Crank type integrated welding machine and control method thereof

Abstract

The invention discloses a crank type integrated welding machine and a control method thereof and aims to solve the problems that existing ultrasonic welding equipment is scattered in structure, strenuous in operation, low in remodeling efficiency and the like. The equipment comprises a welding base, a quick-release workpiece fixing mechanism and an integrated case, wherein the case is divided into a welding execution area (an integrated ultrasonic vibration execution integrated module and a crank driving mechanism) and an electrical installation area (an integrated control unit) through a vertical plate; labor-saving lifting and automatic resetting are achieved through the crank driving mechanism, the quick release structure is matched with multi-variety type changing, the proximity switch triggers precise welding, and parameter configuration, frequency sweeping adaptation and no-load debugging are achieved through the control panel. According to the control method, machining is completed through accessory replacement, parameter configuration, debugging, welding execution and resetting. According to the automatic welding device, equipment compactness, operation convenience and welding precision are achieved, the production efficiency and quality are improved, and the automatic welding device is suitable for multi-variety and small-batch welding scenes of plastic products such as zippers and plastic pipe fittings.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic welding equipment technology, specifically to a crank-type integrated welding machine and its control method that features integrated structure, labor-saving operation, and convenient model changeover. It is mainly suitable for welding and processing plastic products such as zippers, plastic pipes, and small plastic components, and is especially suitable for production scenarios with multiple varieties and small batches. Background Technology

[0002] Ultrasonic welding technology, due to its lack of consumables, high welding efficiency, stable joint strength, and ability to effectively avoid problems such as overflow and discoloration in traditional hot melt welding, has been widely used in the joining and processing of plastic products such as zippers, plastic pipes, and small plastic components. Especially in industries such as clothing accessories and light industrial products, this technology has become one of the core joining processes in the production of mid-to-high-end products.

[0003] However, in the long-term process of industrial application, existing ultrasonic welding equipment still has many technical shortcomings in terms of structural design, operational practicality, control functions, and scenario adaptability, making it difficult to meet the actual needs of the industry for efficient production and flexible adaptation. Specific technical problems are as follows: 1. The structural layout is scattered, making it inconvenient to use and maintain. Most mainstream ultrasonic welding equipment currently adopts a split design, separating the welding actuator, control unit, and power module (such as pneumatic source and drive motor). These functional units are connected via cables, air pipes, and other pipelines. This decentralized layout has significant drawbacks: firstly, each unit occupies its own space, resulting in a large overall footprint and limiting the flexibility of workshop layout, particularly unfavorable for small and medium-sized processing plants with limited space or densely packed production environments with multiple machines; secondly, the crisscrossing pipelines not only affect the cleanliness of the workshop environment but are also prone to scratches and wear due to personnel movement, equipment relocation, or long-term use, leading to signal transmission failures or power supply interruptions, increasing equipment maintenance frequency and costs; furthermore, long-distance signal transmission is susceptible to electromagnetic interference from other electrical equipment in the workshop, causing unstable welding parameter output and indirectly affecting the consistency of welding quality.

[0004] 2. The operation and changeover processes are cumbersome, limiting production efficiency. The plastics processing industry often faces the demand for multi-variety, small-batch production. Existing equipment operation designs and changeover mechanisms are ill-suited to this production scenario: First, most manual or semi-automatic welding equipment uses cylinder direct drive or motor direct drive for its actuators, lacking a labor-saving transmission structure. When changing welding heads or adjusting welding strokes, operators must directly move or manipulate heavy actuators, resulting in high labor intensity. Furthermore, the accuracy of manually adjusted strokes is difficult to guarantee, easily leading to uneven initial contact pressure between the welding head and the workpiece. Second, the connection between the welding head and welding seat is mostly secured with bolts. When changing to different specifications of accessories to adapt to different workpieces, additional tools are required for disassembly and installation. After installation, the coaxiality of the welding head and welding seat must be repeatedly calibrated, making the changeover process cumbersome and time-consuming, severely compressing effective production time. Third, some equipment's welding seats rely solely on planar contact for positioning, lacking error prevention and locking structures. Under the high-frequency vibrations generated by ultrasonic welding, the welding seat is prone to micro-displacement, leading to workpiece positioning deviations, affecting welding accuracy, and even causing product scrap.

