Manufacturing method of inverter inductor and inverter inductor

Abstract

This application provides a method for manufacturing an inverter inductor and an inverter inductor, belonging to the field of inverter inductor technology. The method includes: preparing a copper connection terminal and an aluminum coil; pre-treating the copper connection terminal and the aluminum coil; setting a friction welding device according to preset welding parameters; controlling the stirring head of the friction welding device to rotate and penetrate the weld seam, so as to preheat the target welding interface between the copper connection terminal and the aluminum coil; when the cumulative preheating time of the target welding interface reaches a preset preheating time, controlling the stirring head to move along the welding direction to perform a welding operation, so as to solid-state connection between the copper connection terminal and the aluminum coil, thereby obtaining the inverter inductor. This application aims to reduce the manufacturing cost of the inverter inductor.

Description

Technical Field

[0001] This application relates to the field of inverter inductor technology, and in particular to a method for manufacturing an inverter inductor and the inverter inductor itself. Background Technology

[0002] In related technologies, the high-power section of the aluminum wire inverter inductor connection wires used in the photovoltaic industry is generally welded using either soldering or laser welding. Both of these welding processes have drawbacks; soldering requires high labor costs, while laser welding involves expensive equipment and high maintenance costs, thus affecting the final product cost of the inverter.

[0003] In summary, the technical problems existing in the relevant technologies need to be improved. Summary of the Invention

[0004] The main objective of this application is to provide a method for manufacturing an inverter inductor and an inverter inductor, with the aim of reducing the manufacturing cost of the inverter inductor.

[0005] To achieve the above objectives, one aspect of this application proposes a method for manufacturing an inverter inductor, the method comprising:

[0006] Prepare copper connectors and aluminum coils, and pre-treat the copper connectors and aluminum coils;

[0007] The friction welding device is set according to the preset welding parameters. The stirring head of the friction welding device is controlled to rotate and penetrate the weld seam so that the target welding interface between the copper connection end and the aluminum coil is preheated.

[0008] When the cumulative preheating time of the target welding interface reaches the preset preheating time, the stirring head is controlled to move along the welding direction to perform the welding operation, so that the copper connection end is solid-phase connected with the aluminum coil to obtain the inverter inductance.

[0009] In some embodiments, the method further includes controlling a target temperature of the target weld interface during the welding operation, wherein controlling the target temperature of the target weld interface includes:

[0010] The temperature of the target welding interface is detected by an infrared thermometer and defined as the target temperature.

[0011] When the target temperature is detected to be greater than 548°C, the target welding interface is cooled by water cooling fixture, or the rotation speed of the stirring head is reduced until the target temperature is less than or equal to 548°C.

[0012] When the target temperature is detected to be less than 460°C, the rotation speed of the stirring head is increased until the target temperature is greater than or equal to 460°C.

[0013] In some embodiments, the pretreatment of the copper connector and the aluminum coil includes:

[0014] The copper connector and the aluminum coil are respectively subjected to cutting operations until the surface roughness of the welding end is less than or equal to the preset roughness standard.

[0015] The welded end face is polished with sandpaper of a preset grit, and then ultrasonically cleaned with anhydrous ethanol for at least a preset cleaning time.

[0016] In some embodiments, setting the friction welding device according to preset welding parameters includes:

[0017] The friction welding device is configured with a stirring head with a welding speed of 1500 r / min to 1800 r / min, a friction pressure of 80 MPa to 150 MPa, and a friction time of 1.0 s to 2.5 s.

[0018] In some embodiments, preparing the copper connector includes:

[0019] The prepared T2 copper material is processed into the copper connector end with dimensions of 3.2mm × 15mm.

[0020] In some embodiments, preparing an aluminum coil includes:

[0021] The prepared 1060 aluminum material is processed into aluminum wire with dimensions of 3.2mm × 15mm;

[0022] The aluminum wire is coated with an insulating film to obtain a film-coated aluminum wire;

[0023] The film-coated aluminum wire is wound into two sets of aluminum coils, each with 14 turns, using a figure-eight continuous winding vertical winding machine.

