Composite welding device

Abstract

The invention relates to the technical field of welding, in particular to a composite welding device. The hybrid welding device comprises a machining platform, a feeding mechanism, an electrode wheel mechanism, a pressurization driving mechanism, a moving mechanism, a welding power source and a preheating module. The preheating module is arranged in the path direction between the feeding mechanism and the machining platform and used for heating a welding area of the to-be-combined materials so that a temperature field can be formed in the welding area. And after a temperature field formed in the welding area and the current loop are subjected to joule thermal compounding on the workpiece, the to-be-bonded material and the welding base material are metallurgically bonded and fixedly connected through pressure applied by the electrode wheel.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the technical field of welding, in particular to a composite welding device. BACKGROUND

[0002] Although resistance seam welding technology has been widely used in industrial manufacturing, it still has significant technical bottlenecks in energy consumption, process control and material adaptability.

[0003] In terms of energy and pressure requirements, traditional resistance seam welding relies on an electrode wheel to achieve workpiece fusion through a large current. In order to ensure sufficient joule heat generation and interface bonding, a high welding current and electrode pressure need to be applied. This high energy input mode not only leads to high power consumption, but also causes a series of derivative problems: excessive current is easy to cause electrode wheel overheating loss, shortening its service life and increasing the replacement frequency; and strong pressure action can cause plastic deformation of thin plate workpieces, especially adversely affecting the dimensional accuracy of precision structural parts. SUMMARY

[0004] The present disclosure provides a composite welding device to at least solve the above technical problems existing in the prior art.

[0005] The present disclosure provides a composite welding device, comprising: a machining platform comprising a machining site, the machining site being provided with a first conductive working surface, the first conductive working surface being used to carry a welding base material; a feeding mechanism used to deliver a material to be combined to the surface of the welding base material; an electrode wheel mechanism comprising an electrode wheel, the electrode wheel being rotatable about its axis, the rim of the electrode wheel being provided with a second conductive working surface; a pressure driving mechanism connected with the electrode wheel mechanism, used to drive the electrode wheel to move in a direction perpendicular to the machining site, so as to adjust the pressing force of the electrode wheel on a workpiece formed by the material to be combined and the welding base material; a moving mechanism connected with the pressure driving mechanism, used to drive the pressure driving mechanism to move, the electrode wheel applying pressure on a welding position of the workpiece during the movement of the pressure driving mechanism; a welding power source electrically connected with the first conductive working surface and the second conductive working surface through a conductive connecting piece, used to input a welding current to the electrode wheel, so as to form a current loop among the power source, the first conductive working surface, the workpiece and the second conductive working surface; A preheating module is arranged in the path direction between the feeding mechanism and the processing platform, and is used to heat the welding area of the material to be combined, so that the welding area forms a temperature field. The temperature field formed by the welding area, the Joule heat formed by the current loop in the workpiece, and the pressure applied by the electrode wheel after the combination of the two, make the material to be combined and the welding base material form a metallurgical bond and be fixed.

[0006] Further, the processing platform is provided with a heating unit, which is used to heat the first conductive working surface and the welding base material, so that the first conductive working surface and the welding base material form a temperature field. The temperature field formed by the first conductive working surface and the welding base material, the temperature field formed by the material to be combined in the welding area, and the pressure applied by the electrode wheel after the combination of the two, make the material to be combined and the welding base material form a metallurgical bond and be fixed.

[0007] Further, the control device is electrically connected with the feeding mechanism, the electrode wheel mechanism, the pressure driving mechanism, the welding power supply and the preheating module, respectively, and is used to adjust the feeding speed of the material to be combined, the moving speed of the moving mechanism, the pressure of the electrode wheel, the welding current intensity and the preheating power according to the resistivity parameter and the thickness parameter of the material to be combined. Further, the preheating module comprises a laser head and a height adjusting support, and the laser head is arranged on the height adjusting support. The height of the height adjusting support is adjustable, so as to control the position of the laser preheating acting on the material to be combined. Further, the laser head comprises a blue laser, a red laser, a green laser and a near-infrared laser. The laser head selects one of the blue laser, the red laser, the green laser and the near-infrared laser to heat the welding area of the material to be combined according to the physical characteristics and surface state of the material to be combined.

[0008] Further, an adjusting mechanism is arranged between the laser head and the height adjusting support, and the adjusting mechanism is used to plan and control the scanning path according to the width, thickness and physical properties (thermal conductivity, melting point) of the material to be combined. The scanning path includes continuous straight line trajectory, sinusoidal trajectory or segmented pulse trajectory.

[0009] Further, the scanning speed of the laser head is positively correlated with the feeding speed of the feeding mechanism.

[0010] Further, the power adjustment of the heating unit and the preheating module is negatively correlated.

[0011] Further, the processing platform is provided with a temperature sensor, and the electrode wheel is provided with a pressure sensor; The temperature sensor is used for monitoring the temperature information of the contact interface between the welding base material and the material to be combined in real time, and feeding back to the control device; The pressure sensor is used for monitoring the pressure information of the electrode wheel in real time, and feeding back to the control device; The control device is used for adjusting the feeding speed of the material to be combined, the moving speed of the moving mechanism, the pressure of the electrode wheel, the welding current intensity and the preheating power according to the temperature information and the pressure information. Further, a rack is further included, and the processing platform and the moving mechanism are arranged in the rack; The electrode wheel mechanism includes a connecting piece, and the electrode wheel is rotationally connected with the connecting piece; The pressure driving mechanism includes a cylinder, the cylinder body of the cylinder is arranged in the moving mechanism, and the telescopic end of the cylinder is connected with the connecting piece, and is used for driving the electrode wheel to move towards the direction of approaching or moving away from the processing platform.

[0012] Compared with the prior art, the technical scheme provided by the embodiments of the present disclosure has the following advantages: The composite welding device provided by the embodiments of the present disclosure includes a processing platform, a feeding mechanism, an electrode wheel mechanism, a pressure driving mechanism, a moving mechanism, a welding power supply and a preheating module. The processing platform includes a processing site, and the processing site is provided with a first conductive working surface used for bearing a welding base material. The feeding mechanism is used for conveying a material to be combined to the surface of the welding base material. The electrode wheel mechanism includes an electrode wheel, the electrode wheel can rotate around its axis, and the rim of the electrode wheel is provided with a second conductive working surface. The pressure driving mechanism is connected with the electrode wheel mechanism, and is used for driving the electrode wheel to move in the direction perpendicular to the processing site, so as to adjust the pressing force of the workpiece formed by the electrode wheel on the material to be combined and the welding base material. The moving mechanism is connected with the pressure driving mechanism, and is used for driving the pressure driving mechanism to move. During the movement of the pressure driving mechanism, the electrode wheel applies pressure to the welding position of the workpiece. The welding power supply is electrically connected with the first conductive working surface and the second conductive working surface through a conductive connecting piece, and is used for inputting welding current to the electrode wheel, so as to form a current loop among the power supply, the first conductive working surface, the workpiece and the second conductive working surface. The preheating module is arranged in the path direction between the feeding mechanism and the processing platform, and is used for heating the welding area of the material to be combined, so as to form a temperature field in the welding area. After the temperature field formed in the welding area and the current loop form joule heat in the workpiece, the pressure applied by the electrode wheel makes the material to be combined and the welding base material form metallurgical combination and solid connection.

