Automatic production method and equipment of height-limited preformed soldering piece

Abstract

The application discloses an automatic production method and equipment for a height-limited preformed soldering sheet, and relates to the technical field of welding. The automatic production method for the height-limited preformed soldering sheet comprises the following steps: step one, preparing a preformed soldering sheet material; step two, automatically generating production parameters of the preformed soldering sheet; step three, producing and processing the preformed soldering sheet according to the automatically generated parameters; step four, optimizing the production parameters of the preformed soldering sheet; step five, determining the production parameters of the preformed soldering sheet; and step six, continuously and automatically producing the preformed soldering sheet product. According to the automatic production method for the height-limited preformed soldering sheet, the production parameters are automatically generated in step two, the same product parameters are automatically inquired from a database, or estimated parameters are generated based on a part family and a typical process template, so that the parameters can quickly converge to the optimal value, nitrogen is continuously introduced, air is isolated, and a pre-plating layer structure is further adopted on the soldering wire, thereby further reducing the oxidation risk.

Description

Technical Field

[0001] This invention relates to the field of welding technology, specifically to an automated production method and equipment for height-limited preformed welding sheets. Background Technology

[0002] Preformed solder pads are precision-formed solders that can be made into different shapes, sizes and surface morphologies as required. They are suitable for various product manufacturing processes with small tolerances and are widely used in printed circuit board assembly, connectors and terminal equipment, chip connection, power module substrate attachment, filter connectors and electronic component assembly, etc.

[0003] In traditional production, key parameters such as processing temperature, pressure, and time of the welding pad substrate and welding wire need to be set manually based on experience, lacking an automated generation mechanism. When producing new materials or new products, the parameter debugging cycle is long, and parameter deviations can easily lead to excessive welding pad thickness or misaligned wiring. Furthermore, if the welding pad substrate and welding wire are exposed to air during heating and pressure welding, oxidation can easily occur, resulting in an oxide layer at the welding interface, which reduces the bonding strength between the welding wire and the substrate, thus introducing certain defects. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an automated production method and equipment for height-limited preformed welding sheets. This solves the problems of traditional production where key parameters such as processing temperature, pressure, and time for the welding sheet substrate and welding wires rely on manual, experience-based settings, lacking an automated production mechanism. Furthermore, when producing new materials or products, parameter adjustment cycles are long, and parameter deviations can easily lead to excessive welding sheet thickness or misaligned wiring. Additionally, if the welding sheet substrate and welding wires are exposed to air during heating and pressure welding, oxidation can easily occur, resulting in an oxide layer at the welding interface and reducing the bonding strength between the welding wire and the substrate.

[0005] To achieve the above objectives, the present invention provides an automated production method for height-limited preformed welding sheets, comprising the following specific steps: Step 1: Prepare preformed welding sheet materials to provide materials for the automated production of preformed welding sheets; Step 2: Initialize the production equipment. Input the performance parameters of the preformed welding sheet material and the preset values ​​of the preformed welding sheet product into the control terminal of the production equipment. Based on the input information, automatically generate the production parameters of the preformed welding sheet and establish a product production database. Step 3: Process the preformed welding sheet according to the parameters generated automatically, inspect the produced preformed welding sheet products, and provide feedback on the inspection data of the preformed welding sheet products; Step 4: Compare the test data with the preset values ​​of the preformed solder sheet product, and optimize the production parameters of the preformed solder sheet; Step 5: Repeat steps 3 and 4 until the test parameters of the produced preformed weldment products meet the preset values ​​of the preformed weldment products, and determine the production parameters of the preformed weldment. Step 6: Based on the determined production parameters of the preformed sheet, repeat the preformed sheet production and processing steps to continuously and automatically produce preformed sheet products.

[0006] Preferably, in step one, the preformed solder sheet material includes a solder sheet substrate, solder wire, flux, and nitrogen. The solder wire includes a copper wire and a pre-plating layer. The pre-plating layer is wrapped around the copper wire and includes a nickel layer and a solder layer covering the nickel layer. The pre-plating layer outside the copper wire is hot-melted onto the solder sheet substrate by heating and pressurizing. The nitrogen is used to protect the solder sheet substrate and solder wire from oxidation.