[0024] In some embodiments, the method further includes, after the welding operation, inspecting the target weld interface for welding defects, and after inspecting the target weld interface for welding defects, further comprising:

[0025] When incomplete welding defects exist, set the friction pressure of the stirring head to 150 MPa, or set the friction time to 2.5 s; then repeat the welding operation.

[0026] In some embodiments, after inspecting the welding defects at the target weld interface, the method further includes:

[0027] When interface crack defects are present, reduce the upsetting speed to 2 mm / s, or add a 0.5 s slowing phase before upsetting; repeat the welding operation.

[0028] In some embodiments, after inspecting the welding defects at the target weld interface, the method further includes:

[0029] If excessive flash is present, set the upsetting pressure to 200 MPa, or shorten the holding time to 1 second; then repeat the welding operation.

[0030] To achieve the above objectives, another aspect of the embodiments of this application proposes an inverter inductor, which is manufactured using the method described in any of the preceding claims, and the inverter inductor includes a solid-phase connected copper terminal and an aluminum coil.

[0031] The embodiments of this application include at least the following beneficial effects: This application provides a method for manufacturing an inverter inductor and the inverter inductor itself. This method involves pre-preparing copper connection terminals and aluminum coils, pre-treating the copper connection terminals and aluminum coils, and then setting up a friction welding device according to preset welding parameters. The stirring head of the friction welding device is controlled to rotate and penetrate the weld seam. Based on the principle of frictional heat generation, the target welding interface between the copper connection terminals and the aluminum coil is preheated. When the cumulative preheating time of the target welding interface reaches the preset preheating time, the stirring head is controlled to move along the welding direction to perform the welding operation, so that the copper connection terminals and the aluminum coil are solid-phase connected, completing the friction welding and obtaining the inverter inductor. Compared with soldering and laser welding processes, the friction welding process can balance processing time and equipment costs, reducing the manufacturing cost of the inverter inductor. Attached Figure Description

[0032] Figure 1 This is a flowchart illustrating a method for manufacturing an inverter inductor according to an embodiment of this application;

[0033] Figure 2 This is a schematic diagram of the first angle hardware structure of the inverter inductor provided in an embodiment of this application;

[0034] Figure 3 This is a schematic diagram of the second angle hardware structure of the inverter inductor provided in an embodiment of this application;

[0035] Figure 4 yes Figure 1 Partial flowchart of step S101 in the process;

[0036] Figure 5 Based on Figure 1 Another step in step S103 is shown in the flowchart.

[0037] Figure 6 Based on Figure 1 Flowchart of another step in step S103. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of this application and are not intended to limit it. In the following description, when referring to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with those of this application; they are merely examples of apparatuses and methods consistent with some aspects of the embodiments of this application as detailed in the appended claims.

[0039] It is understood that the terms “first,” “second,” etc., used in this application may be used herein to describe various concepts, but unless otherwise stated, these concepts are not limited by these terms. These terms are only used to distinguish one concept from another. For example, without departing from the scope of the embodiments of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the words “if,” “when,” or “in response to a determination” as used herein may be interpreted as “when…” or “when…” or “in response to a determination.”

[0040] As used in this application, the terms "at least one", "multiple", "each", "any", etc., "at least one" includes one, two or more, "multiple" includes two or more, "each" refers to each of the corresponding multiples, and "any" refers to any one of the multiples.

[0041] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of this application only and is not intended to limit this application.

[0042] Before providing a detailed description of the embodiments of this application, some of the nouns and terms involved in the embodiments of this application will be explained first. The nouns and terms involved in the embodiments of this application are subject to the following interpretations.

[0043] 1) Friction welding is a solid-state welding process. Its core principle is to generate heat on the contact surface of two workpieces through friction, so that the contact surface material reaches a plastic state, does not melt or only partially melts, and then combines axial pressure (forging force) to achieve metallurgical bonding of the workpieces.

