Calibration welding device and calibration welding method for cable conductor

Abstract

The invention relates to a calibration welding device and a calibration welding method for a cable conductor. The calibration welding device comprises a base; the fixing mechanism is mounted on one side of the base and comprises a first clamping assembly, and the first clamping assembly is used for fixing a cable conductor; the butt joint calibration mechanism is arranged on the other side in the base and comprises a second clamping assembly and a moving assembly, and the second clamping assembly is used for clamping the other cable conductor; the moving assembly is arranged below the second clamping assembly, and the moving assembly is configured to move in the transverse direction and the vertical direction; the induction detection unit comprises a plurality of displacement detection pieces which are arranged in the first clamping assembly and the second clamping assembly correspondingly. The driving part is in transmission connection with the moving assembly and is electrically connected with the induction detection unit. The cable conductors are fixed through the two clamping assemblies respectively, the transverse position and the vertical position of the cable conductors are adjusted through the driving piece and the moving assembly, real-time position monitoring and feedback control are achieved, and efficient and high-precision automatic butt joint of the two cable conductors is achieved.

Description

Technical Field

[0001] This application relates to the field of cable conductor welding technology, and in particular to a calibration welding apparatus and calibration welding method for cable conductors. Background Technology

[0002] Cable joints, as critical nodes connecting different cable segments, determine the performance and lifespan of a power system. High-frequency fusion welding technology, due to its advantages such as flameless operation and rapid heating, is increasingly widely used in cable connection. This technology is based on the principle of electromagnetic induction, using high-frequency current to generate an alternating magnetic field, inducing a current inside the conductor and rapidly heating it to a molten state, thereby achieving a metallurgical bond between the conductors.

[0003] In related technologies, the implementation of high-frequency fusion welding mainly relies on manual operation. Before welding, the operator needs to manually align and clamp the two cable conductors to be welded, and perform position calibration by visual inspection or simple tools.

[0004] However, the above-mentioned manual calibration and welding methods have the following problems: manual calibration has low accuracy and poor consistency, making it difficult to ensure a tight fit between the conductor ends, which can easily lead to increased contact resistance at the joint, local overheating, or even poor soldering, thus affecting electrical performance. Summary of the Invention

[0005] Therefore, it is necessary to provide a calibration welding device and calibration welding method for cable conductors to address the problems of low docking accuracy, easy incomplete welding, and high contact resistance in existing manual calibration welding methods.

[0006] A calibration welding apparatus for cable conductors, comprising:

[0007] Base;

[0008] A fixing mechanism, installed on one side of the base, includes a first clamping assembly for fixing a cable conductor;

[0009] A docking calibration mechanism, located on the other side within the base, includes a second clamping assembly and a moving assembly. The second clamping assembly is used to clamp another cable conductor. The moving assembly is located below the second clamping assembly and is configured to move laterally and vertically.

[0010] The sensing and detection unit includes multiple displacement detection elements, which are respectively disposed in the first clamping assembly and the second clamping assembly;

[0011] The driving component is connected to the moving component via a transmission and is electrically connected to the sensing and detection unit.

[0012] In one embodiment, the moving component includes a linear guide, a slider, and a hydraulic cylinder;

[0013] The linear guide rail is arranged laterally within the base;

[0014] The slider is slidably connected to the linear guide rail;

[0015] The hydraulic cylinder is mounted vertically on the slider, and the output end of the hydraulic cylinder is connected to one end of the second clamping assembly.

[0016] In one embodiment, both the first clamping assembly and the second clamping assembly include two clamping members and an adjusting member, with the two clamping members arranged vertically and fixed by the adjusting member;

[0017] The clamping member has an outwardly protruding arc-shaped wall, and the two arc-shaped walls form a clamping space, in which the cable conductor is disposed;

[0018] The adjusting component is an adjusting screw.

[0019] In one embodiment, the displacement detection element includes a first detection element and a second detection element, which are disposed at a distance from each other within the arc-shaped wall.

[0020] In one embodiment, the sensing and detection unit further includes an image recognition element disposed within the base, the image recognition element being configured to acquire images of the two cable conductors mating in real time;

[0021] The first and second detection devices are laser displacement sensors; the image recognition device includes an industrial camera.