[0005] 3. The control system has limited functionality, making it difficult to guarantee welding quality. The control systems of existing ultrasonic welding equipment have significant limitations in parameter adaptation and process control: First, most equipment only supports a single parameter input mode with fixed power and fixed time, and cannot adaptively adjust welding parameters according to differences in workpiece material (such as PP, PE, ABS, etc.), thickness, structural characteristics, etc. Due to the differences in melting characteristics and heat conduction efficiency of different plastic products, welding with uniform parameters is prone to problems such as over-welding (such as overflow, workpiece deformation) or under-welding (such as insufficient joint strength, weak connection), affecting product quality stability; Second, existing equipment generally lacks a built-in workpiece parameter database. When dealing with multi-variety production, operators need to manually record and repeatedly adjust the welding parameters corresponding to different specifications of workpieces, which is not only cumbersome but also prone to production failures due to parameter recording errors or retrieval mistakes; In addition, most low- and mid-range equipment is not equipped with real-time monitoring functions, and cannot collect changes in key parameters such as output power and contact pressure during the welding process. Defective products can only be detected through post-weld finished product inspection, making it difficult to trace the cause of abnormalities in the welding process, resulting in a high scrap rate and the inability to adjust process parameters in a timely manner to avoid subsequent failures.

[0006] 4. Insufficient adaptability to different scenarios and high barrier to entry for use. Existing ultrasonic welding equipment is mostly designed for large-scale production lines, making it poorly suited for small workshops, laboratory sample preparation, and small-batch customized production. Firstly, the cost of purchasing and configuring each functional unit of the modular equipment is high, and it requires additional dedicated power and air supply interfaces, increasing the initial investment and barriers to entry for small users. Secondly, the equipment's user interface and workflow design are complex, lacking integrated and simplified human-machine interaction logic, requiring extensive training for non-professional operators to operate independently. After equipment commissioning and operation, small businesses or workshops face high staff turnover, leading to persistently high training costs, which further limits the promotion and application of the equipment.

[0007] In summary, existing ultrasonic welding equipment suffers from several technical shortcomings in terms of structural integration, ease of operation, control precision, and adaptability to various scenarios, making it difficult to fully meet the industry's demands for efficient, precise, and flexible welding. Therefore, developing an ultrasonic welding device with integrated structure, simplified operation, and intelligent control, along with corresponding control methods, is crucial to addressing these current technical challenges. Summary of the Invention

[0008] I. Purpose of the Invention The purpose of this invention is to overcome the technical defects of existing ultrasonic welding equipment, such as dispersed structure, laborious operation, inefficient model changeover, and single control. It provides a crank-type integrated welding machine and its control method. Through integrated layout, labor-saving transmission mechanism, quick-release positioning structure and intelligent control logic, the machine achieves compact layout, convenient operation and precise welding, improves production efficiency and welding quality, and is suitable for multi-variety and small-batch production scenarios.

[0009] II. Technical Solution

[0010] To achieve the above-mentioned objectives, the present invention adopts the following technical solution: (a) Crank-type integrated welding machine A crank-type integrated welding machine includes a welding base (1), the key features of which are: a quick-release workpiece fixing mechanism (2) and an integrated chassis (3) are configured on the welding base (1), and the integrated chassis (3) integrates an ultrasonic vibration execution integrated module (4) and a control unit (5); the vertical distance between the ultrasonic vibration execution integrated module (4) and the quick-release workpiece fixing mechanism (2) is adjusted by a crank drive mechanism (6) to save effort; the control unit (5) is responsible for controlling the opening and closing of welding and adjusting welding parameters.

[0011] Furthermore, the integrated chassis (3) is divided into a welding execution area and an electrical installation area by a vertical plate (301). An ultrasonic vibration execution integrated module (4) and a crank drive mechanism (6) are integrated in the welding execution area. A control unit (5) and supporting electrical components are integrated in the electrical installation area.

[0012] Furthermore, the crank drive mechanism (6) includes a vertical guide rail (601) disposed on the upright plate (301), on which a sliding mounting seat (602) for assembling the ultrasonic vibration actuation integrated module (4) is slidably constrained. The sliding mounting seat (602) is connected to an operating handle (604) via a crank connecting rod assembly (603), and the operating handle (604) is used to receive driving power.

[0013] Furthermore, the sliding mounting base (602) is connected to the crank connecting rod assembly (603) via an elastic reset component (605), and the elastic reset component (603) is used to buffer the impact force during the welding process and realize automatic reset after welding.

[0014] Furthermore, a proximity switch (7) is provided on the motion path of the ultrasonic vibration execution integrated module (4). The proximity switch (7) is used to detect the downward position of the ultrasonic vibration execution integrated module (4) and trigger the welding start.

[0015] Furthermore, the proximity switch (7) includes a sensor disposed on the upright plate (301) and an identification rod arranged corresponding to the sensor; the identification rod is mounted on the sliding mounting base (602) and can move along with the movement of the sliding mounting base (602).

[0016] Furthermore, the ultrasonic vibration execution integrated module (4) includes an integrated mechanism (401) that integrates a transducer and an amplitude transformer. The integrated mechanism (401) is electrically connected to the control unit (5), and a quick-detachable welding head (402) is connected to the output end of the integrated mechanism (401).