[0044] In related technologies, with the rapid development of the photovoltaic industry, manufacturing processes are constantly being updated and upgraded. Inefficient, costly, and risky production processes are no longer suitable for the overall environment. The welding process between the aluminum wire inductor leads and external connection terminals is particularly prominent. Currently, high-power aluminum wire inverter inductor connections are mainly made using tin soldering and laser welding; this is inefficient, costly, and prone to welding quality problems such as incomplete soldering, detachment, and connection terminal breakage.

[0045] In view of this, this application provides a method for manufacturing an inverter inductor and the inverter inductor itself. This method involves pre-preparing a copper connection terminal 100 and an aluminum coil 200, pre-treating the copper connection terminal 100 and the aluminum coil 200, and then setting a friction welding device according to preset welding parameters. The stirring head of the friction welding device is controlled to rotate and penetrate the weld seam. Based on the principle of frictional heat generation, the target welding interface between the copper connection terminal 100 and the aluminum coil 200 is preheated. When the cumulative preheating time of the target welding interface reaches the preset preheating time, the stirring head is controlled to move along the welding direction to perform the welding operation, so that the copper connection terminal 100 and the aluminum coil 200 are solid-phase connected, completing the friction welding and obtaining the inverter inductor. Compared with soldering and laser welding processes, the friction welding process can balance processing time and equipment costs, reducing the manufacturing cost of the inverter inductor.

[0046] Figure 1 This is an optional flowchart of the method for manufacturing inverter inductors provided in the embodiments of this application. Figure 1 The method may include, but is not limited to, steps S101 to S103.

[0047] Step S101: Prepare the copper connection terminal 100 and the aluminum coil 200, and pre-process the copper connection terminal 100 and the aluminum coil 200.

[0048] The method described in this application is used to manufacture an inverter inductor, which is a device used for energy storage, filtering, and electromagnetic interference suppression during the DC-to-AC conversion process. The inverter inductor manufactured by this method is based on a copper connection terminal 100 and an aluminum coil 200. The copper connection terminal 100 is used to connect the aluminum coil 200 to an external circuit and needs to withstand high current density and dynamic stress during the operation of the inverter inductor. The aluminum coil 200 is used to specifically realize the functions of the inverter inductor. For an inverter inductor including the copper connection terminal 100 and the aluminum coil 200, the welding of copper and aluminum during its manufacturing process is a technical challenge. This embodiment achieves this welding requirement through subsequent steps S102 and S103.

[0049] Before performing the welding operation, it is necessary to prepare the copper connection end 100 and the aluminum coil 200. Based on the prepared copper and aluminum materials, corresponding processing is carried out to obtain the copper connection end 100 and the aluminum coil 200. Then, the two workpieces after processing are pre-treated to reduce the possibility of processing defects in subsequent steps.

[0050] In step S101 of some embodiments, preparing the copper connection terminal 100 includes:

[0051] The prepared T2 copper material is processed into a copper connector 100 with dimensions of 3.2mm × 15mm.

[0052] For copper connection terminals 100, T2 copper can be selected. The copper content of T2 copper is generally greater than or equal to 99.9%, and the content of impurities such as iron, lead, and sulfur can meet industrial requirements. Its conductivity is about 100%-101% in the International Annealed Copper Standard (IACS). In addition, its corrosion resistance and processing performance can also meet the requirements for manufacturing inverter inductor copper connection terminals.

[0053] The prepared T2 copper material is machined to a size of 3.2mm × 15mm. This size represents the cross-sectional dimensions of the welding end face of the copper connector 100, where 3.2mm is the end thickness and 15mm is the end width. Its machining shape can be referenced. Figure 2 , 3 A schematic diagram of the inverter inductor. Figure 2 , 3 Images illustrating the structure of the inverter inductor from different angles. Copper connection terminals 100 are fabricated to support subsequent inverter inductor fabrication steps.