[0013] The composite welding device provided by the present disclosure processes as follows: first, the feed mechanism drives the to-be-bonded material to continuously convey to the welding base material surface above the processing platform, and in the conveying process, the preheating module synchronously heats the welding area of the to-be-bonded material to realize local preheating of the welding interface; then, the electrode wheel is pressed against the metal foil strip under the pressure of the pressure driving mechanism, and under the condition of power-on, the moving mechanism drives the electrode wheel to roll forward, and the temperature field formed by the welding area and the joule heat formed by the current loop in the workpiece and the mechanical pressure form the to-be-bonded material preheated to be consolidated on the welding base material surface. By utilizing the combined effect of the temperature field formed by the welding area and the joule heat formed by the current loop in the workpiece, the present disclosure can prepare a predetermined thickness of the stack on the welding base surface. Among them, the preheating module causes the welding area of the to-be-bonded material to locally soften, which not only helps to achieve greater single-channel to-be-bonded material thickness accumulation in the resistance seam welding process and improve the welding adaptability of low resistivity materials, but also forms a firm metallurgical bonding interface between the to-be-bonded material and the welding base material and between the layers of to-be-bonded material under the combined action of the temperature field, the joule heat and the welding pressure. Through the precise cooperation of the above-mentioned composite heat source and mechanical pressure, the present disclosure effectively solves the technical bottlenecks of insufficient energy input and poor bonding quality of single resistance seam welding in thick-layer to-be-bonded materials and low resistivity materials. The process is stable and reliable, and is suitable for industrialized high-efficiency continuous production.

[0014] That is, when the to-be-bonded material is conveyed to the welding base material surface by the feed mechanism, the preheating module synchronously heats the to-be-bonded material when it reaches the welding base material surface, realizing accurate preheating of the welding interface. The preheating process rapidly softens the to-be-bonded material contact interface, significantly reduces the energy input and electrode pressure required in the subsequent resistance seam welding process, and improves the process controllability; realizes the timing synchronization and heat source coupling of preheating and resistance seam welding. After the to-be-bonded material is preheated, the electrode wheel is immediately pressed and welded with current. Under the synergistic action of the temperature field, the joule heat and the mechanical pressure, the to-be-bonded material and the welding base material, and the to-be-bonded material and the to-be-bonded material are firmly connected to form a dense metallurgical bonding interface. This way can construct a high-quality metallurgical bonding mechanism under the action of heat and force coupling, realize a larger thickness of single-channel to-be-bonded material layer, and solve the welding adaptability of low resistivity materials, effectively expanding the process window and application range of resistance seam welding.

[0015] It should be understood that the content described in this part is not intended to identify key or important features of the embodiments of the present disclosure, nor is it used to limit the scope of the present disclosure. Other features of the present disclosure will become apparent from the following description. BRIEF DESCRIPTION OF DRAWINGS

[0016] The above and other objects, features and advantages of the present disclosure exemplary embodiments will become more apparent from the following detailed description read in conjunction with the accompanying drawings. In the drawings, several embodiments of the present disclosure are illustrated by way of example and not limitation in which: In the drawings, identical or corresponding reference signs indicate identical or corresponding parts.

[0017] Figure 1 A forming schematic diagram of a composite welding device provided by an embodiment of the present disclosure is shown; Figure 2 A structural schematic diagram of a composite welding device provided by an embodiment of the present disclosure is shown; Figure 3 A control logic diagram of a composite welding device provided by an embodiment of the present disclosure is shown.

[0018] Figure legend: 1, rack; 2, air cylinder; 3, machining platform; 31, first conductive working surface; 32, heating unit; 4, electrode wheel; 41, second conductive working surface; 5, connecting piece; 61, laser head; 62, height adjusting support; 63, adjusting mechanism; 631, first adjusting assembly; 632, second adjusting assembly; 71, material to be combined; 711, welding area; 72, welding base material; 81, feed wheel; 82, adapter frame; 9, moving mechanism; 10, working platform. DETAILED DESCRIPTION

[0019] In order to make the purpose, features and advantages of the present disclosure more obvious and easy to understand, the technical solutions in the embodiments of the present disclosure will be described clearly and completely below in conjunction with the drawings in the embodiments of the present disclosure. Obviously, the described embodiments are only part of the embodiments of the present disclosure, rather than all the embodiments. Based on the embodiments in the present disclosure, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present disclosure.

[0020] Traditional resistance seam welding relies on an electrode wheel to achieve workpiece fusion through a large current. In order to ensure sufficient joule heat generation and interface bonding, a high welding current and electrode pressure need to be applied. This high-energy input mode not only leads to large power consumption, but also causes a series of derivative problems: over-high current is easy to cause electrode wheel overheating loss, shortens its service life and increases the replacement frequency; and strong pressure action can cause plastic deformation of thin plate workpieces, especially adversely affecting the dimensional accuracy of precision structural parts. At the same time, high-energy input causes the heat-affected zone to expand during the welding process, which is easy to cause quality defects such as workpiece warping and grain coarsening, increasing the cost of subsequent straightening and processing procedures.

[0021] In terms of material adaptability, traditional resistance seam welding has obvious limitations in welding low resistivity materials (such as copper, aluminum and their alloys). Such materials have excellent electrical conductivity, and the efficiency of Joule heat generation is low when current passes through. In order to reach the welding temperature, the welding current needs to be further increased, which not only aggravates the above-mentioned energy consumption problem, but also may cause spatter, burn-through and other defects on the contact surface between the electrode and the workpiece due to excessive current. In addition, low resistivity materials often have high thermal conductivity, and the heat retention time in the welding area 711 is short, making it difficult to form a stable molten pool, resulting in low weld joint strength and poor sealing, which seriously limits the application of resistance seam welding technology in the manufacturing of high-conductivity material components. Based on this, the disclosed embodiments provide a composite welding device.

[0022] In combination with Figure 1 , Figure 2 and Figure 3 , the composite welding device provided by the disclosed embodiments includes a machining platform 3, a feeding mechanism, an electrode wheel mechanism, a pressure driving mechanism, a welding power supply and a preheating module. The machining platform 3 includes a machining position, and the machining position is provided with a first conductive working surface 31 for carrying a welding base material 72. Optionally, the welding base material 72 is fixed to the machining platform 3 by a clamp. The feeding mechanism is used to transport the material to be combined 71 to the surface of the welding base material 72. The electrode wheel mechanism includes an electrode wheel 4, which can rotate around the axis of the electrode wheel 4, and the rim of the electrode wheel 4 is provided with a second conductive working surface 41. The pressure driving mechanism is connected with the electrode wheel mechanism, and is used to drive the electrode wheel 4 to move in a direction perpendicular to the machining position, so as to adjust the pressing force of the electrode wheel 4 on the workpiece formed by the material to be combined 71 and the welding base material 72. The moving mechanism 9 is connected with the pressure driving mechanism, and is used to drive the pressure driving mechanism to move. During the movement of the pressure driving mechanism, the electrode wheel applies pressure to the welding position of the workpiece. The welding power supply is electrically connected with the first conductive working surface 31 and the second conductive working surface 41 through a conductive connecting piece, and is used to input welding current to the electrode wheel 4, so as to form a current loop between the power supply, the first conductive working surface 31, the workpiece and the second conductive working surface 41. The preheating module is arranged in the path direction between the feeding mechanism and the machining platform 3, and is used to heat the welding area 711 of the material to be combined 71, so as to form a temperature field in the welding area 711. After the temperature field formed by the welding area 711 and the Joule heat formed by the current loop in the workpiece are combined, the pressure applied by the electrode wheel 4 makes the material to be combined 71 and the welding base material 72 form a metallurgical bond and solid joint.