[0022] In one embodiment, a welding aid component is also included, comprising:

[0023] A rotating seat is rotatably mounted on the base;

[0024] A sleeve, disposed on the rotating seat, includes an outer sleeve and an inner sleeve arranged coaxially;

[0025] The inner sleeve is used to fit around the outer periphery of the cable conductor, and the outer wall of the inner sleeve is provided with radial vent holes.

[0026] In one embodiment, the welding aid component includes:

[0027] A heat dissipation tube is wound around the outer wall of the inner sleeve;

[0028] An airflow mixing channel includes at least two inlet channels and a mixing channel communicating with the inlet channels; the inlet channels and the mixing channel are arranged at an angle; a proportional valve is installed in the inlet channel to adjust the flow rate of the incoming airflow.

[0029] Connect the pipe to the mixing channel and the heat dissipation pipe;

[0030] The temperature detection unit includes a temperature equalization column and a thermocouple disposed within the mixing channel.

[0031] In one embodiment, a multi-layer filter assembly is also included, disposed at the opening end of the outer sleeve;

[0032] The outlet direction of the heat dissipation tube is tangential to the inner sleeve, forming a rotating airflow.

[0033] The aforementioned calibration welding device uses two clamping components to fix the cable conductors respectively, and uses a driving component and a moving component to automatically adjust the lateral and vertical positions of one of the conductors. Combined with real-time position monitoring and feedback control, it achieves efficient and high-precision automatic docking of the two cable conductors.

[0034] According to another object of the present invention, a calibration welding method for cable conductors is also provided, comprising the following steps:

[0035] The two cable conductors are respectively fixed in the first clamping assembly and the second clamping assembly;

[0036] The moving component is driven by a drive unit to initially connect the two cable conductors;

[0037] The position and status of the cable conductor are monitored in real time using displacement detection devices and image recognition devices;

[0038] The moving component is moved again to complete the automatic docking calibration.

[0039] In one embodiment, after the docking calibration is completed, a welding step is also included:

[0040] Adjust the position of the welding auxiliary component and insert the inner sleeve into the end of a cable conductor;

[0041] Start the temperature detection unit and adjust the airflow rate via the proportional valve;

[0042] High-frequency fusion welding is performed at the joint of the two cable conductors.

[0043] The above-mentioned calibration welding method effectively eliminates the uncertainty of manual operation, ensures the consistency and reliability of cable conductor connection, provides a connection basis for subsequent high-frequency fusion welding process, and improves calibration efficiency. Attached Figure Description

[0044] Figure 1 Schematic diagram of the structure for calibrating the welding device Figure 1 .

[0045] Figure 2 Schematic diagram of the structure for calibrating the welding device Figure 2 .

[0046] Figure 3 A cross-sectional schematic diagram for calibrating the welding apparatus.

[0047] Figure 4 A partially enlarged schematic diagram for calibrating the welding equipment.

[0048] Figure 5 This is a cross-sectional schematic diagram of the melting auxiliary component.

[0049] Figure 6 A flowchart illustrating the process for calibrating the welding method.

[0050] In the diagram: 10. Base; 11. Fixed bracket; 12. Positioning pin; 21. First clamping assembly; 22. Second clamping assembly; 221. Clamping component; 222. Adjusting component; 30. Moving component; 31. Linear guide rail; 32. Slider; 33. Hydraulic cylinder; 40. Driving component; 51. Rotating seat; 521. Outer sleeve; 522. Inner sleeve; 53. Vent; 54. Heat dissipation pipe; 551. Inlet channel; 552. Mixing channel; 56. Connecting pipe; 571. Temperature equalization column; 572. Thermocouple; 60. Cable conductor. Detailed Implementation

[0051] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0052] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0053] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0054] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0055] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0056] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0057] Currently, the high-frequency fusion welding process for cable conductors mainly relies on manual alignment and calibration. However, manual alignment and calibration suffers from low precision and poor consistency, making it difficult to ensure a tight fit between the conductor ends. This can easily lead to problems such as increased contact resistance at the joint, localized overheating, or even incomplete soldering, severely affecting electrical performance and mechanical strength.