[0007] Preferably, the performance parameters of the preformed welding sheet material in step two include the hot melt temperature of the welding sheet substrate and the welding wire, and the preset values ​​input to the preformed welding sheet product include the thickness parameter and the wiring parameter of the preformed welding sheet product. The wiring parameter includes the number of longitudinal and transverse welding wires on the welding sheet substrate, the spacing of the welding wires, and the tension of the welding wires. The production parameters for automatically generating the preformed welding sheet include the temperature, pressure, time, and position parameters for processing the welding sheet substrate and the welding wire. The position parameters for processing the welding sheet substrate and the welding wire are directly generated from the wiring parameters of the preformed welding sheet product. The generation of the temperature, pressure, and time parameters for processing the welding sheet substrate and the welding wire is achieved by querying a database to find the production parameters of similar products. If the database has the same production parameters, these parameters are taken as the standard preformed welding sheet production parameters, and the preformed welding sheet is processed. If the database does not have the same production parameters, the production parameters of similar products are taken and classified into a part family. Typical process templates are searched, and the production temperature, pressure, and time parameters are adjusted downwards to obtain the estimated preformed welding sheet production parameters.

[0008] Preferably, the welding sheet production and processing in step three is based on the pre-formed welding sheet production parameters automatically generated in step two, and includes the following steps: S3.1: Use a vacuum suction cup to pick up a piece of welding sheet substrate from the tray, move the welding sheet substrate to the center of the heating platform, and turn on the heating platform to heat until the temperature reaches the pre-formed welding sheet heating temperature value automatically generated. Maintain the heating temperature of the heating platform and open the nitrogen valve to introduce nitrogen. S3.2: Arrange the welding wires according to the wiring parameters of the preformed welding sheet product, that is, pull the welding wires out from the spool and immerse them in the flux bath, straighten and position them above the heating platform, and press down on the welding wires so that they adhere to the surface of the heated and heat-insulated welding sheet substrate. S3.3: The pressure head of the vacuum chuck is moved down to press the wire and the substrate assembly with a set pressure and hold for a set time. Under this pressure and temperature, the substrate melts and wets the pre-plating layer of the wire under the action of flux. The wire is pressed into the semi-molten substrate and a metallurgical bond is formed. S3.4: After the pressure application time of the welding wire and the substrate is completed, the vacuum suction head remains in a downward state to position and bind the welding wire and the substrate. The cutter runs to cut off the welding wire located outside the preset positions on both sides of the substrate. S3.5: The guillotine resets, the vacuum suction cup head lifts, and the vacuum suction starts to pick up the finished welded sheet with the weld wire after pressing. The vacuum suction cup moves to place the finished welded sheet onto the conveyor belt.

[0009] Preferably, the inspection of the preformed solder sheet product in step three includes the thickness, number of wires, wire spacing, and oxidation degree of the preformed solder sheet product. The thickness of the preformed solder sheet product is measured by an electronic thickness gauge, and the number of wires and wire spacing of the preformed solder sheet product are detected and analyzed by a vision inspection instrument. By detecting the number of wires and wire spacing of the preformed solder sheet product, it is possible to detect whether the solder wires on the solder sheet substrate are broken, which may result in the broken solder wires not being properly laid out. When there are broken solder wires, the tension during solder wire laying is reduced.

[0010] Preferably, when the data detected in step four does not reach the preset value of the preformed weldment product, the automatically generated preformed weldment production parameters are optimized, and an initial adjustment standard value for the same product is established. When the generated parameters are standard preformed weldment production parameters, and the thickness of the preformed weldment product is greater than the preset value, the production temperature, pressure, and time parameters of the preformed weldment are increased by an initial adjustment standard value for the same product. Conversely, when the thickness of the preformed weldment product is less than the preset value, the production temperature, pressure, and time parameters of the preformed weldment are decreased by an initial adjustment standard value for the same product.

[0011] Preferably, when the generated parameters are estimated preformed solder sheet production parameters, the thickness value of the preformed solder sheet product is compared with the preset thickness value of the preformed solder sheet product, and the percentage of the difference is calculated and set as K. When the thickness value of the preformed solder sheet product is greater than the preset thickness value of the preformed solder sheet product, K is a positive number; conversely, when the thickness value of the preformed solder sheet product is less than the preset thickness value of the preformed solder sheet product, K is a negative number. When optimizing the estimated preformed solder sheet production parameters, the estimated preformed solder sheet production parameters are multiplied by (1+K) to obtain the optimized estimated preformed solder sheet production parameters.