[0023] The composite welding device provided by the present disclosure processes as follows: first, the feeding mechanism drives the to-be-bonded material 71 to continuously convey to the surface of the welding base material 72 above the processing platform 3, and in the conveying process, the preheating module synchronously heats the welding area 711 of the to-be-bonded material 71, so as to realize local preheating of the welding interface; then, the electrode wheel 4 is pressed against the metal foil strip under the pressure of the pressure driving mechanism, and under the condition of power-on, the moving mechanism 9 drives the electrode wheel 4 to roll forward, and the temperature field formed by the welding area 711 and the joule heat formed by the current loop in the workpiece and the mechanical pressure form the to-be-bonded material 71 preheated on the surface of the welding base material 72. By utilizing the combined effect of the temperature field formed by the welding area 711 and the joule heat formed by the current loop in the workpiece, the present disclosure can prepare a predetermined thickness of the stack on the surface of the welding base. Wherein, the preheating module causes the welding area 711 of the to-be-bonded material 71 to locally soften, which not only helps to realize greater single-channel to-be-bonded material 71 thickness accumulation in the resistance seam welding process, and improves the welding adaptability of low resistivity materials, and under the combined action of temperature field, joule heat and welding pressure, a firm metallurgical bonding interface is formed between the to-be-bonded material 71 and the welding base material 72, and between the layers of the to-be-bonded material 71. Through the precise cooperation of the above-mentioned composite heat source and mechanical pressure, the present disclosure effectively solves the technical bottlenecks of insufficient energy input and poor bonding quality of single resistance seam welding in thick-layer to-be-bonded material 71 and low resistivity materials. The process is stable and reliable, and is suitable for industrialized high-efficiency continuous production.

[0024] That is, when the to-be-bonded material 71 is conveyed to the surface of the welding base material 72 by the feeding mechanism, the preheating module has already heated the to-be-bonded material 71 when it reaches the surface of the welding base material 72, so as to realize accurate preheating of the welding interface. The preheating process makes the to-be-bonded material 71 contact interface soften rapidly, significantly reduces the energy input and electrode pressure required in the subsequent resistance seam welding process, and improves the process controllability; realizes the timing synchronization and heat source coupling of preheating and resistance seam welding. After the to-be-bonded material 71 is preheated, the electrode wheel 4 is immediately pressed and welded with current. Under the synergistic action of temperature field, joule heat and mechanical pressure, firm connection between the to-be-bonded material 71 and the welding base material 72, and between the to-be-bonded material 71 and the to-be-bonded material 71 is realized, and a dense metallurgical bonding interface is formed. This way can construct a high-quality metallurgical bonding mechanism under the action of heat and force coupling, realize a larger thickness of single-channel to-be-bonded material 71 layer, and solve the welding adaptability of low resistivity materials, effectively expand the process window and application range of resistance seam welding.

[0025] In the embodiments of the present disclosure, the preheating module precisely acts on the welding area 711 of the to-be-bonded material 71 on the path between the feeding mechanism and the machining platform 3, and forms a stable temperature field in advance, so as to solve the problems of insufficient heat generation and easy heat loss of the resistance seam welding caused by the strong electric conductivity and thermal conductivity of low-resistivity materials (such as copper and high-purity aluminum), and the problem of difficulty in heat penetration to the interface of thick-gauge to-be-bonded materials 71 (such as super 0.5 mm metal foil strips / plates). Meanwhile, the welding power source ensures that the Joule heat precisely acts on the workpiece bonding area through the current loop formed by the first conductive working surface 31 and the second conductive working surface 41. After the combination of the two, stable welding can be achieved without relying on high-power welding equipment under the pressure holding of the electrode wheel 4, which significantly reduces the energy consumption and cost of the equipment and expands the adaptation range of the composite welding device to the material types (low-resistivity and high-thermal-conductivity materials) and specifications (thick to-be-bonded materials 71).

[0026] The temperature field formed by the preheating module can soften the welding area 711 of the to-be-bonded material 71 in advance, reduce the mechanical resistance when the electrode wheel 4 is pressurized, and cooperate with the precise adjustment of the pressing force of the pressurizing driving mechanism to effectively avoid workpiece deformation caused by excessive pressure or interface bonding looseness caused by insufficient pressure. The combined effect of the temperature field and the Joule heat can prolong the high-temperature duration of the welding area 711, promote element diffusion at the interface between the to-be-bonded material 71 and the welding base material 72, increase the thickness of the diffusion layer, reduce defects such as interface pores and cracks, form a more dense and firm metallurgical bonding interface, and significantly improve the mechanical properties (such as tensile strength and shear strength) and corrosion resistance of the welded joint, thereby ensuring the stability of the welding quality.

[0027] The feeding mechanism realizes continuous and stable delivery of the to-be-bonded material 71, the first conductive working surface 31 of the machining platform 3 provides a stable bearing and conductive basis for the welding base material 72, and the electrode wheel mechanism can rotate around the axis to cooperate with the feeding action to realize continuous welding. Each module forms a cooperative working process through structural design, and the whole process can be completed without manual intervention, meeting the needs of industrialized high-efficiency continuous production. At the same time, the adjustability of the pressing force of the pressurizing driving mechanism, the controllability of the welding current of the welding power source, and the precise regulation of the temperature field of the preheating module can flexibly adjust the process parameters according to the different characteristics of the to-be-bonded material 71 (such as metal foil strips, conductive fibers, and plates) and the welding base material 72 (such as steel, aluminum, titanium, and copper), thereby further improving the process adaptability and welding process controllability of the device.

[0028] The to-be-bonded material 71 can be a metal foil strip, and the metal foil strip material can be copper, aluminum, titanium, iron, or other metals. The thickness of the foil strip can be 0.05 mm-0.5 mm. The to-be-bonded material 71 can also be a plate with a specific thickness. The to-be-bonded material 71 can also be a conductive fiber or other material. The welding base material 72 can be steel, aluminum, titanium, copper, or other materials according to preparation requirements.

[0029] In this embodiment, the rotating speed of the electrode wheel 4 can be controlled by controlling the moving speed of the moving mechanism 9. When the moving speed of the moving mechanism 9 is fast, the rotating speed of the electrode wheel 4 is fast; when the moving speed of the moving mechanism 9 is slow, the rotating speed of the electrode wheel 4 is slow. Alternatively, the moving mechanism 9 comprises a guide rail and a sliding block, the sliding block is in sliding cooperation with the guide rail, a driving member is connected with the sliding block, the sliding block moves on the guide rail by the driving member, the moving speed can be controlled, and thus the rotating speed of the electrode wheel 4 can be controlled. The driving member can be an electric motor or a pneumatic cylinder.

[0030] Alternatively, the welding current is 0.1-15 kA, the welding time is 5 ms-2 min, the rotating speed of the electrode wheel 4 is 1-300 mm / min, and the gas pressure of the pressure driving mechanism is 0.01-1 MPa.

[0031] Alternatively, the metal stack prepared by welding the base material 72 can be the same metal or different metals.

[0032] Alternatively, the feeding mechanism comprises a feeding wheel 81, the feeding wheel 81 is fixed on an adapter frame 82 by bolts and rotates through an additional power transmission system; the adapter frame 82 is fixed on the rack 1 by bolts.