[0058] likeFigure 1 , Figure 2 As shown, Figure 1 This is a schematic diagram of the structure of the calibration welding apparatus in one embodiment of this application. Figure 1 . Figure 2 This is a schematic diagram of the structure of the calibration welding apparatus in one embodiment of this application. Figure 2 .

[0059] An embodiment of this application provides a calibration and welding device for cable conductors 60, including a base 10, a fixing mechanism, a docking calibration mechanism, a sensing and detection unit, and a driving component 40, to achieve high-precision automatic docking and welding of cable conductors 60.

[0060] In this embodiment, a fixing mechanism is installed on one side of the base 10, including a first clamping assembly 21 for fixing a cable conductor 60. A docking calibration mechanism is disposed on the other side of the base 10, including a second clamping assembly 22 and a moving assembly 30. The second clamping assembly 22 is used to clamp another cable conductor 60. The moving assembly 30 is disposed below the second clamping assembly 22 and is configured to move laterally and vertically. A sensing detection unit includes multiple displacement detection elements, respectively disposed within the first clamping assembly 21 and the second clamping assembly 22. A driving member 40 is drive-connected to the moving assembly 30 and electrically connected to the sensing detection unit.

[0061] The base 10 is made of metal. The base 10 has a mounting groove for mounting the movable component 30.

[0062] The fixing mechanism is bolted to one side of the base 10. The fixing mechanism includes a fixing bracket 11 and a first clamping assembly 21. The fixing bracket 11 is connected to the base 10. The first clamping assembly 21 is mounted on the fixing bracket 11 and includes two clamping members 221 arranged vertically and an adjusting member 222. The two clamping members 221 are flange structures, and the adjusting member 222 is an adjusting nut. By tightening or loosening the adjusting nut, the distance between the upper and lower flanges is adjusted to clamp and fix the cable conductor 60, and this mechanism is suitable for cable conductors 60 of different diameters.

[0063] The docking calibration mechanism is located on the other side of the base 10 and includes a moving component 30 and a second clamping component 22. The moving component 30 consists of a linear guide rail 31 and a slider 32, with the slider 32 slidably connected to the linear guide rail 31 via pulleys. The moving component 30 also includes a hydraulic cylinder 33, which is mounted on the slider 32, and the piston rod of the hydraulic cylinder 33 is connected to the second clamping component 22.

[0064] The second clamping assembly 22 is fixed to the slider 32 by bolts and is used to clamp another cable conductor 60 to be connected.

[0065] The sensing and detection unit includes multiple displacement detection elements, which are respectively disposed on the first clamping assembly 21 and the second clamping assembly 22. The displacement detection elements are laser displacement sensors. Two laser displacement sensors are disposed on the first clamping assembly 21, and two laser displacement sensors are correspondingly disposed on the second clamping assembly 22. The connection position of the two cable conductors 60 is determined by the signal transmission and reception of the two laser displacement sensors on both sides.

[0066] The drive unit 40 includes a servo motor, which is connected to the slider 32 via a coupling and a ball screw mechanism. The servo motor drives the slider 32 to move laterally, thereby moving the second clamping assembly 22 laterally to adjust the lateral position of the other cable conductor 60. The hydraulic cylinder 33 drives the second clamping assembly 22 to move vertically to adjust the vertical position of the other cable conductor 60.

[0067] In the specific implementation process, one cable conductor 60 is first fixed in the first clamping assembly 21, and then the other cable conductor 60 is fixed in the second clamping assembly 22. The driving component 40 drives the moving component 30 to move the second clamping assembly 22 laterally; and the moving component 30 drives the second clamping assembly 22 to move vertically, thereby adjusting the lateral and vertical positions of the cable conductors 60 and achieving an automatic docking process. Simultaneously, the displacement detection component monitors the position of the cable conductors 60 in real time and controls the movement of the moving component 30, achieving real-time adjustment of the position of the cable conductors 60 and improving the docking accuracy and efficiency of the two cable conductors 60.