[0017] Furthermore, the quick-release workpiece fixing mechanism (2) includes a workpiece fixing seat (201), which is detachably connected to the base through a quick-positioning pin hole and / or a positioning groove.

[0018] Furthermore, a control panel (8) is embedded in the outer wall of the integrated chassis (3). The control panel (8) is electrically connected to the control unit (5) and is equipped with "Settings", "Frequency Sweep", "Debugging" buttons and adjustment buttons; wherein: "Settings" button: Used to enter the welding parameter configuration mode; "Frequency Sweep" button: used to trigger the frequency adaptation and adjustment of the ultrasonic vibration execution integrated module (4) to match the vibration response characteristics of the workpiece to be welded; "Debugging" button: used to start the no-load operation test of the equipment and verify the effectiveness of the crank drive mechanism (6) and the ultrasonic vibration execution integrated module (4); Increase / decrease adjustment buttons: used to adjust the values ​​of welding parameters and sweep frequency.

[0019] (II) Control method of crank-type integrated welding machine The key to the control method of the crank-type integrated welding machine described above lies in the following steps: S1: The workpiece fixing seat (201) adapted to the workpiece to be welded is detachably connected to the welding base (1) by the quick positioning pin hole and / or positioning groove of the quick-release workpiece fixing mechanism (2), and the quick-release welding head (402) at the output end of the ultrasonic vibration execution integrated module (4) is replaced. S2: Operate the control panel (8) on the outer wall of the integrated chassis (3), press the "Settings" button to enter the welding parameter configuration mode, and input or configure the welding parameters by adding or subtracting adjustment buttons; S3: Press the “Sweep Frequency” button on the control panel (8) to trigger the ultrasonic vibration execution integrated module (4) to perform frequency adaptation and adjustment to match the vibration response characteristics of the workpiece to be welded; S4: Press the “Debug” button on the control panel (8) to start the no-load operation test of the equipment. After verifying the effectiveness of the crank drive mechanism (6) and the ultrasonic vibration execution integrated module (4), the debugging is completed and the device is reset. S5: The operating handle (604) of the crank drive mechanism (6) drives the sliding mounting seat (602) to move down along the vertical guide rail (601) through the crank connecting rod assembly (603), so that the ultrasonic vibration execution integrated module (4) moves closer to the workpiece to be welded; S6: When the identification rod on the sliding mounting base (602) moves to the detection position of the proximity switch (7), the proximity switch (7) is triggered and sends a signal to the control unit (5). The control unit (5) starts the ultrasonic vibration execution integrated module (4), so that the integrated transducer and the integrated mechanism (401) of the amplitude rod outputs vibration of the appropriate frequency and transmits it to the welding head (402). At the same time, the elastic reset component (605) buffers the impact force during the welding process. S7: After the welding time corresponding to the preset welding parameters is reached, the control unit (5) shuts down the ultrasonic vibration execution integrated module (4), and the elastic reset component (605) drives the sliding mounting base (602) and the ultrasonic vibration execution integrated module (4) to move up and reset along the vertical guide rail (601) to complete the welding.

[0020] III. Beneficial Effects

[0021] The crank-type integrated welding machine and its control method of the present invention achieve targeted solutions to the pain points of the prior art through the following technical features, and have significant beneficial effects: (i) Integrated layout to solve the problem of dispersed structure: The integrated chassis is divided into welding execution area and electrical installation area by the vertical plate, integrating ultrasonic vibration execution module, crank drive mechanism, control unit and supporting electrical components into one, eliminating the need for external control box and power module, greatly reducing the space occupied by the equipment; at the same time, it shortens the signal and power transmission path, avoids interference and pipeline failures in long-distance transmission, improves the stability of equipment operation and reduces maintenance costs.

[0022] (ii) Crank drive and elastic reset to solve the problem of laborious operation: The crank drive mechanism utilizes the force-saving transmission characteristics of the crank connecting rod assembly, so that the operator only needs to apply a small force to drive the ultrasonic vibration actuator integrated module to lift and lower, which greatly reduces the labor intensity; the elastic reset component not only realizes automatic reset after welding, but also buffers the welding impact force to avoid damage to the workpiece due to excessive pressure, thereby improving the convenience of operation and welding safety.

[0023] (III) Quick-release positioning structure to solve the problem of inefficient changeover: The quick-release design of the quick-release workpiece fixing mechanism with quick-release positioning pin holes or / and positioning grooves and welding heads makes it possible to change over different specifications of workpieces without complicated tools and long-term calibration, which greatly shortens the changeover time; at the same time, the constraint effect of quick-release positioning pin holes or / and positioning grooves and vertical guide rails ensures the coaxiality of welding heads and workpieces, avoids welding misalignment, and improves welding accuracy after changeover.

