts against the flywheel 401. The spring stiffness is 100 N / mm. The compression spring 405 ensures that the centrifugal pendulum 402 is in contact with the inner diameter position at low speeds.

[0032] The driving end of the electromagnetic clutch 407 is fixed to the flywheel 401 via a keyway, and the driven end is connected to the planetary carrier input shaft 204 via a keyway. The electromagnetic clutch 407 uses an electromagnetic control coil 409 with a rated voltage of 24V and a power of 200W. The coil 409 is connected to the controller via a three-core shielded cable. When energized, it generates a magnetic field that engages the driving and driven discs. After engagement, the additional torque generated by the flywheel 401 and centrifugal pendulum 402 is superimposed on the planetary carrier input shaft 204 through the electromagnetic clutch 407, thus adding a short-term torque boost on top of the base torque. The maximum transmitted torque of the clutch is not less than 100 N·m. The clutch is fixed to the frame 100 via an L-shaped bracket and M10 bolts.

[0033] The current detection and control system includes a Hall current sensor 408, a signal processing unit, a threshold comparator, and a controller. The Hall current sensor 408 has a range of 0-100kA and an accuracy of ±1%. It is mounted on the outer periphery of the welding machine's secondary busbar via a sensor bracket to monitor the welding current in real time. The sensor is connected to the signal processing unit via a twisted-pair shielded cable. When the current reaches a set threshold, the controller directly supplies power to the coil 409 of the electromagnetic clutch 407 via a control line, engaging it; when the current drops below the threshold, it cuts off the current to the coil 409, disengaging the electromagnetic clutch 407. The entire current detection and electromagnetic clutch 407 control is fully electrified, with a response time of less than 5 milliseconds. The controller uses an industrial-grade PLC with an Ethernet communication interface and is mounted on the frame 100 via a control cabinet and M8 bolts.

[0034] The frame 100 and guiding system provide support and motion guidance for the entire device. The frame 100 is a welded structure made of Q235B steel with a powder-coated surface. Two sets of parallel linear guides, using THK SSR series, are mounted on the frame 100 via M12 bolts. These guides are 600mm long, and the slides 311 of the upper and lower electrodes move in opposite directions on the guides via sliders. The planetary carrier input shaft 204 bearing housing is fixed to the center of the frame 100 with the differential housing 200 using M10 bolts. This integral design enhances rigidity. The bevel gearboxes, containing reversing bevel gear sets, are mounted on both sides with M12 bolts. All bearings are precision bearings from NSK or SKF, installed with an interference fit H7 / p6.

[0035] Execution steps According to this embodiment, the working process of an intelligent medium-frequency welding machine for slide rail connectors includes the following steps: Self-equalizing pressure distribution steps: The servo motor 310 (rated power not less than 2kW, rated speed 1500rpm) is connected to the reducer (reduction ratio 5:1 to 10:1) via a cross coupling. Torque is input to the planetary carrier input shaft 204 via the first gear set 313 (transmission ratio 1:3). The torque is then distributed to the upper and lower half-shafts 300 by the driving bevel gear pair and planetary bevel gear set 202 within the differential housing 200. The upper half-shaft 300 is splined to the driving bevel gear of the first bevel gear set 301, driving the driven bevel gear keyed to the first intermediate transmission shaft 302. This then drives the second intermediate transmission shaft 304 via the second bevel gear set 303, and finally the third intermediate transmission shaft 306 via the third bevel gear set 305. The pinion 307 (module 4-6) on the third intermediate transmission shaft 306 meshes with the rack 312, causing the upper electrode slide 311 to move on the linear guide rail. The lower transmission chain has the same structure, but the first bevel gear set 301 is installed in the opposite direction to achieve opposing motion on both sides. When one side contacts the workpiece first and generates a large reaction force, the planetary bevel gear begins to rotate, and the other side continues to feed until the pressure on both sides is automatically balanced.

[0036] The self-equalizing pressure distribution step is achieved through the mechanical characteristics of the differential, where the bevel gear set uses Gleason spiral bevel gears (module 3-5, gear ratio 1:1 to 1:2). The differential speed ratio satisfies the relationship that the sum of the upper half-shaft speed (300 rpm) and the lower half-shaft speed (300 rpm) equals twice the planetary carrier speed (203 rpm). (in The upper half-shaft rotates at 300 RPM. The lower half-shaft rotates at 300 rpm. (The rotational speed of the planetary carrier 203) and the linear velocity of the rack 312 are equal to the radius of the pinion 307 multiplied by the rotational speed multiplied by the bevel gear transmission ratio, i.e. (in The pinion has a radius of 307. (This refers to the bevel gear transmission ratio).