[0012] Preferably, in step five, repeating steps three and four continuously optimizes the preformed solder sheet production parameters. When the generated parameters are standard preformed solder sheet production parameters, and are adjusted again, the production temperature, pressure, and time parameters of the preformed solder sheet are adjusted one by one to half the previous value, until the difference between the values ​​detected by the preformed solder sheet produced for more than three consecutive times and the preset value of the preformed solder sheet product is within the allowable error range. Then, the adjusted standard preformed solder sheet production parameters are saved as parameters for continuous production of preformed solder sheets. When the generated parameters are estimated preformed solder sheet production parameters, they are still optimized by multiplying the estimated preformed solder sheet production parameters by (1+K), until the difference between the values ​​detected by the preformed solder sheet produced for more than three consecutive times and the preset value of the preformed solder sheet product is within the allowable error range. Then, the adjusted estimated preformed solder sheet production parameters are saved as parameters for continuous production of preformed solder sheets.

[0013] Preferably, in step six, the continuous automated production of preformed welding sheet products is carried out according to the adjusted and confirmed preformed welding sheet production parameters, performing step three, including feeding the welding sheet substrate, heating, introducing nitrogen, immersing the welding wire in flux, arranging the wire, pressing the wire, cutting the wire, and unloading the product. The produced preformed welding sheets are sampled and tested, and the production quality of the preformed welding sheet products is fed back in real time.

[0014] Another objective of this invention is to provide an automated production equipment for height-limited preformed welding sheets, comprising a mounting housing, a heating platform installed inside the mounting housing, a nitrogen exhaust pipe located inside the mounting housing on the side of the heating platform, a vacuum suction cup on the heating platform, a guillotine blade installed on the side of the vacuum suction cup, a preset cutting area corresponding to the guillotine blade inside the mounting housing, a spool on the side of the mounting housing, a guide rod and a guide bar between the spool and the mounting housing, a flux tank between the guide rod and the mounting housing, and a fixing rod on the other side of the mounting housing.

[0015] This invention discloses an automated production method and equipment for height-limited preformed welding sheets, which has the following beneficial effects: The automated production method for this height-limited preformed solder sheet achieves automated generation of production parameters in step two, automatically querying the database to call parameters of similar products, or generating predictive parameters based on part families and typical process templates. Through closed-loop optimization in steps four and five, the parameters are ensured to converge quickly to the optimal value. Nitrogen gas is continuously introduced to isolate air, and the solder wire adopts a pre-plating structure of "copper wire + nickel layer + solder layer" to further reduce the risk of oxidation. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a flowchart of the automated production method for the height-limited preformed welding sheet of the present invention; Figure 2 This is a top view schematic diagram of the automated production equipment of the present invention.

[0018] In the diagram: 1. Mounting housing; 2. Heating platform; 3. Vacuum suction cup; 4. Guillotine cutter; 5. Bollard; 6. Guide rod; 7. Guide rod; 8. Fixing rod; 9. Flux tank. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are described clearly and completely. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] This application provides an automated production method and equipment for height-limited preformed welding sheets. It solves the problems of traditional production where key parameters such as processing temperature, pressure, and time for the welding sheet substrate and welding wires rely on manual, experience-based settings, lacking an automated production mechanism. Furthermore, when producing new materials or products, parameter adjustment cycles are long, and parameter deviations can easily lead to excessive welding sheet thickness or misaligned wiring. Additionally, if the welding sheet substrate and welding wires are exposed to air during heating and pressure welding, oxidation can easily occur, resulting in an oxide layer at the welding interface and reducing the bonding strength between the welding wire and the substrate. This method enables continuous automated production of preformed welding sheet products, ensuring the production quality of the preformed welding sheet products.

[0021] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0022] This invention discloses an automated production method for height-limited preformed welding sheets.

[0023] According to the appendix Figure 1-2 As shown, the specific steps include the following: Step 1: Prepare preformed welding sheet materials to provide materials for the automated production of preformed welding sheets, thereby ensuring the subsequent automated production of preformed welding sheets; Step 2: Initialize the production equipment. Input the performance parameters of the preformed welding sheet material and the preset values ​​of the preformed welding sheet product into the control terminal of the production equipment. Based on the input information, the production parameters of the preformed welding sheet are automatically generated. This allows the production and processing parameters of the product to be automatically generated according to the product requirements, eliminating the need for manual calibration of the production parameters. This improves the production efficiency of the product and establishes a product production database. The database is used to store historical product production parameters and also stores the product production standard quality requirements. Step 3: Process the preformed welding sheet according to the parameters generated by automation, inspect the produced preformed welding sheet products, and provide feedback on the inspection data of the preformed welding sheet products so as to adjust the product production and processing parameters according to the quality of the product production; Step 4: Compare the test data with the preset values ​​of the preformed solder sheet product, and optimize the production parameters of the preformed solder sheet to ensure the quality of product production; Step 5: Repeat steps 3 and 4 until the test parameters of the produced preformed weldment product meet the preset values ​​of the preformed weldment product. Determine the production parameters of the preformed weldment to facilitate the subsequent production parameters and continue to process the product. Step 6: Based on the determined production parameters of the preformed sheet, repeat the preformed sheet production and processing steps to continuously and automatically produce preformed sheet products.