[0024] (iv) Intelligent control to solve the problem of single control: The "Settings", "Frequency Sweep" and "Debug" buttons on the control panel, together with the control unit, enable precise configuration of welding parameters, frequency adaptation between workpiece and equipment, and early troubleshooting of equipment failures; the frequency adaptation function can adjust the vibration frequency according to the workpiece material to avoid over- or under-welding and improve the stability of welding quality; the parameter configuration and storage function (the control unit has a built-in parameter storage module) adapts to the production needs of multiple varieties, eliminating the need for repeated parameter debugging and improving production efficiency.

[0025] (v) Strong adaptability to various scenarios and lower barriers to use: The integrated structural design reduces the cost of equipment procurement and configuration, and there is no need to arrange additional power or gas interfaces, making it suitable for small workshops, laboratories and other scenarios; The button design of the control panel is intuitive and convenient, and non-professionals can operate it after simple training, reducing personnel training costs and expanding the application scope of the equipment. Attached Figure Description

[0026] 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.

[0027] Figure 1 This is a schematic diagram of the overall structure of the crank-type integrated welding machine in this invention; Figure 2 This is a schematic diagram (a) of the internal structure of the crank-type integrated welding machine in this invention; Figure 3 This is a schematic diagram (II) of the internal structure of the crank-type integrated welding machine in this invention; Figure 4 This is an exploded view of the crank-type integrated welding machine in the first direction of the present invention; Figure 5 This is an exploded view of the crank-type integrated welding machine in the second direction of the present invention; The markings in the diagram are as follows: 1-Welding base, 2-Quick-release workpiece fixing mechanism, 201-Workpiece fixing seat, 3-Integrated chassis, 301-Upright plate, 4-Ultrasonic vibration actuator integrated module, 401-Integrated mechanism (integrated transducer and amplitude transformer), 402-Welding head, 5-Control unit, 6-Crank drive mechanism, 601-Vertical guide rail, 602-Sliding mounting seat, 603-Crank connecting rod assembly, 604-Operating handle, 605-Elastic reset assembly, 7-Proximity switch, 8-Control panel. Detailed Implementation

[0028] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0029] In the description of this invention, it should be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, in the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0030] Please see Figures 1 to 5 The present invention first provides a crank-type integrated welding machine, including a welding base 1, on which a quick-release workpiece fixing mechanism 2 and an integrated housing 3 are configured. The integrated housing 3 integrates an ultrasonic vibration execution integrated module 4 and a control unit 5. The vertical distance between the ultrasonic vibration execution integrated module 4 and the quick-release workpiece fixing mechanism 2 is adjusted by a crank drive mechanism 6 to save effort. The control unit 5 is responsible for controlling the opening and closing of welding and adjusting welding parameters.

[0031] First, by integrating the ultrasonic vibration execution module 4 and the control unit 5 into the same chassis and forming an integrated structure with the welding base 1, the problem of the dispersed layout of traditional equipment is effectively solved, making the overall equipment more compact and significantly reducing the space occupied. This also greatly facilitates the overall movement of the equipment, daily operation, and subsequent maintenance, reducing the workload and intensity for maintenance personnel. Second, the design of the quick-release workpiece fixing mechanism 2, combined with the crank drive mechanism 6 for effortless adjustment of the vertical distance between the ultrasonic vibration execution module 4 and the workpiece fixing mechanism 2, significantly simplifies the clamping and fixing process of workpieces of different specifications and the welding position adjustment process, significantly shortening operation and changeover time, avoiding production interruptions caused by traditional cumbersome processes, and thus effectively improving overall production efficiency, especially suitable for multi-variety, small-batch production scenarios. Third, the control unit 5 is not only responsible for the opening and closing of welding but also for precisely adjusting welding parameters such as welding time, vibration frequency, and amplitude, achieving refined control of the welding process. This overcomes the shortcomings of traditional control systems with limited functionality, helps ensure the stability and consistency of welding quality, reduces welding defects caused by unstable parameters, and improves product qualification rate. Finally, the integrated design and intelligent control unit make the equipment operation simpler and more intuitive, reducing the skill requirements for operators. Meanwhile, the quick-release structure and adjustable crank drive mechanism enhance the equipment's adaptability to workpieces of different sizes and shapes, broadening its application scenarios, effectively lowering the barrier to entry, and enabling it to meet the welding needs of more industries and working conditions.

[0032] like Figure 4 As shown, specifically, the enclosure space of the integrated chassis 3 is divided into a welding execution area and an electrical installation area by the upright plate 301. The welding execution area is integrated with an ultrasonic vibration execution integrated module 4 and a crank drive mechanism 6; the electrical installation area is integrated with a control unit 5 and supporting electrical components.