[0068] like Figure 3 As shown, Figure 3 This is a cross-sectional schematic diagram of a calibration welding device provided in one embodiment of this application. In one embodiment, the moving component 30 includes a linear guide rail 31, a slider 32, and a hydraulic cylinder 33; the linear guide rail 31 is arranged laterally within the base 10; the slider 32 is slidably connected to the linear guide rail 31; the hydraulic cylinder 33 is vertically mounted on the slider 32, and the output end of the hydraulic cylinder 33 is connected to one end of the second clamping component 22.

[0069] Specifically, the moving component 30 includes a linear guide rail 31, a slider 32, and a hydraulic cylinder 33, enabling the second clamping component 22 to move laterally and vertically.

[0070] The linear guide 31 is a ball-bearing linear guide 31, which is fixedly installed in the mounting groove of the base 10 in the transverse direction.

[0071] The slider 32 is made of aluminum alloy. Through the cooperation of ball bearings and the linear guide 31, the slider 32 achieves smooth lateral movement. The hydraulic cylinder 33 is vertically mounted on the upper surface of the slider 32. The cylinder body of the hydraulic cylinder 33 is fixedly connected to the slider 32 by bolts, and the end of the piston rod is connected to the base of the second clamping assembly 22 via a universal joint. This connection method effectively compensates for installation errors and ensures motion accuracy. The hydraulic cylinder 33 is equipped with a displacement sensor, which can monitor the displacement of the piston rod in real time, achieving closed-loop control of the vertical position.

[0072] In actual operation, when the lateral position of the cable conductor 60 needs to be adjusted, the drive unit 40 drives the slider 32 to move along the linear guide rail 31 via the ball screw mechanism, thereby causing the entire second clamping assembly 22 and the clamped cable conductor 60 to move laterally. When the vertical position needs to be adjusted, the hydraulic cylinder 33 pushes the piston rod to extend and retract, driving the second clamping assembly 22 to move vertically via the universal joint. Through the coordinated lateral and vertical movements, precise alignment of the cable conductor 60 can be achieved.

[0073] Limit blocks are provided at both ends of the linear guide rail 31 to prevent the slider 32 from moving beyond its travel range.

[0074] The aforementioned moving component 30 has a compact structure and stable movement, which can meet the requirements of high-frequency melting welding process for conductor docking accuracy, ensure the accurate positioning of the cable conductor 60 during the welding process, and thus guarantee the quality of the welded joint.

[0075] In one embodiment, the first clamping assembly 21 and the second clamping assembly 22 each include two clamping members 221 and an adjusting member 222. The two clamping members 221 are arranged vertically and fixed by the adjusting member 222. The clamping members 221 are provided with outwardly protruding arc-shaped walls, and the two arc-shaped walls form a clamping space. The cable conductor 60 is disposed in the clamping space. The adjusting member 222 is an adjusting screw.

[0076] Specifically, the first clamping assembly 21 and the second clamping assembly 22 adopt the same structural design, both including two clamping members 221 and an adjusting member 222, to achieve clamping of cable conductors 60 with different diameters.

[0077] The clamping members 221 are made of aluminum alloy, and the main body of each clamping member 221 has an outwardly protruding arc-shaped wall. The inner surface of the arc-shaped wall is machined with anti-slip texture to effectively increase the friction with the surface of the cable conductor 60 and prevent slippage during the docking process. The two clamping members 221 are arranged symmetrically, and when the two clamping members 221 are closed, the two arc-shaped walls together form a cylindrical clamping space.

[0078] The adjusting member 222 uses adjusting screws to control the clamping force. Multiple mounting holes are provided at the four corners of each clamping member 221, and the upper and lower clamping members 221 are connected and fixed by multiple sets of adjusting screws.

[0079] In actual use, the operator can control the distance between the upper and lower clamping parts 221 by tightening or loosening the adjusting screws at the four corners. When it is necessary to clamp a thicker cable conductor 60, loosen the adjusting screws to expand the clamping space; when it is necessary to clamp a thinner cable conductor 60, tighten the adjusting screws to reduce the clamping space.