[0037] Peak phase instantaneous boosting step: During the welding energized rising stage, the flywheel shaft 400, driven by the second gear set 314 (transmission ratio 1:2), reaches a set angular velocity 1.5 times higher than that of the planetary carrier input shaft 204. The six equally spaced centrifugal pendulum blocks 402 (each weighing 1.5 kg) on ​​the flywheel 401, which has a diameter of 300 mm and a thickness of 40 mm, generate centrifugal force. (in For the mass of centrifugal pendulum 402, For the equivalent radius, (This refers to angular velocity). When the current enters the set threshold or phase window, the Hall current sensor 408 (range 0-100kA) detects and triggers the electromagnetic clutch 407 (maximum transmitted torque ≥100N·m) to engage. Centrifugal force drives the centrifugal pendulum 402 to swing in and out of the T-shaped slide rail 406 (25mm wide, 30mm deep), and the roller 410 (40mm in diameter) slides along the inclined track 403 (inclination angle 15°-25°). As the swing angle θ of the centrifugal pendulum 402 increases, the roller 410 slides along the inclined track 403, and the position of the roller 410 moves along the inclined direction. The centrifugal force is converted into a tangential component force through the inclined track 403: normal reaction force. tangential component (in (where the slope angle is 1). The resulting additional torque is: (in (The distance from roller 410 to the center of rotation). The additional torque is superimposed on the planetary carrier input shaft 204 via the electromagnetic clutch 407, and after being combined with the base torque, it enters the differential via the planetary carrier 203, where it is redistributed by the electrodes on both sides according to the real-time reaction force.

[0038] Pressure holding and return steps: After the peak value, the current decreases, and the Hall current sensor 408 detects a signal below the threshold. The controller cuts off the current to the coil 409 (24V, 200W) of the electromagnetic clutch 407, causing it to disengage. The system returns to base pressure mode, where pressure holding is maintained by a normally closed electromagnetic brake (braking torque ≥20N·m). After pressure holding is completed, the servo motor 310 reverses, the differential mechanism retracts in the opposite direction by an equal amount, and the slides 311 of the upper and lower electrodes separate in opposite directions on the linear guide rail (rated dynamic load ≥2000N). The annular cooling channel (inner diameter 20mm, outer diameter 30mm) inside the electrode holder 308 continuously dissipates heat.

Claims

1. An intelligent medium-frequency welding machine for slide rail connectors, characterized in that, include: The frame, along with the guiding system, provides support and movement guidance for the welding machine; The differential welding clamp assembly includes a differential housing and a planetary carrier. A pair of drive bevel gears and a set of planetary bevel gears are arranged inside the differential housing. The pair of drive bevel gears includes two drive bevel gears, one on the left and one on the right. The set of planetary bevel gears includes several evenly distributed planetary bevel gears. The drive bevel gears are connected to bearings inside the differential housing. The planetary bevel gears are connected to the planetary carrier through pins. The transmission chain includes a half-shaft, a first bevel gear set, a second bevel gear set, a third bevel gear set, an upper electrode, and a lower electrode. The half-shaft extends from the differential housings on both sides and connects to the first bevel gear set. The first bevel gear set drives the third intermediate transmission shaft in sequence through the first intermediate transmission shaft, the second bevel gear set, the second intermediate transmission shaft, and the third bevel gear set. A pinion is fixedly installed on the third intermediate transmission shaft. The pinion meshes with a rack. The rack is fixed to the slides of the upper and lower electrodes by bolts. The third intermediate transmission shaft drives the slides to move on the frame through the pinion and the rack. The phase-coupled instantaneous booster chain includes a flywheel shaft, a centrifugal pendulum block, an inclined plane track, and an electromagnetic clutch. A flywheel is mounted on the flywheel shaft, the centrifugal pendulum block is hinged to the flywheel by an eccentric pin, a roller is mounted on the outer end of the centrifugal pendulum block, the roller is in contact with the inclined plane track, the clutch driving end of the electromagnetic clutch is fixedly connected to the flywheel, and the clutch driven end of the electromagnetic clutch is connected to the planetary carrier input shaft. The flywheel shaft and the input shaft of the planetary carrier are coaxially set but rotate at different speeds. The two ends of the inclined track are at different vertical distances from the flywheel shaft axis, forming an inclined surface. The centrifugal pendulum can swing outward under the action of centrifugal force. The roller slides along the inclined track to generate a tangential component force. The additional torque is superimposed on the input shaft of the planetary carrier through the electromagnetic clutch. The base pressure actuator chain includes a servo motor, which is fixed to the frame by a motor mount, and its output end is connected to the planetary carrier input shaft.