[0033] This partitioned integrated design effectively solves the problem of the dispersed layout of traditional welding machines by integrating the originally scattered mechanical actuators and electrical control components into the same chassis, significantly reducing the overall footprint of the equipment and making the structure more compact. At the same time, this centralized layout greatly facilitates daily use and maintenance. Operators no longer need to shuttle between multiple scattered components for operation or inspection, and maintenance personnel can more easily inspect and repair each core component, reducing maintenance time and difficulty.

[0034] Please see Figure 2 and Figure 3 In a specific implementation, the crank drive mechanism 6 includes a vertical guide rail 601 mounted on the upright plate 301. A sliding mounting seat 602 for assembling the ultrasonic vibration actuation integrated module 4 is slidably constrained on the vertical guide rail 601. The sliding mounting seat 602 is connected to an operating handle 604 via a crank connecting rod assembly 603, and the operating handle 604 is used to receive driving power.

[0035] By rotating the handle 604, the crank-connecting rod assembly 603 can be driven to move the sliding mounting base 602 precisely up and down along the vertical guide rail 601, thereby realizing the rapid adjustment and positioning of the welding position of the ultrasonic vibration execution integrated module 4. This design allows operators to control the feed and retraction of the welding head through intuitive handle operation. Compared with traditional complex CNC adjustment or manual fine-tuning methods, it greatly simplifies the operation process and reduces the professional skill requirements for operators. Even less experienced workers can quickly get started and accurately complete the welding position setting, effectively improving the convenience of operation and changeover efficiency. Especially in production scenarios that require frequent changes in workpiece type or adjustment of welding parameters, it can significantly reduce the production efficiency loss caused by cumbersome operation and changeover processes.

[0036] from Figure 5 As can be seen, in this embodiment, the sliding mounting base 602 is connected to the crank connecting rod assembly 603 through the elastic reset component 605, and the elastic reset component 603 is used to buffer the impact force during the welding process and realize automatic reset after welding.

[0037] During welding, when the welding head contacts the workpiece and generates impact force, the elastic reset component 605 can effectively absorb and buffer this impact force through its own elastic deformation. This prevents rigid impact from damaging the welding head, workpiece, and equipment transmission components, thus protecting key equipment components, extending equipment lifespan, and reducing welding position displacement caused by impact, which helps ensure the stability of welding quality. After welding is completed, the elastic reset component 605 automatically releases its elastic potential energy, driving the sliding mounting base 602 to quickly return the ultrasonic vibration actuator integrated module 4 to its initial position without the need for manual reset by the operator. This further simplifies the operation steps, shortens the time of a single welding cycle, and helps improve the overall production cycle time. This automatic reset function not only reduces the labor intensity of operators and avoids the safety hazards that may be caused by human error in forgetting to reset, but also makes the entire welding process more continuous and smooth, improving the automation level and safety of equipment operation.

[0038] In practical applications, a proximity switch 7 is provided on the movement path of the ultrasonic vibration execution integrated module 4. The proximity switch 7 is used to detect the downward position of the ultrasonic vibration execution integrated module 4 and trigger the welding start.

[0039] When the ultrasonic vibration actuator integrated module 4 moves downward to the sensing area of ​​the proximity switch 7 under the drive of the crank transmission mechanism 5, the proximity switch 7 quickly sends a trigger signal to the control system 8. The control system 8 then precisely controls the ultrasonic vibration actuator integrated module 4 to start the ultrasonic welding operation. This automatic triggering method based on position detection replaces the traditional operation mode that relies on manual judgment of the start time, effectively avoiding the problem of inaccurate welding start time caused by human operation delays or misjudgments. This makes the start time of the welding process more precise and controllable, further ensuring the consistency and stability of the welded joint. At the same time, the setting position of the proximity switch 7 can be flexibly adjusted according to different welding process requirements. With just simple mechanical adjustment or parameter setting, it can adapt to the needs of workpieces of different thicknesses or different welding depths, greatly enhancing the equipment's adaptability to diverse welding scenarios and reducing the difficulty and time cost of adjusting the equipment due to product changes. This provides strong support for small-batch, multi-variety production modes.

[0040] Specifically, the proximity switch 7 includes a sensor disposed on the upright plate 301 and an identification rod arranged corresponding to the sensor; the identification rod is mounted on the sliding mounting base 602 and can move along with the sliding mounting base 602.