[0033] Alternatively, the second conductive working surface 41 is provided with grooves or protrusions. Alternatively, the grooves extend along the circumference of the electrode wheel 4. Alternatively, the protrusions extend along the circumference of the electrode wheel 4. The grooves or protrusions can change the contact form of the second conductive working surface: the protrusion structure can increase the contact pressure (local pressure increase) with the material to be combined, even if there is slight undulation or oxidation layer on the workpiece surface, the oxidation film can be broken and the workpiece surface can be attached through the extrusion effect of the protrusion, avoiding "virtual connection" caused by contact gap; the groove structure can accommodate small impurities (such as dust and oxidation debris) on the workpiece surface, preventing impurities from affecting the contact effect and ensuring that the electrode wheel always maintains stable attachment with the workpiece during rolling, providing a continuous and reliable conductive path for the current loop.

[0034] The circumferentially extending grooves or protrusions can make the current conduction path more dispersed and uniform. The multiple contact lines formed by the circumferentially extending protrusions or the multiple area contact surfaces formed by the grooves can disperse the welding current to the entire welding area, so that the joule heat is uniformly distributed at the interface between the material to be combined and the welding base material, reducing the local over-melting or non-melting defects caused by current concentration. The groove or protrusion structure can increase the friction between the electrode wheel and the material to be combined: during the welding process, the electrode wheel rolls to drive the workpiece to be conveyed synchronously, the "occlusion" effect of the protrusion or the negative pressure effect formed by the groove can effectively avoid the relative sliding between the workpiece and the electrode wheel, ensuring the precise matching of the feeding speed and the rotating speed of the electrode wheel.

[0035] In some specific embodiments, the processing platform 3 is provided with a heating unit 32, which is used to heat the first conductive working surface 31 and the welding base material 72 to form a temperature field; the temperature field formed by the first conductive working surface 31 and the welding base material 72, the temperature field formed by the to-be-bonded material 71 in the welding area 711, and the pressure applied by the electrode wheel 4 after the Joule heat generated by the current loop in the workpiece are combined to form a “triple heat source synergy” effect, so that the to-be-bonded material 71 and the welding base material 72 form a metallurgical bond and are fixed.

[0036] The heating unit 32 in the processing platform 3 heats the first conductive working surface 31 and the welding base material 72 to form a temperature field, and the temperature field formed by the to-be-bonded material 71 in the welding area 711 by the preheating module and the Joule heat generated by the current loop in the workpiece form a “triple heat source synergy” effect. On the one hand, the overall temperature level of the welding area 711 of the low-resistivity and high-thermal-conductivity material (such as copper and high-purity aluminum) can be significantly improved, which makes up for the problem of fast Joule heat loss and insufficient heat generation due to its own electrically conductive and thermally conductive characteristics, and avoids the defect that it is difficult to maintain the interface melting requirement under a single heat source. On the other hand, the superposition of the three heat sources can make the heat more uniformly penetrate to the bonding interface of the thick-gauge to-be-bonded material 71 (such as a metal foil strip / plate with a thickness greater than 0.5 mm) and the welding base material 72, prolong the duration of high temperature at the interface, promote atomic diffusion and fusion at the interface, reduce defects such as pores and incomplete fusion, and cooperate with the pressure action of the electrode wheel 4 to form a more compact and higher-strength metallurgical bonding interface, thereby significantly improving the mechanical properties (such as tensile strength and shear strength) and corrosion resistance of the welding joint.

[0037] In this embodiment, the welding base material 72 and the first conductive working surface 31 are preheated by the heating unit 32 in advance, which can reduce the energy demand of the Joule heat in the welding process. The disclosure can achieve the required temperature for interface fusion without increasing the welding current (which avoids excessive current that can cause workpiece burning and accelerated electrode wheel 4 wear) or prolonging the welding time (which avoids reduced efficiency), thereby significantly reducing the energy consumption of the welding power supply and reducing the dependence on high-power welding equipment, saving equipment investment and operating costs. In addition, this heat source combination mode can effectively adapt to the welding needs of more types of materials, not only can stably realize the combination of low-resistivity and high-thermal-conductivity materials with conventional base materials (such as steel and titanium), but also can solve the interface stress problem caused by the difference in thermal expansion coefficient when welding dissimilar materials (such as copper-aluminum and aluminum-steel) (preheating can release part of the stress), thereby further expanding the material application scenarios of the composite welding device.

[0038] The heating unit 32 can build a stable substrate temperature environment by heating the first conductive working surface 31 and the welding substrate 72, so as to avoid the rapid heat loss of the welding area 711 to the inside of the substrate due to the low initial temperature (such as room temperature environment) of the welding substrate 72, and ensure that the temperature field of the bonding interface between the material to be combined 71 and the welding substrate 72 is always maintained in a stable range. This stable heat field environment, combined with the continuous feeding of the feeding mechanism, the stable pressure of the electrode wheel 4 and the continuous power supply of the current loop, can effectively avoid the problem of uneven welding quality (such as loose bonding in some areas and excessive melting in some areas) caused by heat field fluctuations, ensure the consistency of the quality of each welding joint in the industrial continuous production process, and improve the product qualification rate and production efficiency.

[0039] Optionally, the heating unit 32 can make the maximum temperature of the heating platform reach 400°C.

[0040] In some specific embodiments, a control device is further included, which is electrically connected with the feeding mechanism, the electrode wheel mechanism, the pressure driving mechanism, the welding power supply and the preheating module, and is used for adjusting the feeding speed of the material to be combined 71, the moving speed of the moving mechanism 9, the pressure of the electrode wheel 4, the welding current intensity and the preheating power according to the resistivity parameter and the thickness parameter of the material to be combined 71.

[0041] The control device can adjust the core process parameters according to the resistivity (such as low-resistivity copper and high-resistivity titanium alloy) and thickness (such as 0.05mm thin foil strip and 0.5mm thick plate) parameters of the material to be combined 71. For low-resistivity materials, the preheating power can be increased to supplement heat in advance and avoid insufficient joule heat, and the welding current intensity can be matched to prevent rapid heat loss. For thick materials to be combined 71, the feeding speed and the rotating speed of the electrode wheel 4 can be reduced to prolong the heat action time, and the pressure of the electrode wheel 4 can be increased to ensure the interface fusion. For high-resistivity or thin materials, the parameters can be adjusted in the opposite direction to avoid excessive heating and workpiece deformation. Through the dynamic and accurate matching of parameters, the welding requirements of different materials to be combined 71 can be met without manual repeated adjustment, which greatly improves the compatibility of the device to materials and the flexibility of the welding process.

[0042] The control device synchronously controls the feeding mechanism, the electrode wheel mechanism, the pressure driving mechanism, the welding power supply and the preheating module through electrical connection, which can avoid poor coordination caused by independent adjustment of parameters of each module. For example, when the thickness of the material to be combined 71 increases, the control device can synchronously reduce the feeding speed, slow down the rotation speed of the electrode wheel 4 (to ensure sufficient heat penetration), increase the preheating power (to supplement the interface heat), and finely adjust the welding current and the pressure of the electrode wheel 4, so that the parameters of the whole process of “feeding-preheating-welding-pressing” are always in the optimal matching state, preventing defects such as interface unmelting, porosity and deep indentation caused by imbalance of a single parameter. Especially in industrial continuous production, the welding quality consistency of different batches and different specifications of the material to be combined 71 can be ensured, the defective product rate is significantly reduced, and the production efficiency is improved.