[0080] In one embodiment, the displacement detection element includes a first detection element and a second detection element, which are disposed at a distance from each other within the arc-shaped wall.

[0081] Specifically, both the first and second detection elements are laser displacement sensors. The two detection elements are arranged at a 90-degree angle interval inside the arc-shaped wall, with the first detection element located at the top center of the arc-shaped wall and the second detection element located at the side center of the arc-shaped wall. This arrangement allows for the simultaneous detection of displacement changes of the cable conductor 60 in both the vertical and horizontal directions.

[0082] In one embodiment, the sensing and detection unit further includes an image recognition element disposed within the base 10, the image recognition element being configured to acquire images of two cable conductors 60 mating in real time; the first and second detection elements are laser displacement sensors; the image recognition element includes an industrial camera.

[0083] Specifically, the image recognition component uses an industrial camera, which is fixedly installed inside the base 10. The industrial camera is connected to the base 10, and its optical axis is parallel to the docking axis of the two cable conductors 60. The industrial camera is equipped with a telecentric optical lens to effectively eliminate perspective errors and ensure the accuracy of image acquisition. The laser displacement sensor works in conjunction with the industrial camera to form a redundant detection system.

[0084] like Figure 3 , Figure 4 As shown, Figure 3 This is a cross-sectional schematic diagram of a calibration welding apparatus provided in one embodiment of this application. Figure 4 This is a partially enlarged schematic diagram of a calibration welding apparatus provided in one embodiment of this application. In one embodiment, it further includes a welding auxiliary component, comprising a rotating base 51 and a sleeve. The rotating base 51 is rotatably mounted on the base 10; the sleeve is disposed on the rotating base 51 and includes an outer sleeve 521 and an inner sleeve 522 coaxially arranged; wherein the inner sleeve 522 is used to fit around the outer periphery of the cable conductor 60, and the outer wall of the inner sleeve 522 is provided with radial vent holes 53.

[0085] Specifically, the welding auxiliary component adopts a double-layer sleeve structure to provide a reliable protective environment for the high-frequency melting welding process of the cable conductor 60.

[0086] The rotating seat 51 is rotatably mounted on one side of the base 10 via bearings. A positioning groove is provided at the bottom of the rotating seat 51, which engages with the positioning pin 12 on the base 10 to ensure the accuracy of the rotation angle. A manual operating handle is provided on the side of the rotating seat 51 for easy control of the rotation angle by the operator.

[0087] The sleeve assembly adopts a coaxial double-layer structure, including an outer sleeve 521 and an inner sleeve 522. The outer sleeve 521 is made of stainless steel, and its inner diameter is larger than the outer diameter of the inner sleeve 522, forming an annular airflow channel. The inner sleeve 522 is made of aluminum ceramic, which has high temperature resistance and insulation properties. The inner diameter of the inner sleeve 522 is slightly larger than the outer diameter of the cable conductor 60, ensuring that the cable conductor 60 can be smoothly inserted.

[0088] Multiple radial vent holes 53 are evenly distributed on the outer wall of the inner sleeve 522 to ensure that the gas generated during welding can be discharged smoothly and maintain sufficient gas pressure inside the sleeve. Furthermore, a metal filter screen is provided at the inner opening of each vent hole 53 to prevent molten metal from entering the channel and causing blockage.

[0089] In practical use, after the two cable conductors 60 are joined, the operator rotates the rotating seat 51 to the working position by turning the handle, so that the inner sleeve 522 is fitted onto the outer circumference of the joined cable conductors 60. At this time, the axis of the inner sleeve 522 is completely aligned with the axis of the cable conductors 60, ensuring uniform heating of the welding area. During the welding process, the heat generated by the high-frequency induction coil melts the end of the cable conductors 60, and the generated gas is discharged through the radial vent 53, effectively preventing the formation of porosity defects.

[0090] The double-layer sleeve structure and the vent hole 53 design effectively improve the consistency and reliability of welding quality, providing an important guarantee for the stable implementation of high-frequency fusion welding process.