[0041] This structural design not only ensures the accuracy and timeliness of the proximity switch's position detection of the sliding mounting base 602, but its separate sensor and identification rod layout also avoids the adverse effects of vibration, high temperature, and spatter that might occur when the sensor is directly exposed to the welding operation area. This effectively extends the service life of the proximity switch and reduces the frequency and cost of equipment maintenance. Furthermore, the synchronous movement of the identification rod with the sliding mounting base makes the transmission of position detection signals more direct and reliable, reducing errors that might be introduced by intermediate transmission links. This further improves the response speed and accuracy of the trigger signal, laying a solid foundation for precise control of the entire welding process.

[0042] In this embodiment, the ultrasonic vibration execution integrated module 4 includes an integrated mechanism 401 that integrates a transducer and an amplitude transformer. The integrated mechanism 401 is electrically connected to the control unit 5, and a quick-detachable welding head 402 is connected to the output end of the integrated mechanism 401.

[0043] This integrated mechanism 401, which combines the transducer and amplitude transformer, effectively shortens the energy transmission path and reduces energy loss caused by connecting components in traditional split structures. This allows ultrasonic energy to be transmitted to the welding head 402 more efficiently and directly, thereby improving energy utilization and welding efficiency while reducing energy consumption. Secondly, the integrated structure enhances overall rigidity and stability, reducing vibration attenuation and resonance interference during welding, helping to ensure the stability and consistency of welding amplitude and improving welding quality reliability. Simultaneously, the integrated design simplifies the assembly process, reduces the number of parts, lowers assembly errors and failure rates, and extends the equipment's service life. The quick-release design of the welding head 402, combined with the quick-release workpiece fixing mechanism 2, further optimizes the changeover process. When different specifications or types of welding heads need to be replaced to meet the welding requirements of different workpieces, operators can quickly disassemble and replace the welding head without the need for complex tools, significantly reducing production downtime caused by welding head replacement and improving the equipment's continuous operation capability and production efficiency. In addition, this quick-release design facilitates the individual maintenance, upkeep, and replacement of the welding head, reducing maintenance costs and ensuring that the welding head is always in good working condition, thereby continuously guaranteeing welding quality.

[0044] Specifically, the quick-release workpiece fixing mechanism 2 includes a workpiece fixing seat 201, which is detachably connected to the base through a quick-positioning pin hole and / or a positioning groove.

[0045] When it is necessary to fix workpieces of different sizes or shapes, the operator only needs to pull out the quick-locating pin or loosen the locking component that mates with the locating slot to remove the current workpiece holder 201 from the base 1 and replace it with a holder that matches the new workpiece. Then, through the precise engagement of the locating pin hole and the locating pin or the guide engagement of the locating slot, the new holder is quickly positioned and installed. The entire process does not require complex adjustments or recalibration of the fixing mechanism, significantly reducing the preparation time when changing workpieces. This design not only improves the flexibility and convenience of workpiece clamping and meets the fixing needs of diverse workpieces, but also ensures the positional accuracy of the workpiece after each replacement, avoiding the impact of fixing deviations on the welding effect. This further ensures the stability and consistency of welding quality from the workpiece fixing stage, complementing the quick-release design of the welding head and jointly improving the overall production efficiency of the equipment.

[0046] In specific implementation, a control panel 8 is embedded in the outer wall of the integrated chassis 3. The control panel 8 is electrically connected to the control unit 5 and is equipped with "Settings," "Frequency Sweep," "Debugging," and adjustment buttons; wherein: "Settings" button: Used to enter the welding parameter configuration mode; "Frequency Sweep" button: used to trigger the frequency adaptation and debugging of the ultrasonic vibration execution integrated module 4 to match the vibration response characteristics of the workpiece to be welded; "Debug" button: Used to start the no-load operation test of the equipment to verify the effectiveness of the crank drive mechanism 6 and the ultrasonic vibration execution integrated module 4. Increase / decrease adjustment buttons: used to adjust the values ​​of welding parameters and sweep frequency.

[0047] This integrated operation design centralizes core control functions in the control panel 8, significantly reducing the learning curve and operational difficulty for operators. Without the need for frequent switching between disparate components, the intuitive button layout and clear function labels allow even beginners to quickly master the basic operating procedures, effectively solving the problem of high barriers to entry caused by the complexity of traditional welding machines. Simultaneously, the close cooperation between the control panel 8 and the control unit 5 ensures real-time and accurate parameter adjustments. Operators can conveniently set and adjust parameters according to the welding requirements of different workpieces, further enhancing the equipment's adaptability to various scenarios and enabling the same machine to better handle diverse welding tasks.

[0048] The present invention will be further described in detail below with reference to specific embodiments: Example 1: Zipper Welding Application In this embodiment, the workpiece to be welded is a PP zipper. The crank-type integrated welding machine of the present invention is used for zipper tooth welding. The specific operation process is as follows: Workpiece fixing and accessory replacement: Select the appropriate welding head 402 and workpiece fixing seat 201 according to the specifications of the PP material zipper; install the workpiece fixing seat 201 on the welding base 1 through the quick positioning pin hole; install the welding head 402 on the output end of the integrated mechanism 401 of the ultrasonic vibration execution integrated module 4 through the quick-release connector.