[0043] The traditional composite welding process requires technicians to manually and repeatedly test and adjust multiple parameters according to the material properties, which is complex and requires high experience. However, the control device can automatically calculate and output the optimal combination of process parameters based on the resistivity and thickness of the material to be combined 71, automatically complete the coordinated adjustment of the feeding speed, the rotation speed of the electrode wheel 4, the pressure, the current and the preheating power, and start the stable welding process without manual intervention. This not only simplifies the operation steps and reduces the dependence on the professional skills of the operators, but also shortens the process debugging period, especially suitable for multi-specification and small-batch production scenarios, which greatly reduces the application threshold of composite welding technology.

[0044] In some specific embodiments, the preheating module includes a laser head 61 and a height-adjustable support 62, and the laser head 61 is arranged on the height-adjustable support 62. The height of the height-adjustable support 62 is adjustable to control the position of the laser preheating on the material to be combined 71. The height-adjustable support 62 can flexibly adjust the relative distance and vertical position of the laser head 61 and the material to be combined 71, ensuring that the laser beam can be accurately focused on the welding area 711 of the material to be combined 71 (such as the pre-set combination surface of the material to be combined 71 and the welding base material 72, or the specific interlayer of the material to be combined 71 that needs to be melted), avoiding uneven preheating caused by the deviation of the laser action position. For example, for a metal foil strip as thin as 0.05 mm, the height of the height-adjustable support 62 can be adjusted to make the laser head 61 focus closely, ensuring that the heat is concentrated on the foil welding interface. For a plate or conductive fiber as thick as 0.5 mm, the height of the height-adjustable support 62 can be appropriately adjusted to adjust the laser action range, ensuring that the whole welding area 711 forms a uniform temperature field. This accurate positioning enables the temperature field formed by the laser preheating to accurately combine with the joule heat generated by the subsequent electrode wheel 4 pressure and welding power supply, avoiding energy waste or insufficient interface melting caused by mispositioning of the heat source, and ensuring the coordination and stability of the “preheating-welding” process.

[0045] Optionally, when welding the narrow metal foil strip, the laser needs to be focused on the center welding line of the foil strip, and when welding the wide plate, the laser needs to cover the full-width welding area 711 of the plate. The height adjustment bracket 62 can be adjusted in height to adapt to these differences by adjusting the position of the laser head 61, without the need to replace the special preheating assembly to meet the welding needs of multiple specifications of materials; at the same time, when the assembly height of the material to be combined 71 and the welding base material 72 changes (such as the presence of protruding structures on the surface of the welding base material 72, the material to be combined 71 needs to be welded in multiple layers), the height adjustment bracket 62 can be adjusted in height to compensate for the difference in assembly height, ensuring that the laser always acts on the effective welding area 711, greatly improving the adaptability of the composite welding device to different material specifications and different assembly scenarios.

[0046] The height adjustment bracket 62 can be adjusted in height to further optimize the preheating effect in cooperation with the scanning path of the laser head 61 (such as linear scanning according to the width of the material, reciprocating scanning according to the physical properties of the material). Optionally, for high thermal conductivity copper foil strips, the height of the height adjustment bracket 62 can be adjusted to increase the laser energy density, quickly increase the temperature of the welding area 711 to offset heat loss; for thin aluminum foil strips that are prone to overheating and deformation, the height of the height adjustment bracket 62 can be adjusted to reduce the local energy density to avoid material deformation caused by excessive preheating. This height-adjusted preheating effect optimization can reduce defects such as loose interface bonding caused by insufficient preheating, or material burning caused by excessive preheating; at the same time, the operator can adjust the height of the height adjustment bracket 62 according to the real-time feedback during the welding process (such as the interface fusion state, the workpiece surface temperature) to further improve the controllability of the preheating process and ensure the stability of the welding quality.

[0047] The height adjustment bracket 62 can be adjusted in height by a threaded transmission adjustment structure or a sliding guide and driving adjustment structure, and the height can be adjusted by the rotation and relative movement of the threaded pair. Optionally, the height adjustment bracket 62 includes a guide rail, a sliding block, and a motor driving structure. Optionally, the height adjustment bracket 62 includes a first bracket and a sliding block, the first bracket is provided with a guide rail, and the sliding block is in sliding cooperation with the guide rail. The sliding block is driven to ascend and descend along the guide rail by a driving assembly (such as a gear and rack transmission, a synchronous belt transmission), and the laser head 61 is connected to the sliding block, thereby realizing the height adjustment of the laser head 61.

[0048] Optionally, the rack 1 is provided with a working platform 10, and the height adjustment bracket 62 is installed on the working platform 10.

[0049] In some specific embodiments, the laser head 61 includes a blue laser, a red laser, a green laser, and a near-infrared laser; the laser head 61 selects one of the blue laser, the red laser, the green laser, and the near-infrared laser to heat the welding area 711 of the material to be combined 71 according to the physical characteristics and surface state of the material to be combined 71. For different physical characteristics of the material to be combined 71 (such as metal foil strips, conductive fibers, and plates), by selecting a laser with an appropriate wavelength, the absorption efficiency of laser energy can be maximized, and energy waste or insufficient preheating can be avoided. For example, for high-conductivity metals such as copper and silver, the reflectivity of the near-infrared laser is high (easy to cause energy loss), and the wavelength of the blue laser is shorter (about 450 nm), which can be effectively absorbed by high-conductivity metals to quickly raise the temperature of the welding area 711; for materials to be combined 71 with surface oxidation layers such as aluminum and titanium, the green laser (about 532 nm) has stronger penetration ability for the oxidation layer and can directly act on the substrate body to achieve precise preheating; for regular metals such as iron and steel or thin conductive fibers, the red laser (about 650 nm) or the near-infrared laser (about 1064 nm) can reduce the cost of the equipment while ensuring energy absorption, and adapt to the economic preheating needs of different materials. Through targeted selection of lasers, the material to be combined 71 with different physical characteristics can form a stable temperature field before welding, laying a foundation for subsequent combination with joule heat.

[0050] When the material to be combined 71 has a thick oxidation layer (such as long-stored aluminum foil strips) or a rough surface (such as cold-rolled steel plates), the near-infrared laser is prone to uneven energy distribution due to surface scattering, while the green or blue laser has a shorter wavelength and is less affected by surface scattering, which can achieve uniform preheating of the welding area 711 and avoid interface defects caused by local overheating or insufficient preheating; when the surface of the material to be combined 71 is smooth (such as polished copper foil), the red laser can reduce local burning caused by excessive laser focusing while ensuring energy absorption, and adapt to the fine preheating requirement. Through the selection of lasers suitable for the surface state, the preheating process is stable and controllable, the welding quality fluctuations caused by differences in surface state are reduced, and the metallurgical bonding consistency of the material to be combined 71 and the welding substrate 72 is improved.

[0051] In some specific embodiments, an adjusting mechanism 63 is arranged between the laser head 61 and the height adjusting support 62, and is used to plan and control the scanning path according to the width, thickness and physical properties (thermal conductivity, melting point) of the material to be combined 71. The scanning path includes a continuous straight line track, a sinusoidal wave track or a segmented pulse track. The adjusting mechanism 63 can plan the corresponding scanning path according to the width and thickness of the material to be combined 71, and solve the problem of uneven preheating of different specifications of materials. For narrow-width material to be combined 71 (such as narrow-width metal foil strip), a continuous straight line track is planned to make the laser energy concentrate on the material welding area 711, avoiding the problem of insufficient local preheating caused by energy dispersion; for wide-width material (such as large-width metal plate), a sinusoidal wave track can cover the full-width welding area 711 of the material, ensuring that the temperature of the edge and the center area is uniform; for thick specifications of materials (such as ultra-0.5mm metal foil strip / plate), a segmented pulse track can make the heat fully penetrate to the internal welding interface of the material, avoiding the problem that only the surface of the thick layer material is preheated and the internal temperature does not reach the appropriate temperature. The preheating requirements of the 0.05mm-0.5mm thickness range and various width specifications of the material to be combined 71 (metal foil strip, plate, etc.) in the file are met.