[0091] like Figure 5 As shown, Figure 5This is a cross-sectional schematic diagram of a welding auxiliary component provided in one embodiment of this application. In one embodiment, the welding auxiliary component includes: a heat dissipation and drainage pipe 54 wound around the outer wall of the inner sleeve 522; an airflow mixing channel including at least two inlet channels 551 and a mixing channel 552 communicating with the inlet channels 551; the inlet channels 551 and the mixing channel 552 are arranged at an angle; a proportional valve is installed in the inlet channel 551 for adjusting the flow rate of the incoming airflow; a connecting pipe 56 connects the mixing channel 552 and the heat dissipation and drainage pipe 54; and a temperature detection unit including a temperature equalization column 571 and a thermocouple 572 disposed in the mixing channel 552.

[0092] Specifically, the heat dissipation tube 54 is made of copper. The heat dissipation tube 54 is wound around the outer wall of the inner sleeve 522, forming a uniform heat dissipation surface. The inner cavity of the heat dissipation tube 54 is used for the flow of cooling gas, and its outer surface maintains close contact with the outer wall of the inner sleeve 522 to ensure efficient heat conduction.

[0093] The airflow mixing channel includes two independent inlet channels 551 and one mixing channel 552. The two inlet channels 551 are respectively connected to dry compressed air and cooling nitrogen. The connection between the inlet channels 551 and the mixing channel 552 is at an inclined angle, causing the two airflows to form a rotating vortex within the mixing channel 552, promoting thorough mixing of the gases. A proportional valve is installed at the inlet of each inlet channel 551, driven by a stepper motor, to adjust the gas flow rate.

[0094] The mixing channel 552 has a cylindrical structure. A temperature equalization column 571 is coaxially arranged at the central axis of the mixing channel 552. The temperature equalization column 571 is made of aluminum alloy, has a cylindrical shape, and has spiral guide grooves on its surface to further enhance the mixing effect of the airflow.

[0095] The temperature detection unit includes a type K thermocouple 572 embedded in the front end of the temperature distribution column 571. The measuring end of the thermocouple 572 is in direct contact with the airflow, enabling real-time monitoring of the temperature of the gas mixture. The measurement signal from the thermocouple 572 is transmitted to the temperature control system via a shielded cable.

[0096] The connecting pipe 56 is made of silicone flexible tubing. Quick-connect fittings are used at both ends of the pipe to connect to the outlet of the mixing channel 552 and the inlet of the heat dissipation pipe 54, ensuring convenient installation.

[0097] In actual operation, the temperature control system adjusts the opening of the two proportional valves in real time through the PLC controller based on the temperature data fed back by thermocouple 572, and controls the mixing ratio of dry compressed air and cooling nitrogen, so that the gas temperature entering the heat dissipation tube 54 is stable within the set range, effectively avoiding welding quality problems caused by temperature fluctuations during the welding process. At the same time, the forced convection cooling of the gas prevents the inner sleeve 522 from overheating and extends the service life of the equipment.

[0098] In one embodiment, a multi-layer filter assembly is further provided at the opening end of the outer sleeve 521; the outlet direction of the heat dissipation drain pipe 54 is arranged tangentially to the inner sleeve 522 to form a rotating airflow.

[0099] Specifically, the multi-layer filter assembly is disposed at the open end of the outer sleeve 521. The filter assembly includes multiple filter layers, specifically a stainless steel metal filter screen, an activated carbon fiber layer, and an air filter layer. The filter assembly is connected to the outer sleeve 521 via a snap-fit ​​structure, facilitating regular replacement and maintenance.

[0100] The outlet of the heat dissipation pipe 54 adopts a flat nozzle structure, and its outlet axis forms an angle with the outer wall of the inner sleeve 522, so that the cooling gas ejected from the pipe forms a high-speed rotating airflow along the outer wall of the inner sleeve 522. The rotating airflow forms a stable vortex field in the annular space between the inner sleeve 522 and the outer sleeve 521, which not only enhances the heat dissipation effect, but also has an entraining effect on the welding waste gas discharged from the air outlet 53 of the inner sleeve 522.