[0049] Parameter configuration and debugging: Press the "Settings" button on the control panel 8, and input the welding parameters through the increase and decrease adjustment buttons: welding power 1200W, welding time 0.8s; press the "Frequency Sweep" button, and the control unit 5 drives the power supply to sweep the frequency vibration within the range of the transducer's natural frequency ±1kHz, matching the vibration response characteristics of the customized ultrasonic mold (Horn), and finally determine the appropriate frequency as 28kHz; press the "Debug" button, and the equipment runs under no-load: the operating handle 604 drives the sliding mounting base 602 to rise and fall along the vertical guide rail 601, and the ultrasonic vibration execution integrated module 4 outputs 28kHz vibration. After verifying that the operation of each component is normal, the equipment is reset.

[0050] Welding execution: The PP zipper is placed in the clamping groove of the workpiece fixing seat 201. The operating handle 604 drives the sliding mounting seat 602 to move down through the crank connecting rod assembly 603, and the ultrasonic vibration execution integrated module 4 moves down accordingly. When the identification rod on the sliding mounting seat 602 moves to the detection position of the proximity switch 7, the proximity switch 7 is triggered, and the control unit 5 starts the ultrasonic vibration execution integrated module 4. The transducer converts the electrical signal into 28kHz mechanical vibration, which is amplified by the amplitude transformer and transmitted to the welding head 402. The welding head 402 transmits the vibration to the contact surface of the zipper teeth. Friction generates heat and melts the PP material. The elastic reset component 605 buffers the downward impact force to prevent deformation of the zipper teeth. After the welding time reaches 0.8s, the control unit 5 shuts down the ultrasonic vibration execution integrated module 4, and the elastic reset component 605 drives the sliding mounting seat 602 and the ultrasonic vibration execution integrated module 4 to move up and reset, and the welded zipper is removed.

[0051] Changeover operation: When welding PE zippers, simply replace the welding head 402 and workpiece fixing seat 201 with the PE zipper adapter. Call the pre-stored PE zipper welding parameters through the control panel 8. Welding amplitude is 70%, welding time is 1.0s, and curing time is 0.5s. Welding can be started after no-load debugging. Changeover time is shortened to less than 5 minutes.

[0052] In this embodiment, the welding defect rate of the equipment is reduced from 8% of the existing equipment to 1.2%, the changeover efficiency is increased by 70%, and the labor intensity of operators is reduced by 60%, which fully demonstrates the technical advantages of the present invention.

[0053] Example 2: Application of Welding for Plastic Pipe Fittings The workpiece to be welded is a PE plastic pipe fitting. The end face welding is performed using the crank-type integrated welding machine of this invention. The operation process is similar to that of Example 1, except that: Replace the welding head 402 with the workpiece fixing seat 201 to match the outer diameter of the plastic pipe fitting. Welding parameter settings: welding amplitude 80%, welding time 1.5s. The resonant frequency of the ultrasonic mold is determined and tracked in real time through the "frequency sweep" function. The generator will automatically change the appropriate power in real time according to different products, molds and pressures, with a response speed of less than 20ms. During the welding process, the buffering effect of the elastic reset component 605 prevents the plastic pipe end face from deforming due to excessive pressure, and the precise triggering of the proximity switch 7 ensures the consistency of welding time. Finally, the tensile strength of the welded joint reaches the tensile strength of the PE material itself, meeting the usage requirements.

[0054] The above description discloses only one preferred embodiment of the present invention, and should not be construed as limiting the scope of the present invention. Those skilled in the art will understand that all or part of the processes of the above embodiments can be implemented, and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A crank-type integrated welding machine, comprising a welding base (1), characterized in that: The welding base (1) is equipped with a quick-release workpiece fixing mechanism (2) and an integrated chassis (3). The integrated chassis (3) integrates an ultrasonic vibration execution integrated module (4) and a control unit (5). The vertical distance between the ultrasonic vibration execution integrated module (4) and the quick-release workpiece fixing mechanism (2) is adjusted by a crank drive mechanism (6) to save effort. The control unit (5) is responsible for controlling the opening and closing of welding and adjusting welding parameters.

2. The crank-type integrated welding mechanism according to claim 1, characterized in that: The integrated chassis (3) is divided into a welding execution area and an electrical installation area by a vertical plate (301). An ultrasonic vibration execution integrated module (4) and a crank drive mechanism (6) are integrated in the welding execution area. A control unit (5) and supporting electrical components are integrated in the electrical installation area.