[0054] In step S101 of some embodiments, preparing the aluminum coil 200 includes:

[0055] The prepared 1060 aluminum material is processed into aluminum wire with dimensions of 3.2mm × 15mm;

[0056] Aluminum wire is obtained by wrapping aluminum wire with an insulating film;

[0057] The film-coated aluminum wire is wound into two sets of 14-turn aluminum coils 200 using a figure-eight continuous winding vertical winding machine.

[0058] For aluminum coil 200, 1060 aluminum can be selected. The aluminum content of 1060 aluminum is generally greater than or equal to 99.6%. Its impurities mainly include iron and silicon. It belongs to the 1 series aluminum alloy. In addition, its low density and lightweight, electrical conductivity, thermal conductivity and processing performance can meet the requirements for manufacturing inverter inductor aluminum coil 200. However, its corrosion resistance is insufficient and additional protection is required.

[0059] First, the prepared 1060 aluminum material is processed into aluminum wires with dimensions of 3.2mm × 15mm. This size corresponds to the cross-sectional dimensions of the welding end face of the aluminum coil 200, which is the same as the welding end face dimensions of the copper connection end 100 in the above embodiment. Next, the aluminum wire is wrapped with an insulating film to obtain film-coated aluminum wire. The insulating film not only provides electrical insulation but also acts as a physical barrier, improving the corrosion resistance of the aluminum coil 200. Finally, the coils are continuously wound in an "∞" (figure-eight) pattern using a figure-eight winding machine. The first group of 14 turns is wound first, followed by the second group of 14 turns, ensuring a symmetrical distribution of the two winding groups. During winding, the coil frame is placed vertically, and a tension control system ensures the tightness of the windings. After winding, the wire is mechanically sheared or thermally melted to form a complete aluminum coil 200. Its processing shape can be referenced... Figure 2 , 3 A schematic diagram of the inverter inductor. An aluminum coil 200 is obtained through processing, which supports the subsequent steps of inverter inductor fabrication.

[0060] refer to Figure 4 In step S101 of some embodiments, the pretreatment of the copper connection terminal 100 and the aluminum coil 200 includes:

[0061] Step S201: Perform cutting operations on the welding end faces of the copper connection end 100 and the aluminum coil 200 respectively until the surface roughness of the welding end faces is less than or equal to the preset roughness standard.

[0062] Step S202: Grind the welding end face with sandpaper of a preset grit, and use anhydrous ethanol to perform ultrasonic cleaning on the ground welding end face. The ultrasonic cleaning lasts for at least a preset cleaning time.

[0063] In order to perform welding, pretreatment is required based on the processed copper connection end 100 and aluminum coil 200. This pretreatment is actually the treatment of the welding end faces of the two workpieces to reduce the possibility of processing defects during the welding process.

[0064] First, the welding end faces of the copper connector 100 and the aluminum coil 200 are machined to make them flat, which also removes the oxide film and oil. The flatness of the welding end faces of the two workpieces is then evaluated by setting a preset roughness standard; for example, the preset roughness standard can be set to 6.3. When the surface roughness of the welded end faces of both workpieces is less than or equal to the preset roughness standard, that is... When the cutting process is complete, the welding end faces of the two workpieces are then polished with sandpaper of a preset grit (e.g., 800 or 1000 grit) to further smooth them. After sanding, the welded end faces are ultrasonically cleaned with anhydrous ethanol for 5 minutes. This ultrasonic cleaning removes fine particles generated during cutting or polishing, completing the pretreatment of the copper connector 100 and the aluminum coil 200.

[0065] Step S102: Set the friction welding device according to the preset welding parameters, control the stirring head of the friction welding device to rotate and penetrate the weld, so as to preheat the target welding interface between the copper connection end 100 and the aluminum coil 200.

[0066] The preset welding parameters are the relevant parameters that control the operation of the friction welding device in the preheating and welding stages, such as the rotation speed of the stirring head and the friction pressure. These parameters are set in advance by the operators so that the friction welding process, including the preheating and welding stages, can be automated.