[0101] like Figure 6 As shown, Figure 6 This is a schematic flowchart of a calibration welding method provided in one embodiment of the present application. In one embodiment, a calibration welding method for a cable conductor 60 is also provided, comprising the following steps:

[0102] Step S1: Fix the two cable conductors 60 in the first clamping assembly 21 and the second clamping assembly 22 respectively;

[0103] Step S2: Drive the moving component 30 through the driving component 40 to initially connect the two cable conductors 60;

[0104] Step S3: Monitor the position status of the cable conductor 60 in real time using displacement detection and image recognition devices;

[0105] Step S4: Control the moving component 30 to move again to complete the automatic docking calibration.

[0106] In step S1, the first cable conductor 60 is first clamped in the first clamping assembly 21 of the fixing mechanism. The operator tightens the adjusting screws at the four corners so that the clamping members 221 of the upper and lower flange structures hold the cable conductor 60, ensuring that its axis is parallel to the reference plane of the base 10. Then, the second cable conductor 60 is clamped in the second clamping assembly 22. During this process, the laser displacement sensor inside the clamping assembly automatically detects the clamping position of the cable conductor 60, ensuring that it is at the correct clamping center.

[0107] In step S2, the servo motor is started, and the support block is driven to move laterally along the linear guide rail 31 via the ball screw mechanism, causing the second clamping assembly 22 and the clamped cable conductor 60 to move closer to the first cable conductor 60. At the same time, the hydraulic cylinder 33 pushes the second clamping assembly 22 to adjust its vertical position.

[0108] In step S3, after the two cable conductors 60 enter the docking area, four laser displacement sensors installed on the first clamping assembly 21 and the second clamping assembly 22 are simultaneously activated to monitor the displacement changes of the cable conductors 60 in the vertical direction and in the alignment state in real time. An industrial camera acquires image data of the docking area.

[0109] In step S4, the control system generates motion commands based on multi-sensor feedback data. The servo motor and hydraulic cylinder 33 are fine-tuned in closed-loop control mode. First, the axial angle deviation is corrected to make the axes of the two conductors coincide; then, the end faces are brought closer together by controlling the end faces of the two conductors to slowly approach each other until the preset mating gap is reached.

[0110] The above calibration method effectively eliminates the uncertainty of manual operation, ensures the consistency and reliability of the cable conductor 60 mating, provides a mating basis for subsequent high-frequency fusion welding process, and improves calibration efficiency.

[0111] In one embodiment, after the docking calibration is completed, a welding step is also included:

[0112] Step S5: Adjust the position of the welding auxiliary component and fit the inner sleeve 522 onto the end of a cable conductor 60;

[0113] Step S6: Start the temperature detection unit and adjust the airflow rate through the proportional valve;

[0114] Step S7: Perform high-frequency fusion welding at the joint position of the two cable conductors 60.

[0115] In step S5, after completing the alignment of the cable conductors 60, the operator rotates the welding auxiliary assembly to the working position using the manual operating handle of the rotating base 51. At this time, the axis of the inner sleeve 522 is coaxial with the axis of the joined cable conductors 60. The operator advances the welding auxiliary assembly so that the inner sleeve 522 first fits onto the end of the first cable conductor 60, until the inner sleeve 522 covers the joining area of ​​the two cable conductors 60.

[0116] In step SS6, the temperature detection unit is activated, and thermocouple 572 begins real-time monitoring of the gas temperature within the mixing channel 552, transmitting the data to the PLC control system. A proportional valve controls the dry compressed air and cooling nitrogen to enter the mixing channel 552 through two separate inlet channels 551. Under the action of the equalization column 571, the two gases are fully mixed and form a stable vortex, which is then transported through connecting pipe 56 to the heat dissipation drain pipe 54 wound around the outer wall of the inner sleeve 522.

[0117] In step S7, the high-frequency induction power supply is activated, and a high-frequency alternating current is passed through the induction coil, generating an alternating magnetic field in the working area. The cable conductor 60 generates an induced current under the action of the alternating magnetic field, and its temperature rises to a molten state. During the welding process, cooling gas continuously flows within the heat dissipation pipe 54 to cool the induction coil and prevent overheating damage; heat dissipation is controlled through the outer wall of the inner sleeve 522 to prevent excessive temperature from causing material oxidation. Simultaneously, the gas generated during welding is discharged through the radial vent holes 53 on the wall of the inner sleeve 522, and guided to the filter assembly for processing under the action of the rotating airflow.