[0052] The precise matching of different scanning paths and material properties can optimize the temperature field stability of the welding area 711 and reduce welding defects caused by uneven preheating. The continuous straight line track for concentrated preheating of narrow-width materials can avoid the problem of loose interface combination caused by too large temperature difference between the edge and the center of the material; the sinusoidal wave track for full-area coverage of wide-width materials can prevent the problem of incomplete fusion defects at the edge of the wide-width material due to insufficient preheating; the segmented pulse track for energy supplement of high-thermal-conductivity and thick-layer materials can reduce the problems of interface pores and cracks caused by insufficient heat penetration. At the same time, after the stable temperature field is combined with the subsequent resistance seam welding joule heat, a more compact metallurgical bonding interface can be formed under the pressure of the electrode wheel 4, the bonding strength of the material to be combined 71 and the welding base material 72 (steel, aluminum, titanium, copper, etc.) is improved, the process goal of “improving the quality of the interface metallurgical bonding” in the file is met, and the consistency of the welding quality in the industrial continuous production is ensured.

[0053] Optionally, the adjusting mechanism 63 can be a two-dimensional translation adjusting mechanism 63, a galvanometer scanning mechanism or a multi-axis mechanical arm adjusting mechanism 63. The adjusting mechanism 63 is programmed by a control device (such as PLC, motion controller), and automatically switches the track mode according to the parameters of the material to be combined 71. The adjusting mechanism 63 cooperates with the multi-wavelength selection of the laser head 61 and the height adjustment of the height adjusting support 62 to realize the full-parameter adaptation of the preheating process.

[0054] Optionally, the adjusting mechanism 63 comprises a first adjusting assembly 631 and a second adjusting assembly 632. The first adjusting assembly 631 comprises a first guide rail and a first slider. The first guide rail extends along the first direction X. The first slider is in sliding fit with the first guide rail. The second adjusting assembly 632 is arranged on the first slider. Optionally, the second adjusting assembly 632 comprises a second guide rail and a second slider. The second guide rail is arranged on the first slider. The second guide rail extends along the second direction Y. The second slider is in sliding fit with the second guide rail. The laser head 61 is mounted on the second slider. The first guide rail extends along the X direction (the vertical direction of the material conveying path, i.e., the width direction of the material). Through the sliding fit between the first slider and the first guide rail, the laser head can be driven to translate along the width direction (e.g., from the edge of the material to the center area). The second guide rail extends along the Y direction (the conveying direction of the material, i.e., the length direction of the material). Through the sliding fit between the second slider and the second guide rail, the laser head can be driven to translate along the length direction (e.g., to adapt to different length specifications of the material). The first slider and the first guide rail, and the second slider and the second guide rail are in precise sliding fit (e.g., the gap is less than or equal to 0.01 mm). In combination with a driving assembly (e.g., a servo motor and a ball screw), the laser head can be adjusted in micrometer level.

[0055] In some specific embodiments, the scanning speed of the laser head 61 is positively correlated with the feeding speed of the feeding mechanism. The scanning speed of the laser head 61 is positively adjusted with the feeding speed of the feeding mechanism, which can ensure that the welding area 711 of the material 71 can be continuously and stably covered by the laser during the conveying process. The positive correlation between the speeds can avoid local overheating or insufficient preheating of the material 71, and ensure uniform temperature field of the welding area 711. When the feeding mechanism reduces the feeding speed due to the increase in the thickness of the material 71 (e.g., from 0.05 mm foil to 0.5 mm plate), the scanning speed of the laser head 61 is also reduced synchronously, which prolongs the action time of the laser on the welding area 711 per unit length, and ensures that the welding area 711 of the thick material absorbs sufficient heat. When the feeding speed is increased to improve the production efficiency, the scanning speed is also increased synchronously, which avoids the situation that the material 71 has been conveyed to the lower side of the electrode wheel 4 but the preheating is not completed due to the lag of the scanning, ensures that the preheated welding area 711 can be timely pressed by the electrode wheel 4 and combined with the joule heat of the welding power source, and reduces the energy waste or insufficient interface fusion caused by the misalignment of the heat source.

[0056] In some specific embodiments, the heating unit 32 is negatively correlated with the power adjustment of the preheating module. This embodiment can optimize the total heat input in real time according to the welding scene, and ensure that the temperature of the welding area 711 is always maintained in the range suitable for metallurgical bonding. For example, when the material to be bonded 71 is a copper foil with high thermal conductivity (heat is easy to dissipate), the power of the preheating module can be increased to strengthen the local heating of the material to be bonded 71, while the power of the heating unit 32 is reduced to avoid excessive heat absorption of the base material, resulting in excess total heat; when the material to be bonded 71 is a thick layer of steel plate with low thermal conductivity (heat is easy to accumulate), the power of the preheating module can be reduced to reduce local energy input, while the power of the heating unit 32 is appropriately increased to compensate for the problem of insufficient heat penetration of the material to be bonded 71 by uniform heat absorption of the base material. This negative correlation adjustment can accurately balance the "base substrate temperature" and "local temperature of the material to be bonded 71", avoiding the imbalance of the total heat caused by single power adjustment (such as simultaneous over-high power of the double module causing welding area 711 burnout, or simultaneous over-low power causing interface not to be fused), and ensuring the stability of the heat source composite. For different combinations of materials to be bonded 71 and welding base material 72 (such as copper foil-steel base material, aluminum foil-titanium base material, iron foil-aluminum base material), the thermal conductivity and melting point difference of the two will result in different heat requirements, and the negative correlation power adjustment can flexibly adapt to these differences. The negative correlation adjustment can avoid repeated input and waste of energy, and realize the "on-demand distribution" of energy supply mode. Under different material combinations and specifications, the welding area 711 has different matching requirements for "local temperature" and "substrate temperature", and the negative correlation power adjustment can dynamically balance the two to optimize the interface element diffusion environment and reduce defects.

[0057] Optionally, the heating unit 32 can be a resistance wire heating structure built into the machining platform 3; the heating unit 32 can also be an electromagnetic induction heating structure.

[0058] In some specific embodiments, the machining platform 3 is provided with a temperature sensor, and the electrode wheel 4 is provided with a pressure sensor; the temperature sensor is used to monitor the temperature information of the contact interface between the welding base material 72 and the material to be bonded 71 in real time, and feedback to the control device; the pressure sensor is used to monitor the pressure information of the electrode wheel 4 in real time, and feedback to the control device; the control device is used to adjust the feeding speed of the material to be bonded 71, the moving speed of the moving mechanism 9, the pressure of the electrode wheel 4, the welding current intensity and the preheating power according to the temperature information and the pressure information.

[0059] The temperature sensor accurately captures the temperature information of the contact interface between the welding base material 72 and the material to be combined 71, and can timely find temperature abnormalities, such as local overheating / preheating insufficient caused by sudden change of thermal conductivity of the material to be combined 71. The pressure sensor real-time feedbacks the actual pressure value of the electrode wheel 4, avoiding pressure deviation caused by mechanical wear, air pressure fluctuation, etc., such as pressure drop caused by long-term use of the electrode wheel 4 and rim wear. Both of them will transmit the monitoring data to the control device in real time, forming a closed-loop control of “monitoring-feedback-regulation”, ensuring that the core parameters in the welding process are always in the optimal interval, and providing data support for stable metallurgical combination.