[0024] Furthermore, in step one, the preformed solder sheet material includes a solder sheet substrate, solder wire, flux, and nitrogen. The solder wire includes a copper wire and a pre-plating layer. The pre-plating layer is wrapped around the outside of the copper wire and includes a nickel layer and a solder layer covering the nickel layer. The pre-plating layer outside the copper wire is hot-melted and welded to the solder sheet substrate by heating and pressurizing. Nitrogen is used to protect the solder sheet substrate and solder wire from oxidation and reduce the probability of oxidation during hot-press welding of the solder sheet substrate and solder wire.

[0025] Furthermore, the performance parameters of the preformed solder sheet material in step two include the hot melt temperature of the solder sheet substrate and the welding wire. The preset values ​​input for the preformed solder sheet product include the thickness parameters and the wiring parameters of the preformed solder sheet product. The wiring parameters include the number of longitudinal and transverse welding wires on the solder sheet substrate, the spacing of the welding wires, and the tension of the welding wires. The wiring can be parallel straight lines, a grid, or other predetermined geometric shapes. The production parameters for automatically generating the preformed solder sheet include the temperature, pressure, time, and position parameters for processing the solder sheet substrate and the welding wire. The position parameters for processing the solder sheet substrate and the welding wire are directly generated from the wiring parameters of the preformed solder sheet product. The generation of the temperature, pressure, and time parameters for processing the solder sheet substrate and the welding wire is achieved by querying a database to find the production parameters of similar products. If the database has the same production parameters, these parameters are taken as the standard preformed solder sheet production parameters, and the preformed solder sheet is processed. If the database does not have the same production parameters, the production parameters of similar products are taken and classified into a part family. Typical process templates are searched, and the production temperature, pressure, and time parameters are adjusted downwards to serve as the estimated preformed solder sheet production parameters.

[0026] In particular, the solder sheet production and processing in step three is based on the pre-formed solder sheet production parameters automatically generated in step two, and involves the following steps: S3.1: Use vacuum suction cup 3 to pick up a piece of welding sheet substrate from the tray, move the welding sheet substrate to the center of heating platform 2, and turn on heating platform 2 to heat until the temperature reaches the heating temperature value of the pre-formed welding sheet automatically generated. The heating temperature range is 220℃ - 350℃. Maintain the heating temperature of heating platform 2 for 10s - 60s. Open the nitrogen valve to introduce nitrogen gas, thereby reducing the probability of oxidation during hot pressing welding of welding sheet substrate and welding wire, and ensuring the quality of pre-formed welding sheet production. S3.2: Arrange the welding wires according to the wiring parameters of the preformed welding sheet product, that is, pull the welding wires out from the spool 5 and immerse the welding wires in the flux tank 9, stay for a few seconds, drip off the excess flux to reduce the waste of flux, straighten and position them above the heating platform 2, and press down on the welding wires so that the welding wires adhere to the surface of the heated and heat-insulated welding sheet substrate. S3.3: The pressure head of the vacuum chuck 3 is moved downward to press the wire and the substrate assembly with a set pressure and hold for a set time. The pressure range is 1MPa - 5MPa and the pressing time is 5s - 30s. The hard alloy column at the bottom of the pressure head contacts the heating platform 2 or the reference surface to ensure that the total thickness of the pressing is equal to the preset limit value, thereby improving the quality of the preformed substrate. Under this pressure and temperature, the substrate melts and the substrate wets the pre-plated layer of the wire under the action of flux. The wire is pressed into the semi-molten substrate and forms a metallurgical bond. S3.4: After the pressure application time of the welding wire and the substrate is completed, the vacuum chuck 3 pressure head remains in a downward state to position and bind the welding wire and the substrate, and the guillotine 4 runs to cut off the welding wire located outside the preset positions on both sides of the substrate. S3.5: The guillotine 4 resets, the vacuum suction cup 3 lifts its pressure head, and at the same time, the vacuum suction is activated to pick up the finished welded sheet with the weld wire after pressing. The vacuum suction cup 3 moves to place the finished welded sheet onto the conveyor belt.