[0067] In step S102 of some embodiments, setting the friction welding device according to preset welding parameters includes:

[0068] The friction welding device is configured with a stirring head with a welding speed of 1500 r / min to 1800 r / min, a friction pressure of 80 MPa to 150 MPa, and a friction time of 1.0 s to 2.5 s.

[0069] Specifically, the preset welding parameters include welding speed, friction pressure, and friction time, which are set according to the parameters mentioned above. The friction pressure is the axial pressure, used to actually bond the copper connection end 100 and the aluminum coil 200 during upsetting. By specifically setting the preset welding parameters, the manufacturing efficiency and yield rate of inverter inductors using friction welding are improved.

[0070] After setting the preset welding parameters, the friction welding process can begin. Specifically, the stirring head of the friction welding device is controlled to rotate at the set welding speed, and then inserted into the weld seam to preheat the welding end faces of the two workpieces. The portion of the two workpieces to be welded together is defined as the target welding interface.

[0071] It should be noted that the stirring head is the core component of the friction welding process. When it rotates, the surface contacts the workpiece material, generating frictional heat and raising it to a plastic state. Then, through the structural design of the stirring head, such as a spiral pattern, the plastic material is forced to flow and fully mix, thereby eliminating interfacial gaps. In this embodiment, the stirring head can be made of WC-Co cemented carbide (containing 90-94% WC), with a hardness of 1600-2000 HV and a thermal conductivity of 80-100 W / m*K. This material design ensures rapid heat dissipation during operation. Additionally, the stirring head can be coated with an AlCrN+Si nanocomposite coating, reducing its coefficient of friction to 0.28, reducing adhesion and increasing its service life. Furthermore, its shape and structure can adopt a variable helix angle design, specifically... and the latter part This improves chip removal capability and rigidity, while the cutting edge has a 0.1mm wide chip breaking groove to prevent aluminum chips from entangled during welding stirring and affecting welding quality.

[0072] Step S103: When the cumulative preheating time of the target welding interface reaches the preset preheating time, control the stirring head to move along the welding direction to perform the welding operation, so that the copper connection end 100 and the aluminum coil 200 are solid-phase connected to obtain the inverter inductance.

[0073] Set a preset preheating time to assess the duration required for the preheating stage, such as 10 seconds. When the cumulative preheating time reaches the preset preheating time, the next actual welding stage can begin. Control the stirring head to move along the welding direction to perform the welding operation. The welding direction is along the weld seam. The softened metal that has reached a plastic state continuously fills the cavity formed behind the stirring needle under the rotation of the stirring head, and achieves solid-phase bonding under the extrusion of stirring and axial pressure.

[0074] refer to Figure 5 In some embodiments, the welding operation in step S103 further includes controlling the target temperature of the target welding interface, which may include, but is not limited to:

[0075] Step S301: The temperature of the target welding interface is detected by an infrared thermometer and defined as the target temperature;

[0076] Step S302: When the target temperature is detected to be greater than 548°C, the target welding interface is cooled by water cooling fixture or the speed of stirring head is reduced until the target temperature is less than or equal to 548°C.

[0077] Step S303: When the target temperature is detected to be less than 460°C, increase the rotation speed of the stirring head until the target temperature is greater than or equal to 460°C.

[0078] The final product quality of friction welding is closely related to the temperature control during the welding process, because the temperature of the target welding interface directly determines the state of the softened metal layer during the welding process. The temperature of the target welding interface is defined as the target temperature.

[0079] Optionally, an infrared thermometer is used to monitor the target temperature of the target welding interface. In this embodiment, the target temperature range is set to [460℃, 548℃], which is lower than the melting point of aluminum, 660℃. When the detected target temperature is lower than the lower limit of the target temperature range, i.e., 460℃, the rotation speed of the stirring head is increased to further raise the target temperature based on the principle of frictional heating, until the target temperature is greater than or equal to 460℃. When the detected target temperature is greater than the upper limit of the target temperature range, i.e., 548℃, it needs to be cooled down. Cooling methods include using a water-cooled fixture or reducing the rotation speed of the stirring head to allow the target temperature to decrease naturally through conduction, until the target temperature is less than or equal to 548℃. In this way, by combining temperature monitoring and heating / cooling methods, the target temperature of the target welding interface is controlled, thereby improving the quality of the welded product.