[0060] During the welding process, the surface state of the material to be combined 71 (such as local oxidation, thickness deviation), the equipment running state (such as electrode wheel 4 speed fluctuation, power output instability) may all cause parameter fluctuation, which can be responded in real time through sensor feedback and control device adjustment: if the temperature sensor monitors that the interface temperature is too high (such as exceeding the material melting point threshold), the control device can immediately reduce the preheating power, increase the feeding speed or reduce the welding current, to avoid burning and deformation of the material to be combined 71; if the temperature is too low, the parameters can be adjusted in the opposite direction (increase the preheating power, reduce the feeding speed), to ensure that the interface reaches the fusion temperature. If the pressure sensor monitors that the pressure of the electrode wheel 4 is too large (such as exceeding the base material resistance threshold), the control device can reduce the air pressure of the pressurizing driving mechanism to prevent the welding base material 72 from being pressed too deep or deformed; if the pressure is too small, the air pressure can be increased to ensure that the interface is in full contact to form a dense metallurgical combination. This dynamic adaptation can effectively offset the impact of process fluctuations on quality, reduce defects such as pores, incomplete fusion, and excessive indentation caused by parameter imbalance, and ensure the consistency of the quality of each welded joint in industrial continuous production.

[0061] For the welding needs of different material combinations (such as copper foil-steel, aluminum foil-titanium) and different specifications of the material to be combined 71 (0.05mm-0.5mm foil strip / plate), sensor feedback can assist the control device to realize accurate matching of parameters: when welding high thermal conductivity copper foil, the temperature sensor is easy to monitor the rapid decrease of the interface temperature, and the control device can accordingly increase the preheating power, reduce the feeding speed, and fine-tune the pressure of the electrode wheel 4 (to avoid excessive pressure accelerating heat loss); when welding thin aluminum foil with low melting point, if the temperature sensor monitors that the local temperature rises sharply, the control device can immediately reduce the welding current and increase the speed of the electrode wheel 4 to prevent excessive melting of the aluminum foil; when welding thick plates, if the pressure sensor feedbacks that the pressure is insufficient (the interface is not fully attached), the control device can increase the pressure of the electrode wheel 4, while reducing the feeding speed to ensure that the Joule heat penetrates fully.

[0062] The control device is connected with the driving part in the moving mechanism 9, and the speed of the sliding block is controlled by controlling the driving part, so as to control the speed of the electrode wheel 4.

[0063] In some specific embodiments, the rack 1 is further included, and the machining platform 3 and the moving mechanism 9 are arranged on the rack 1, that is, the guide rail of the moving mechanism 9 is arranged on the rack 1; the electrode wheel mechanism further includes a connecting piece 5, and the electrode wheel 4 is rotationally connected with the connecting piece 5; the pressurizing driving mechanism includes a gas cylinder 2, and the cylinder body of the gas cylinder 2 is arranged on the moving mechanism 9, that is, the cylinder body of the gas cylinder 2 is arranged on the sliding block of the moving mechanism 9, and the telescopic end of the gas cylinder 2 is connected with the connecting piece 5, and is used to drive the electrode wheel 4 to move towards the direction close to or away from the machining platform 3. The connecting piece 5 is fixedly connected with the telescopic end of the gas cylinder 2, the gas cylinder 2 is controlled to move through the moving mechanism 9, the rotating speed of the electrode wheel 4 can be accurately controlled (adapted to the process parameter range of 1-300 mm / min), and the rolling speed of the electrode wheel 4 is ensured to be matched with the feeding speed of the feeding mechanism and the scanning speed of the laser head 61. The cylinder body of the gas cylinder 2 is fixed on the sliding block of the moving mechanism 9, and the telescopic end is directly connected with the connecting piece 5 (driving the electrode wheel 4), so that the pressing force of the electrode wheel 4 on the material to be combined 71 and the welding base material 72 can be accurately controlled by adjusting the air pressure (adapted to the process range of 0.01-1 MPa).

[0064] In some specific embodiments, the conductive working surface of the machining platform 3 is provided with a partition heating module, a temperature difference of 50-150°C in the width direction of the material to be combined 71 can be formed, a three-dimensional gradient temperature field is constructed in cooperation with the preheating module, and the softening degree of the edge region and the central region of the material to be combined 71 is different. The partition heating module forms a controllable temperature difference of 50-150°C in the vertical direction of the conveying path of the material to be combined 71 (that is, the width direction of the material to be combined 71), and the local heating of the welding area 711 of the material to be combined 71 is cooperated with the preheating module to construct a three-dimensional gradient temperature field of the width direction temperature gradient and the thickness direction temperature gradient. This gradient design can make the softening degree of the edge region and the central region of the material to be combined 71 accurately different.

[0065] When welding a wide metal foil strip (such as a width of more than 100 mm), the edge region temperature of the foil strip is higher than the central region (such as 150°C at the edge and 100°C at the center) through partition heating, and the higher softening degree of the edge can offset the edge stress concentration when welding the wide material, and the foil strip wrinkling and warping caused by uneven softening of the edge and the center is avoided; when welding a special-shaped material to be combined 71 (such as a plate with a thin edge and a thick center), the gradient temperature field can compensate for the different heat requirements caused by the thickness difference of the material, and ensure that the thin edge region is not overheated and the thick central region is sufficiently softened, laying a foundation for the subsequent electrode wheel 4 pressurization to form uniform metallurgical bonding.

[0066] In some specific embodiments, an interface bonding quality monitoring module is further included, which acquires the acoustic impedance signal of the welding area 711 in real time through the high-frequency ultrasonic probe, and the collaborative control unit automatically corrects the welding current and electrode pressure parameters according to the acoustic impedance change. The collaborative control unit can be the core functional unit of the control device. The high-frequency ultrasonic probe (sampling frequency ≥ 10 MHz) can accurately acquire the acoustic impedance signal of the welding area 711, which can directly reflect the bonding state of the interface between the material to be bonded 71 and the welding base material 72. For example, when there are defects such as pores and incomplete fusion at the interface, the acoustic impedance will change significantly due to the difference in medium (air / metal, incomplete fusion gap / metallurgical bonding); and when the interface forms a dense metallurgical bond, the acoustic impedance signal is stable and close to the inherent acoustic impedance of the base material. When the collaborative control unit detects that the acoustic impedance change exceeds the ±5% threshold, it can immediately determine that there is a quality risk at the interface and automatically correct the welding parameters: if the acoustic impedance increases (indicating that the interface is too dense or locally overheated), the welding current and electrode pressure should be appropriately reduced to avoid joint brittleness caused by excessive fusion; if the acoustic impedance decreases (indicating that there are defects at the interface), the welding current should be increased to enhance the Joule heat and increase the electrode pressure to promote the interface to fit and timely compensate for defects. The interface acoustic impedance reference values of different materials (such as copper-steel, aluminum-titanium) and multi-layered structures are different, and the high sampling frequency of the high-frequency ultrasonic probe can accurately identify these differences. The collaborative control unit can realize targeted monitoring and parameter correction by presetting the acoustic impedance threshold values for different material combinations. In some specific embodiments, the first conductive working surface 31 is provided with an insulating and heat-insulating frame. The insulating and heat-insulating frame forms a closed or semi-closed heat-confining area around the first conductive working surface 31, which can effectively block the lateral diffusion of heat generated by the processing platform 3 (including the partition heating module) to the outside of the delivery path of the material to be bonded 71, avoiding the distortion of the temperature field of the welding area 711 due to the loss of edge heat. The insulating frame can block the lateral diversion of current to the non-welding area 711 of the processing platform 3 (such as the platform base and the peripheral clamps). The insulating and heat-insulating frame can isolate the high temperature and current of the first conductive working surface 31, preventing high temperature from damaging the non-heat-resistant components at the edge of the processing platform 3.