[0027] Furthermore, the preformed solder sheet product inspection in step three includes the thickness, number of wires, wire spacing, and oxidation degree of the wires. The thickness of the preformed solder sheet product is measured using an electronic thickness gauge, which uses ultrasonic testing and can be used to measure the thickness of both metals and non-metals, especially suitable for thinner solder sheets. The electronic thickness gauge calculates the thickness by emitting sound waves and measuring their reflection time. The number of wires and the wire spacing of the preformed solder sheet product are detected and analyzed using a vision inspection instrument. By detecting the number of wires and the wire spacing of the preformed solder sheet product, it is possible to detect whether the solder wires on the solder sheet substrate are broken, which may result in the broken solder wires not being properly laid out. When there are broken solder wires, the tension during solder wire laying is reduced, thereby reducing the probability of breakage during solder wire laying.

[0028] Preferably, if the data detected in step four does not reach the preset value of the preformed weldment product, the automatically generated preformed weldment production parameters are optimized, and an initial adjustment standard value for the same product is established. When the generated parameters are standard preformed weldment production parameters, and the thickness of the preformed weldment product is greater than the preset value, the production temperature, pressure, and time parameters of the preformed weldment are increased by one initial adjustment standard value for the same product. Conversely, when the thickness of the preformed weldment product is less than the preset value, the production temperature, pressure, and time parameters of the preformed weldment are decreased by one initial adjustment standard value for the same product. According to industry standards, weldments with different thickness ranges have clear tolerance requirements. The basic range of the initial adjustment standard value should not exceed 50% of the thickness tolerance. According to the preformed weldment production steps in step three, the initial adjustment standard value for temperature is 10℃, the initial adjustment standard value for pressure is 0.2MPa, and the initial adjustment standard value for time is 4s.

[0029] Furthermore, when the generated parameters are estimated preformed solder sheet production parameters, the thickness value of the preformed solder sheet product is compared with the preset thickness value, and the percentage difference is calculated and set as K. When the thickness value of the preformed solder sheet product is greater than the preset thickness value, K is positive, meaning the temperature, pressure, and time during preformed solder sheet production are increased, thereby reducing the thickness of the produced preformed solder sheet. Conversely, when the thickness value of the preformed solder sheet product is less than the preset thickness value, K is negative. When optimizing the estimated preformed solder sheet production parameters, the estimated preformed solder sheet production parameters are multiplied by (1+K), meaning the temperature, pressure, and time during preformed solder sheet production are decreased, thereby increasing the thickness of the produced preformed solder sheet. The calculation formula is as follows:

[0030] in For the optimized production parameters of the preformed welding sheet, The production parameters of the preformed sheet are given before optimization, and K takes the value of 0-1. The optimized production parameters of the preformed sheet can then be calculated using the above formula.

[0031] Furthermore, step five involves repeating steps three and four to continuously optimize the preformed solder sheet production parameters. When the generated parameters are standard preformed solder sheet production parameters, and adjustments are made again, the production temperature, pressure, and time parameters of the preformed solder sheet are adjusted by half the previous value. That is, after each adjustment, the difference between the produced product parameters and the preset values ​​will gradually decrease, thereby gradually reducing the adjustment value and improving the accuracy of the production parameters. This continues until the difference between the values ​​detected by the preformed solder sheet after three or more consecutive production processes and the preset values ​​of the preformed solder sheet products is within the allowable error range. Then, the adjusted standard preformed solder sheet production parameters are saved as parameters for continuous production of preformed solder sheets. When the generated parameters are estimated preformed solder sheet production parameters, optimization is still performed by multiplying the estimated preformed solder sheet production parameters by (1+K) until the difference between the values ​​detected by the preformed solder sheet after three or more consecutive production processes and the preset values ​​of the preformed solder sheet products is within the allowable error range. Then, the adjusted estimated preformed solder sheet production parameters are saved as parameters for continuous production of preformed solder sheets.

[0032] Specifically, in step six, the continuous automated production of preformed welding sheet products is carried out according to the adjusted and confirmed preformed welding sheet production parameters, following the steps of feeding the welding sheet substrate, heating, introducing nitrogen, immersing the welding wire in flux, arranging the wire, pressing the wire, cutting the wire, and unloading the product. The produced preformed welding sheets are sampled and inspected, and the production quality of the sampled preformed welding sheet products is fed back in real time to improve the quality of product production.