[0080] refer to Figure 6 In some embodiments, after step S103, the method further includes inspecting the welding defects of the target weld interface; after inspecting the welding defects of the target weld interface, the method further includes:

[0081] Step S401: When there is a defect of incomplete welding, set the friction pressure of the stirring head to 150MPa or set the friction time to 2.5s; and re-execute the welding operation.

[0082] Specifically, the presence of incomplete welding defects indicates that the welded end faces are not fully bonded, and the welding strength needs to be increased. Within the range of the preset welding parameters in the above embodiment, the friction pressure is set to its upper limit of 150MPa, or the friction time is set to its upper limit of 2.5s, and welding is attempted again to ensure that the welded end faces are fully bonded.

[0083] In some embodiments, after inspecting welding defects at the target weld interface, the method further includes:

[0084] Step S402: When interface crack defects exist, reduce the upsetting speed to 2 mm / s, or add a slowing phase lasting 0.5 s before upsetting; repeat the welding operation.

[0085] The appearance of interface cracks may be due to an excessively slow upsetting speed. After friction heating stops, the material in its plastic state will rapidly harden due to cooling. The hardened material cannot be effectively compressed, resulting in cracks. Alternatively, it may be due to overheating of the material, causing localized melting at the interface and a significant increase in brittleness. During upsetting, this makes the material prone to cracking due to compressive stress. Therefore, the problem of interface cracks can be addressed by either reducing the upsetting speed to 2 mm / s or adding a 0.5s delay phase before upsetting, and then attempting welding again after setting these parameters.

[0086] In some embodiments, after inspecting welding defects at the target weld interface, the method further includes:

[0087] Step S403: When there is a defect of excessive flash, set the upsetting pressure to 200MPa, or shorten the holding time to 1s; and re-execute the welding operation.

[0088] The excessive flash defect may be caused by excessive upsetting pressure, exceeding the critical extrusion pressure required for material plasticization, causing the material to be excessively extruded from the interface, forming excessive flash. Based on this, the upsetting pressure can be adjusted to 200MPa, or the holding time can be shortened to 1s to reduce the possibility of the material being excessively extruded from the interface during upsetting. After setting, try welding again to solve the problem of excessive flash defect.

[0089] Steps S101 to S103 as shown in the embodiments of this application balance processing time and equipment costs through friction welding, so that the copper connection terminal 100 and the aluminum coil 200 form a solid-phase connection, thereby reducing the manufacturing cost of the inverter inductor.

[0090] The following is a detailed description and explanation of the solutions in the embodiments of the present invention, using specific application examples:

[0091] This application provides a method for manufacturing an inverter inductor, used to fabricate an inverter inductor having a copper connection terminal 100 and an aluminum coil 200. First, T2 copper material and 1060 aluminum material are prepared, and the T2 copper material is processed to a thickness of 3.2mm. 15mm copper connector end cap 100; 1060 aluminum material machined to 3.2mm. Aluminum wire with a diameter of 15mm is wrapped with an insulating film to obtain film-coated aluminum wire. This film-coated aluminum wire is then wound into two sets of 14-turn aluminum coils 200 using a figure-eight continuous winding machine. The welding surfaces of the copper connection end 100 and the aluminum coils 200 are machined until the surface roughness of the welding surfaces is less than or equal to a preset roughness standard. The welding surfaces are then polished with sandpaper of a preset grit and ultrasonically cleaned with anhydrous ethanol for at least a preset cleaning time.

[0092] After the workpiece is prepared for welding, the welding speed of the stirring head of the friction welding device is set to 1500 r / min to 1800 r / min, the friction pressure to 80 MPa to 150 MPa, and the friction time to 1.0 s to 2.5 s. The stirring head of the friction welding device is controlled to rotate and penetrate the weld seam to preheat the target welding interface between the copper connection end 100 and the aluminum coil 200.