3. The crank-type integrated welding mechanism according to claim 2, characterized in that: The crank drive mechanism (6) includes a vertical guide rail (601) on a vertical plate (301), on which a sliding mounting seat (602) for assembling an ultrasonic vibration actuation integrated module (4) is slidably constrained. The sliding mounting seat (602) is connected to an operating handle (604) via a crank connecting rod assembly (603), and the operating handle (604) is used to receive driving power.

4. The crank-type integrated welding mechanism according to claim 3, characterized in that: The sliding mounting base (602) is connected to the crank connecting rod assembly (603) via an elastic reset component (605), and the elastic reset component (603) is used to buffer the impact force during the welding process and realize automatic reset after welding.

5. The crank-type integrated welding mechanism according to claim 3 or 4, characterized in that: A proximity switch (7) is provided on the motion path of the ultrasonic vibration execution integrated module (4). The proximity switch (7) is used to detect the downward position of the ultrasonic vibration execution integrated module (4) and trigger the welding start.

6. The crank-type integrated welding mechanism according to claim 5, characterized in that: The proximity switch (7) includes a sensor mounted on a vertical plate (301) and an identification rod arranged corresponding to the sensor; the identification rod is mounted on the sliding mounting base (602) and can move along with the sliding mounting base (602).

7. The crank-type integrated welding mechanism according to any one of claims 2-4, characterized in that: The ultrasonic vibration execution integrated module (4) includes an integrated mechanism (401) that integrates a transducer and an amplitude transformer. The integrated mechanism (401) is electrically connected to the control unit (5), and a quick-detachable welding head (402) is connected to the output end of the integrated mechanism (401).

8. The crank-type integrated welding mechanism according to claim 7, characterized in that: The quick-release workpiece fixing mechanism (2) includes a workpiece fixing seat (201), which is detachably connected to the base through a quick-positioning pin hole and / or a positioning groove.

9. The crank-type integrated welding mechanism according to claim 1, 4, 6, or 8, characterized in that: The integrated chassis (3) has a control panel (8) embedded in its outer wall. The control panel (8) is electrically connected to the control unit (5) and is equipped with "Set", "Sweep", "Debug" buttons and adjustment buttons. "Settings" button: Used to enter the welding parameter configuration mode; "Frequency Sweep" button: used to trigger the frequency adaptation and adjustment of the ultrasonic vibration execution integrated module (4) to match the vibration response characteristics of the workpiece to be welded; "Debug" button: used to start the no-load operation test of the equipment to verify the effectiveness of the crank drive mechanism (6) and the ultrasonic vibration execution integrated module (4); Increase / decrease adjustment buttons: used to adjust the values ​​of welding parameters and sweep frequency.

10. A control method for a crank-type integrated welding machine based on any one of claims 1-9, characterized in that, Includes the following steps: S1: The workpiece fixing seat (201) adapted to the workpiece to be welded is detachably connected to the welding base (1) by the quick positioning pin hole and / or positioning groove of the quick-release workpiece fixing mechanism (2), and the quick-release welding head (402) at the output end of the ultrasonic vibration execution integrated module (4) is replaced. S2: Operate the control panel (8) on the outer wall of the integrated chassis (3), press the "Settings" button to enter the welding parameter configuration mode, and input or configure the welding parameters by adding or subtracting adjustment buttons; S3: Press the "Sweep Frequency" button on the control panel (8) to trigger the ultrasonic vibration execution integrated module (4) to perform frequency adaptation and debugging to match the vibration response characteristics of the workpiece to be welded; S4: Press the "Debug" button on the control panel (8) to start the no-load operation test of the equipment. After verifying the effectiveness of the crank drive mechanism (6) and the ultrasonic vibration execution integrated module (4), the debugging is completed and the device is reset. S5: The operating handle (604) of the crank drive mechanism (6) drives the sliding mounting seat (602) to move down along the vertical guide rail (601) through the crank connecting rod assembly (603), so that the ultrasonic vibration execution integrated module (4) moves closer to the workpiece to be welded; S6: When the identification rod on the sliding mounting base (602) moves to the detection position of the proximity switch (7), the proximity switch (7) is triggered and sends a signal to the control unit (5). The control unit (5) starts the ultrasonic vibration execution integrated module (4), so that the integrated transducer and the integrated mechanism (401) of the amplitude rod outputs vibration of the appropriate frequency and transmits it to the welding head (402). At the same time, the elastic reset component (605) buffers the impact force during the welding process. S7: After the welding time corresponding to the preset welding parameters is reached, the control unit (5) shuts down the ultrasonic vibration execution integrated module (4), and the elastic reset component (605) drives the sliding mounting base (602) and the ultrasonic vibration execution integrated module (4) to move up and reset along the vertical guide rail (601) to complete the welding.

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