[0033] As one implementation method, if the hot melt characteristics of the solder substrate shift due to supplier changes when there are batch differences in materials, fluctuations in ambient humidity, or changes in equipment status, and the parameters can only be adjusted in reverse by the thickness deviation of the produced solder, it is impossible to compensate for such changes in advance during the production process.

[0034] Therefore, to address this issue, this embodiment also includes an integrated multi-source sensor network and an adaptive control module. Specifically, a high-precision thermocouple array is embedded inside the heating platform 2 to monitor the surface temperature distribution of the platform in real time and feed the data back to the control terminal. A gas concentration sensor is deployed at the nitrogen emission pipe outlet to dynamically detect the local oxygen content. Simultaneously, strain gauges are installed on the online shaft tension adjustment mechanism to track the tensile state of the welding wire in real time. After preprocessing by the edge computing unit, these sensor data are input to the adaptive control module based on machine learning algorithms. This module establishes a nonlinear mapping model between material properties, environmental parameters, and optimal production parameters, and can dynamically predict the optimal combination of temperature, pressure, and time parameters in each production cycle. For example, when the edge temperature of the heating platform 2 is detected to be lower than that of the central area, the system automatically adjusts the heat preservation time parameter of that area, rather than relying on subsequent thickness measurement results for delayed adjustment. This embodiment upgrades parameter optimization from a passive "production-measurement-adjustment" mode to an active "monitoring-prediction-compensation" mode, significantly improving adaptability to dynamic production environments.

[0035] As one implementation method, when using a nitrogen exhaust pipe to locally protect the heated area, the nitrogen gas is prone to turbulence after flowing out of the fixed pipe opening, resulting in insufficient nitrogen concentration at the edge of the solder substrate or in areas with complex structures. At the same time, although the solder wire is treated by dripping after being immersed in flux, the uniformity of flux coating depends entirely on the weight of the fluid, making it difficult to ensure complete coverage of the pre-plated surface.

[0036] Therefore, to optimize this defect, this embodiment optimizes the single nitrogen exhaust pipe into a porous nitrogen diffusion hood, which is integrated into a liftable frame 10mm above the heating platform 2. The diffusion hood has micron-sized pores evenly distributed on its surface. The gas pressure regulating device ensures that the nitrogen covers the entire surface of the solder substrate in a laminar flow state, keeping the oxygen concentration below 10ppm. Secondly, an ultrasonic oscillator is added inside the flux tank 9 to form uniform atomized flux particles. When the solder wire passes through, a coating of uniform thickness can be obtained through ultrasonic adsorption effect. Most importantly, an instant sealing nozzle is added to the cutter 4 module. The nozzle sprays nano-silver anti-oxidation coating through an external feeding system. The nozzle spraying operation is existing technology and will not be described in detail here. After the solder wire is cut, the micro-robotic arm immediately applies the nano-silver anti-oxidation coating to the exposed end face and cures it quickly within 0.5 seconds through an infrared heating device. This embodiment reduces the oxidation risk blind spot through a triple protection mechanism of "gas laminar flow coverage + flux ultrasonic atomization + instant end face sealing".

[0037] Another objective of this invention is to provide an automated production equipment for height-limited preformed welding sheets, comprising a mounting housing 1, a heating platform 2 installed inside the mounting housing 1, a nitrogen exhaust pipe located on the side of the heating platform 2, a vacuum suction cup 3 mounted on the heating platform 2, a wire-crushing pressure head mounted on the bottom of the vacuum suction cup 3, and a carbide column mounted on the bottom of the pressure head, the carbide column contacting the heating platform 2 or a reference surface to ensure the distance between the pressure head and the heating platform 2, and the carbide column being removable and replaceable, thereby ensuring that the distance between the pressure head and the heating platform 2 is the same as the thickness of the product, thus improving the quality of product production. A guillotine 4 is mounted on the side of the vacuum suction cup 3, the guillotine 4 being electrically driven to move up and down relative to the vacuum suction cup 3, thereby performing wire cutting operations. The mounting housing 1 has a preset cutting area corresponding to the guillotine 4 inside. A spool 5 is provided on the side of the mounting housing 1. A guide rod 6 and a guide rod 7 are provided between the spool 5 and the mounting housing 1. A flux tank 9 is provided between the guide rod 6 and the mounting housing 1. A fixing rod 8 is provided on the other side of the mounting housing 1. A wire clamp is installed on both the fixing rod 8 and the guide rod 7 for clamping the welding wire. The vacuum suction cup 3 and the guide rod 7 are installed and moved by a robotic arm. The flux tank 9, the fixing rod 8, the guide rod 6, the spool 5 and the mounting housing 1 are all installed on the production site by a frame. The installation is existing technology and will not be described in detail here. The mounting housing 1 is equipped with a control terminal for controlling the operation of the heating platform 2, the vacuum suction cup 3, the guillotine 4, the spool 5, the guide rod 7 and the fixing rod 8.