[0093] When the cumulative preheating time of the target welding interface reaches the preset preheating time, the stirring head is controlled to move along the welding direction to perform the welding operation, so that the copper connection end 100 and the aluminum coil 200 are solid-phase connected. During the welding operation, the target temperature of the target welding interface is controlled; specifically, the temperature of the target welding interface is detected by an infrared thermometer and defined as the target temperature; when the detected target temperature is greater than... At this time, the target welding interface is cooled by using a water-cooling fixture, or the rotation speed of the stirring head is reduced until the target temperature is less than or equal to the target temperature. When the detected target temperature is less than At this point, increase the stirring head speed until the target temperature is greater than or equal to the target temperature. .

[0094] After the welding operation is completed, inspect the target weld interface for welding defects and take appropriate measures based on the inspection results. Specifically: if incomplete welding defects are present, set the friction pressure of the stirring head to 150 MPa or the friction time to 2.5 s, and repeat the welding operation; if interface crack defects are present, reduce the upsetting speed to 2 mm / s, or add a 0.5 s slowing phase before upsetting, and repeat the welding operation; if excessive flash defects are present, set the upsetting pressure to 200 MPa, or shorten the holding time to 1 s, and repeat the welding operation. After confirming that the above welding defects have been eliminated, the completed inverter inductor is obtained.

[0095] This application embodiment balances processing time and equipment costs through friction welding, enabling the copper connection terminal 100 to form a solid-phase connection with the aluminum coil 200, thereby reducing the manufacturing cost of the inverter inductor.

[0096] This application also provides an inverter inductor, see reference. Figure 2 , 3 The inverter inductor is manufactured using the method described in the above embodiments. The inverter inductor includes a solid-state connected copper terminal 100 and an aluminum coil 200. It is understood that the content of the above method embodiments is applicable to this embodiment, and the specific functions implemented in this embodiment are the same as those in the above method embodiments, and the beneficial effects achieved are also the same as those achieved in the above method embodiments.

[0097] The present application provides a method for manufacturing an inverter inductor and the inductor itself. This method involves pre-preparing a copper connection terminal 100 and an aluminum coil 200, pre-treating the copper connection terminal 100 and the aluminum coil 200, and then setting up a friction welding device according to preset welding parameters. The stirring head of the friction welding device is controlled to rotate and penetrate the weld seam. Based on the principle of frictional heat generation, the target welding interface between the copper connection terminal 100 and the aluminum coil 200 is preheated. When the cumulative preheating time of the target welding interface reaches the preset preheating time, the stirring head is controlled to move along the welding direction to perform the welding operation, so that the copper connection terminal 100 and the aluminum coil 200 are solid-phase connected, completing the friction welding and obtaining the inverter inductor. Compared with soldering and laser welding processes, the friction welding process can balance processing time and equipment costs, reducing the manufacturing cost of the inverter inductor.

[0098] The embodiments described in this application are for the purpose of more clearly illustrating the technical solutions of the embodiments of this application, and do not constitute a limitation on the technical solutions provided by the embodiments of this application. As those skilled in the art will know, with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by the embodiments of this application are also applicable to similar technical problems.

[0099] Those skilled in the art will understand that the technical solutions shown in the figures do not constitute a limitation on the embodiments of this application, and may include more or fewer steps than shown, or combine certain steps, or different steps.

[0100] Those skilled in the art will understand that all or some of the steps in the methods disclosed above, as well as the functional modules / units in the systems and devices, can be implemented as software, firmware, hardware, or suitable combinations thereof.

[0101] The terms “first,” “second,” “third,” “fourth,” etc. (if present) in the specification and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms “comprising” and “having,” and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0102] It should be understood that in this application, "at least one (item)" means one or more, and "more than" means two or more. "And / or" is used to describe the relationship between related objects, indicating that three relationships can exist. For example, "A and / or B" can represent three cases: only A exists, only B exists, and both A and B exist simultaneously, where A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "At least one (item) of the following" or similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one (item) of a, b, or c can represent: a, b, c, "a and b", "a and c", "b and c", or "a and b and c", where a, b, and c can be single or multiple.