[0118] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0119] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A calibration and welding apparatus for cable conductors, characterized in that, include: Base; A fixing mechanism, installed on one side of the base, includes a first clamping assembly for fixing a cable conductor; A docking calibration mechanism, located on the other side within the base, includes a second clamping assembly and a moving assembly. The second clamping assembly is used to clamp another cable conductor. The moving assembly is located below the second clamping assembly and is configured to move laterally and vertically. The sensing and detection unit includes multiple displacement detection elements, which are respectively disposed in the first clamping assembly and the second clamping assembly; The driving component is connected to the moving component via a transmission and is electrically connected to the sensing and detection unit.

2. The calibration and welding apparatus for cable conductors according to claim 1, characterized in that, The moving component includes a linear guide, a slider, and a hydraulic cylinder; The linear guide rail is arranged laterally within the base; The slider is slidably connected to the linear guide rail; The hydraulic cylinder is mounted vertically on the slider, and the output end of the hydraulic cylinder is connected to one end of the second clamping assembly.

3. The calibration and welding apparatus for cable conductors according to claim 2, characterized in that, The first clamping assembly and the second clamping assembly each include two clamping members and an adjusting member. The two clamping members are arranged vertically and fixed by the adjusting member. The clamping member has an outwardly protruding arc-shaped wall, and the two arc-shaped walls form a clamping space, in which the cable conductor is disposed; The adjusting component is an adjusting screw.

4. The calibration and welding apparatus for cable conductors according to claim 3, characterized in that, The displacement detection element includes a first detection element and a second detection element, which are spaced apart within the arc-shaped wall.

5. The calibration and welding apparatus for cable conductors according to claim 4, characterized in that, The sensing and detection unit also includes an image recognition component, which is disposed within the base and configured to acquire images of the two cable conductors mating in real time. The first and second detection devices are laser displacement sensors; the image recognition device includes an industrial camera.

6. The calibration and welding apparatus for cable conductors according to claim 2, characterized in that, It also includes welding auxiliary components, including: A rotating seat is rotatably mounted on the base; A sleeve, disposed on the rotating seat, includes an outer sleeve and an inner sleeve arranged coaxially; The inner sleeve is used to fit around the outer periphery of the cable conductor, and the outer wall of the inner sleeve is provided with radial vent holes.

7. The calibration and welding apparatus for cable conductors according to claim 6, characterized in that, The welding auxiliary component includes: A heat dissipation tube is wound around the outer wall of the inner sleeve; An airflow mixing channel includes at least two inlet channels and a mixing channel communicating with the inlet channels; the inlet channels and the mixing channel are arranged at an angle; a proportional valve is installed in the inlet channel to adjust the flow rate of the incoming airflow. Connect the pipe to the mixing channel and the heat dissipation pipe; The temperature detection unit includes a temperature equalization column and a thermocouple disposed within the mixing channel.

8. The calibration and welding apparatus for cable conductors according to claim 7, characterized in that, It also includes a multi-layer filter assembly disposed at the opening end of the outer sleeve; The outlet direction of the heat dissipation tube is tangential to the inner sleeve, forming a rotating airflow.

9. A calibration welding method for cable conductors, characterized in that, Includes the following steps: The two cable conductors are respectively fixed in the first clamping assembly and the second clamping assembly; The moving component is driven by a drive unit to initially connect the two cable conductors; The position and status of the cable conductor are monitored in real time using displacement detection devices and image recognition devices; The moving component is moved again to complete the automatic docking calibration.

10. The calibration and welding method for cable conductors according to claim 9, characterized in that, After completing the docking calibration, the welding step is also included: Adjust the position of the welding auxiliary component and insert the inner sleeve into the end of a cable conductor; Start the temperature detection unit and adjust the airflow rate via the proportional valve; High-frequency fusion welding is performed at the joint of the two cable conductors.

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