[0038] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. An automated production method for height-limited preformed welding sheets, characterized in that, The specific steps include the following: Step 1: Prepare preformed welding sheet materials to provide materials for the automated production of preformed welding sheets; Step Two: Initialize the production equipment. Input the performance parameters of the preformed welding sheet material into the control terminal of the production equipment. These performance parameters include the hot melt temperature of the welding sheet substrate and the welding wire. Input the preset values ​​for the preformed welding sheet product, including the thickness parameters and wiring parameters. The wiring parameters include the number of longitudinally and transversely arranged welding wires on the welding sheet substrate, the spacing of the welding wires, and the tension of the welding wires. Based on the input information, automatically generate the production parameters for the preformed welding sheet. These production parameters include the temperature, pressure, time, and position parameters for processing the welding sheet substrate and the welding wire. The processing position parameters are directly generated from the wiring parameters of the preformed solder sheet product. The temperature, pressure, and time parameters for processing the solder sheet substrate and welding wire are generated by querying the database and looking up the production parameters of similar products. If the database has the same production parameters, these parameters are taken as the standard preformed solder sheet production parameters and the preformed solder sheet is processed. If the database does not have the same production parameters, the production parameters of similar products are taken and classified into part families. Typical process templates are searched and the production temperature, pressure, and time parameters are adjusted to serve as the estimated preformed solder sheet production parameters, and a product production database is established. Step 3: Process the preformed welding sheet according to the parameters generated automatically, inspect the produced preformed welding sheet products, and provide feedback on the inspection data of the preformed welding sheet products; Step 4: Compare the test data with the preset values ​​of the preformed solder sheet product, and optimize the production parameters of the preformed solder sheet; Step 5: Repeat steps 3 and 4 until the test parameters of the produced preformed weldment products meet the preset values ​​of the preformed weldment products, and determine the production parameters of the preformed weldment. Step 6: Based on the determined production parameters of the preformed sheet, repeat the preformed sheet production and processing steps to continuously and automatically produce preformed sheet products.

2. The automated production method of a height-limited preformed welding sheet according to claim 1, characterized in that, In step one, the pre-formed solder sheet material includes a solder sheet substrate, solder wire, flux, and nitrogen. The solder wire includes a copper wire and a pre-plating layer. The pre-plating layer is wrapped around the copper wire and includes a nickel layer and a solder layer covering the nickel layer. The pre-plating layer outside the copper wire is hot-melted and welded to the solder sheet substrate by heating and pressurizing. The nitrogen is used to protect the solder sheet substrate and solder wire from oxidation.

3. The automated production method of a height-limited preformed welding sheet according to claim 2, characterized in that, The welding sheet production and processing in step three is based on the pre-formed welding sheet production parameters automatically generated in step two, and involves the production and processing of the welding sheet substrate and welding wire, including the following steps: S3.1: Use a vacuum suction cup (3) to pick up a piece of welding substrate from the tray, move the welding substrate to the center of the heating platform (2), and turn on the heating platform (2) to heat until the temperature reaches the heating temperature value of the pre-formed welding sheet generated automatically, and maintain the heating temperature of the heating platform (2), and open the nitrogen valve to introduce nitrogen. S3.2: Arrange the welding wires according to the wiring parameters of the preformed welding sheet product, that is, pull the welding wires out from the spool (5) and immerse the welding wires in the flux tank (9), straighten and position them above the heating platform (2), and press down the welding wires so that the welding wires adhere to the surface of the heated and heat-insulated welding sheet substrate. S3.3: The pressure head of the vacuum chuck (3) is moved down to press the wire and the substrate assembly with a set pressure and hold for a set time. Under this pressure and temperature, the substrate melts and the substrate wets the pre-plated layer of the wire under the action of flux. The wire is pressed into the semi-molten substrate and a metallurgical bond is formed. S3.4: After the pressure time of the welding wire and the substrate is over, the vacuum chuck (3) press head is kept in a downward state to position and bind the welding wire and the substrate, and the guillotine (4) runs to cut off the welding wire located outside the preset position on both sides of the substrate. S3.5: The guillotine (4) is reset, the vacuum suction cup (3) press head is raised, and the vacuum suction is started at the same time to pick up the finished welded sheet with the weld wire after pressing. The vacuum suction cup (3) moves to place the finished welded sheet on the conveyor belt.