[0103] The preferred embodiments of the present application have been described above with reference to the accompanying drawings, but this does not limit the scope of the claims of the present application. Any modifications, equivalent substitutions, and improvements made by those skilled in the art without departing from the scope and substance of the embodiments of the present application shall be within the scope of the claims of the present application.

Claims

1. A method for manufacturing an inverter inductor, characterized in that, The method includes the following steps: Prepare copper connectors and aluminum coils, and pre-treat the copper connectors and aluminum coils; The friction welding device is set according to the preset welding parameters. The stirring head of the friction welding device is controlled to rotate and penetrate the weld seam so that the target welding interface between the copper connection end and the aluminum coil is preheated. When the cumulative preheating time of the target welding interface reaches the preset preheating time, the stirring head is controlled to move along the welding direction to perform the welding operation, so that the copper connection end is solid-phase connected with the aluminum coil to obtain the inverter inductance. The preparation of the copper connection terminal includes: The prepared T2 copper material is processed into a copper connector end with a size of 3.2mm × 15mm, where 3.2mm × 15mm is the cross-sectional size of the welding end face of the copper connector end. Prepare aluminum coils, including: The prepared 1060 aluminum material is processed into an aluminum wire with a size of 3.2mm × 15mm. The size of 3.2mm × 15mm is the cross-sectional size of the welding end face of the aluminum coil. The aluminum wire is coated with an insulating film to obtain a film-coated aluminum wire; The film-coated aluminum wire is wound into two sets of aluminum coils, each with 14 turns, using a figure-eight continuous winding vertical winding machine. The method further includes controlling a target temperature of the target weld interface during the welding operation, wherein controlling the target temperature of the target weld interface includes: The temperature of the target welding interface is detected by an infrared thermometer and defined as the target temperature. When the target temperature is detected to be greater than 548°C, the target welding interface is cooled by water cooling fixture, or the rotation speed of the stirring head is reduced until the target temperature is less than or equal to 548°C. When the target temperature is detected to be less than 460°C, the rotation speed of the stirring head is increased until the target temperature is greater than or equal to 460°C.

2. The method according to claim 1, characterized in that, The pretreatment of the copper connector and the aluminum coil includes: The copper connector and the aluminum coil are respectively subjected to cutting operations until the surface roughness of the welding end is less than or equal to the preset roughness standard. The welded end face is polished with sandpaper of a preset grit, and then ultrasonically cleaned with anhydrous ethanol for at least a preset cleaning time.

3. The method according to claim 1, characterized in that, The step of setting the friction welding device according to preset welding parameters includes: The friction welding device is configured with a stirring head with a welding speed of 1500 r / min to 1800 r / min, a friction pressure of 80 MPa to 150 MPa, and a friction time of 1.0 s to 2.5 s.

4. The method according to claim 1, characterized in that, The method further includes, after the welding operation, inspecting the target weld interface for welding defects, and after inspecting the target weld interface for welding defects, further comprising: When incomplete welding defects exist, set the friction pressure of the stirring head to 150 MPa, or set the friction time to 2.5 s; then repeat the welding operation.

5. The method according to claim 4, characterized in that, After inspecting the welding defects at the target weld interface, the method further includes: When interface crack defects are present, reduce the upsetting speed to 2 mm / s, or add a 0.5 s slowing phase before upsetting; repeat the welding operation.

6. The method according to claim 4, characterized in that, After inspecting the welding defects at the target weld interface, the method further includes: If excessive flash is present, set the upsetting pressure to 200 MPa, or shorten the holding time to 1 second; then repeat the welding operation.

7. An inverter inductor, said inverter inductor being manufactured using the method of any one of claims 1 to 6, said inverter inductor comprising a solid-phase connected copper terminal and an aluminum coil.

Images