2. The intelligent medium-frequency welding machine for slide rail connectors according to claim 1, characterized in that, The output shaft of the servo motor is connected to a reducer, and the output shaft of the reducer is connected to a first gear set and a second gear set. The first gear set is connected to the planetary carrier input shaft, and the second gear set is connected to the flywheel. The speed of the flywheel shaft is designed to be greater than the speed of the planetary carrier input shaft. A holding brake is installed on the planetary carrier input shaft to maintain welding pressure during the dwell period.

3. The intelligent medium-frequency welding machine for slide rail connectors according to claim 1, characterized in that, The system also includes a current detection and control system, comprising a Hall current sensor and a controller. The Hall current sensor monitors the welding current in real time, and the controller controls the engagement and disengagement of the electromagnetic clutch based on a current threshold.

4. The intelligent medium-frequency welding machine for slide rail connectors according to claim 1, characterized in that, Two symmetrical T-shaped slide rails are provided on the flywheel. The eccentric pin of the centrifugal pendulum is installed on the T-shaped slider. The T-shaped slider slides in the T-shaped slide rail. Each centrifugal pendulum is equipped with a compression spring on its inner side. The compression spring has an initial preload to ensure that the centrifugal pendulum fits the inner diameter position at low speed.

5. The intelligent medium-frequency welding machine for slide rail connectors according to claim 4, characterized in that, The centrifugal pendulum adopts a fan-shaped mass block structure, with the center of mass of the centrifugal pendulum offset from the hinge point. The centrifugal pendulum is connected to the T-shaped slider through an eccentric pin. Each centrifugal pendulum is equipped with a roller at its outer end, and the roller is rotatably connected to the centrifugal pendulum through a roller shaft. The slope angle of the inclined track is set to 15° to 25°.

6. The intelligent medium-frequency welding machine for slide rail connectors according to claim 1, characterized in that, The slide table is equipped with an electrode holder, and an annular cooling channel is opened inside the electrode holder. The annular cooling channel connects the water inlet and the water outlet, and passes through the front and rear end faces of the electrode holder in the axial direction. The sealing connection is achieved by an O-ring, so as to achieve continuous cooling during the welding process.

7. The intelligent medium-frequency welding machine for slide rail connectors according to claim 1, characterized in that, The electromagnetic clutch uses an electromagnetic control coil. When the current reaches a set threshold, the controller supplies power to the coil of the electromagnetic clutch to engage it. When the current drops below the threshold, the coil current is cut off to disengage the electromagnetic clutch.

8. The intelligent medium-frequency welding machine for slide rail connectors according to claim 1, characterized in that, Two sets of parallel linear guide rails are installed on the frame, and the slides of the upper and lower electrodes move in opposite directions on the guide rails via sliders.

9. The intelligent medium-frequency welding machine for slide rail connectors according to claim 2, characterized in that, The first gear set has a transmission ratio of 1:3, the second gear set has a transmission ratio of 1:2, and the first and second gear sets are connected by a flat key to achieve transmission. The speed of the flywheel shaft is 1.5 times the speed of the planetary carrier input shaft.

10. A method for intelligent medium-frequency welding of slide rail connectors, using an intelligent medium-frequency welding machine for slide rail connectors as described in any one of claims 1-9, characterized in that, Includes the following steps: Self-equalizing pressure distribution step: The servo motor outputs torque to the planetary carrier input shaft via the reducer, and distributes it to the upper and lower half shafts via the differential mechanism. The upper and lower electrode slides are driven to move in opposite directions through the compound bevel gear transmission chain. When one side contacts the workpiece first and generates a large reaction force, the planetary bevel gear starts to rotate, and the other side continues to feed until the pressure on both sides is automatically balanced. Peak phase instantaneous pressure boosting step: During the welding energization rising stage, the flywheel shaft reaches the set angular velocity under the drive of the second gear set. The centrifugal pendulum generates centrifugal force. When the current enters the set threshold, the Hall current sensor triggers the electromagnetic clutch to engage. The centrifugal force drives the centrifugal pendulum to swing outward, and the roller slides along the inclined track to generate a tangential component force. The additional torque is superimposed on the planetary carrier input shaft through the electromagnetic clutch. Pressure holding and return step: After the current peak, the Hall current sensor detects a signal below the threshold. The controller cuts off the current in the electromagnetic clutch coil to separate it, and the system returns to the base pressure mode. The holding brake maintains the pressure. After the pressure holding is completed, the servo motor reverses, the differential mechanism retracts in the opposite direction by an equal amount, and the upper and lower electrode slides separate in opposite directions.

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