[0067] In some specific embodiments, the control device further comprises a digital twin module, which can construct a virtual welding model based on the real-time collected temperature field, pressure field and current data, pre-visualize the welding state after 0.5-2 seconds and trigger the parameter adjustment instruction in advance. The laser wavelength of the preheating module can be adaptively switched in the range of 450-1064 nm, and the scanning path can be real-time adjusted to a continuous sinusoidal trajectory or a segmented pulse trajectory according to the width of the material to be combined 71, and the scanning speed and the conveying speed of the feeding mechanism are matched in a 1:1 linkage. Through the virtual model, it is predicted that "the slight increase in the thickness of the material to be combined 71 will cause the interface temperature to drop by 5% after 2 seconds", or "the wear of the electrode wheel 4 will cause the pressure to decay", without waiting for the physical process to appear quality abnormalities (such as incomplete fusion, too deep indentation), the parameter adjustment instruction (such as increasing the preheating power, increasing the air cylinder 2 air pressure) can be triggered in advance. This "early intervention" mode completely solves the lag defect of "first problem and then correction" in traditional real-time control, upgrades the welding quality control from "passive response" to "active prevention", and greatly reduces the risk of interface defects caused by parameter fluctuations.

[0068] It should be understood that various forms of flow shown above can be used to reorder, add or delete steps. For example, each step described in the present disclosure can be executed in parallel, sequentially or in a different order, as long as the desired results of the technical solutions disclosed in the present embodiment can be achieved, which is not limited herein.

[0069] In addition, the terms "first", "second" are only for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Therefore, the features defined with "first", "second" can explicitly or implicitly include at least one of the features. In the description of the present disclosure, the meaning of "a plurality of" is two or more, unless otherwise specifically limited.

[0070] The above is only a specific embodiment of the present disclosure, but the protection scope of the present disclosure is not limited thereto, and any person skilled in the art can easily think of changes or replacements within the technical scope disclosed in the present disclosure, which should be covered within the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure should be subject to the protection scope of the claims.

Claims

1. A composite welding device, characterized by, The application relates to a welding device, comprising: a processing platform (3) comprising a processing position provided with a first conductive working surface (31) for carrying a welding base material (72); a feeding mechanism for feeding a material to be combined (71) to the surface of the welding base material (72); an electrode wheel mechanism comprising an electrode wheel (4) rotatable about its axis, the rim of the electrode wheel (4) being provided with a second conductive working surface (41); a pressure driving mechanism connected with the electrode wheel mechanism for driving the electrode wheel (4) to move in a direction perpendicular to the processing position to adjust the pressure of the electrode wheel (4) on a workpiece formed by the material to be combined (71) and the welding base material (72); a moving mechanism (9) connected with the pressure driving mechanism for driving the pressure driving mechanism to move, the electrode wheel applying pressure on a welding position of the workpiece during the movement of the pressure driving mechanism; a welding power source electrically connected with the first conductive working surface (31) and the second conductive working surface (41) through conductive connecting members for inputting welding current to the electrode wheel (4) to form a current loop among the power source, the first conductive working surface (31), the workpiece and the second conductive working surface (41); a preheating module arranged in the path direction between the feeding mechanism and the processing platform (3) for heating a welding area (711) of the material to be combined (71) to form a temperature field, the temperature field formed by the welding area (711) and the Joule heat formed by the current loop in the workpiece being combined to make the material to be combined (71) and the welding base material (72) form metallurgical combination and solidification under the pressure applied by the electrode wheel (4).

2. The composite welding device of claim 1, wherein, The processing platform (3) is provided with a heating unit (32) for heating the first conductive working surface (31) and the welding base material (72) to form a temperature field; The temperature field formed by the first conductive working surface (31) and the welding base material (72), the temperature field formed by the material to be combined (71) in the welding area (711) and the pressure applied by the electrode wheel (4) after the Joule heat formed by the current loop in the workpiece are combined to make the material to be combined (71) and the welding base material (72) form metallurgical combination and solidification.

3. The composite welding device of claim 1, wherein, The application further comprises a control device electrically connected with the feeding mechanism, the electrode wheel mechanism, the pressure driving mechanism, the moving mechanism (9), the welding power source and the preheating module for adjusting the feeding speed of the material to be combined (71), the moving speed of the moving mechanism (9), the pressure of the electrode wheel (4), the welding current intensity and the preheating power according to the resistivity parameter and the thickness parameter of the material to be combined (71).

4. The composite welding device of claim 1, wherein, The preheating module comprises a laser head (61) and a height-adjustable support (62), and the laser head (61) is arranged on the height-adjustable support (62); The height of the height-adjustable support (62) is adjustable, so as to control the position of the laser preheating acting on the material to be combined (71).

5. The composite welding device of claim 4, wherein, The laser head (61) comprises a blue laser, a red laser, a green laser and a near-infrared laser. The laser head (61) selects one of the blue laser, the red laser, the green laser and the near-infrared laser to heat the welding area (711) of the material to be combined (71) according to the physical characteristics and surface state of the material to be combined (71).

6. The composite welding device of claim 4, wherein, An adjusting mechanism (63) is arranged between the laser head (61) and the height-adjustable support (62), and the adjusting mechanism (63) is used for planning and controlling a scanning path according to the width, thickness and physical properties of the material to be combined (71), wherein the scanning path comprises a continuous straight line track, a sine wave track or a segmented pulse track.

7. The composite welding device of claim 4, wherein, The scanning speed of the laser head (61) is positively correlated with the feeding speed of the feeding mechanism.

8. The composite welding device of claim 2, wherein, The heating unit (32) is negatively correlated with the power adjustment of the preheating module.

9. The composite welding device of claim 3, wherein, The processing platform (3) is provided with a temperature sensor, and the electrode wheel (4) is provided with a pressure sensor. The temperature sensor is used for monitoring the temperature information of the contact interface between the welding base material (72) and the material to be combined (71) in real time, and feeding back to the control device. The pressure sensor is used for monitoring the pressure information of the electrode wheel (4) in real time, and feeding back to the control device. The control device is used for adjusting the feeding speed of the material to be combined (71), the moving speed of the moving mechanism (9), the pressure of the electrode wheel (4), the welding current intensity and the preheating power according to the temperature information and the pressure information.

10. The composite welding device of claim 1, wherein, Further comprising a rack (1), and the processing platform (3) and the moving mechanism (9) are arranged on the rack (1); The electrode wheel mechanism comprises a connecting piece (5), and the electrode wheel (4) is rotationally connected with the connecting piece (5); The pressurizing driving mechanism comprises a gas cylinder (2), the cylinder body of the gas cylinder (2) is arranged on the moving mechanism (9), and the telescopic end of the gas cylinder (2) is connected with the connecting piece (5), so as to drive the electrode wheel (4) to move towards the direction close to or away from the processing platform (3).

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