4. The automated production method of a height-limited preformed welding sheet according to claim 3, characterized in that, The inspection of the preformed solder sheet product in step three includes the thickness, number of wires, wire spacing, and oxidation degree of the wires. The thickness of the preformed solder sheet product is measured by an electronic thickness gauge. The number of wires and wire spacing of the preformed solder sheet product are detected and analyzed by a vision inspection instrument. By detecting the number of wires and wire spacing of the preformed solder sheet product, it is possible to detect whether the solder wires on the solder sheet substrate are broken, which may result in the broken solder wires not being properly laid out. When there are broken solder wires, the tension during solder wire laying is reduced.

5. The automated production method of a height-limited preformed welding sheet according to claim 4, characterized in that, When the data detected in step four does not reach the preset value of the preformed sheet product, the automatically generated preformed sheet production parameters are optimized, and an initial adjustment standard value for the same product is established. When the generated parameters are standard preformed sheet production parameters, and the thickness of the preformed sheet product is greater than the preset value, the production temperature, pressure, and time parameters of the preformed sheet are increased by one initial adjustment standard value for the same product. Conversely, when the thickness of the preformed sheet product is less than the preset value, the production temperature, pressure, and time parameters of the preformed sheet are decreased by one initial adjustment standard value for the same product.

6. The automated production method of a height-limited preformed welding sheet according to claim 5, characterized in that, When the generated parameters are estimated preformed solder sheet production parameters, the thickness value of the preformed solder sheet product is compared with the preset thickness value of the preformed solder sheet product, and the percentage of the difference is calculated and set as K. When the thickness value of the preformed solder sheet product is greater than the preset thickness value of the preformed solder sheet product, K is a positive number; conversely, when the thickness value of the preformed solder sheet product is less than the preset thickness value of the preformed solder sheet product, K is a negative number. When optimizing the estimated preformed solder sheet production parameters, the estimated preformed solder sheet production parameters are multiplied by (1+K) to obtain the optimized estimated preformed solder sheet production parameters.

7. The automated production method of a height-limited preformed welding sheet according to claim 6, characterized in that, The repetition of steps three and four in step five involves continuously optimizing the preformed solder sheet production parameters. When the generated parameters are standard preformed solder sheet production parameters, and adjustments are made again, the production temperature, pressure, and time parameters of the preformed solder sheet are adjusted one by one to half the previous value, until the difference between the values ​​detected by the preformed solder sheet produced for more than three consecutive times and the preset value of the preformed solder sheet product is within the allowable error range. Then, the adjusted standard preformed solder sheet production parameters are saved as parameters for continuous production of preformed solder sheets. When the generated parameters are estimated preformed solder sheet production parameters, optimization is still performed by multiplying the estimated preformed solder sheet production parameters by (1+K), until the difference between the values ​​detected by the preformed solder sheet produced for more than three consecutive times and the preset value of the preformed solder sheet product is within the allowable error range. Then, the adjusted estimated preformed solder sheet production parameters are saved as parameters for continuous production of preformed solder sheets.

8. The automated production method of a height-limited preformed welding sheet according to claim 7, characterized in that, In step six, the continuous automated production of preformed welding sheet products is carried out according to the adjusted and confirmed preformed welding sheet production parameters. Step three is performed, including feeding the welding sheet substrate, heating, introducing nitrogen, immersing the welding wire in flux, arranging the wire, pressing the wire, cutting the wire, and unloading the material. The produced preformed welding sheets are sampled and tested, and the production quality of the preformed welding sheet products is fed back in real time.

9. An automated production equipment for height-limited preformed weld sheets, implementing the automated production method for height-limited preformed weld sheets according to any one of claims 1-8, characterized in that, The system includes a mounting housing (1), inside which a heating platform (2) is installed. Inside the mounting housing (1) is a nitrogen exhaust pipe located on the side of the heating platform (2). On the heating platform (2) is a vacuum suction cup (3), and on the side of the vacuum suction cup (3) is a guillotine cutter (4). Inside the mounting housing (1) is a pre-set cutting area corresponding to the guillotine cutter (4). On the side of the mounting housing (1) is a spool (5). Between the spool (5) and the mounting housing (1) are a guide rod (6) and a guide rod (7). Between the guide rod (6) and the mounting housing (1) is a flux tank (9). On the other side of the mounting housing (1) is a fixing rod (8).

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