Welding device and process for processing bus bar of vehicle-mounted film capacitor

Abstract

The invention discloses a welding device and process for machining a bus bar of a vehicle-mounted thin film capacitor, and relates to the technical field of intelligent welding. A clamping cavity is formed in a clamp formed by splicing two clamping blocks, and a cylindrical air bag capable of being inflated and expanded is installed at the end position of a bidirectional hydraulic push rod; when laser welding is carried out, the clamp carries out circumferential wrapping and limiting on busbar spare and accessory parts from the outside, the cylindrical air bag carries out uniform flexible supporting on the busbar spare and accessory parts from the inside, a cooperative clamping structure with the outer side limiting and the inner supporting can be formed, the busbar is evenly stressed in the whole clamping process, and the clamping effect is good. Predeformation caused by local over-tightness and welding dislocation caused by local over-looseness can be avoided, and the welding accuracy in the busbar machining process can be effectively improved.

Description

Technical Field

[0001] This invention relates to the field of intelligent welding technology, and in particular to a welding device and process for processing busbars of vehicle-mounted thin-film capacitors. Background Technology

[0002] In the production of new energy vehicles, the on-board film capacitor is the core energy storage component of new energy vehicles. The reliability of its busbar connection directly determines the stability of the vehicle's power system. In the existing technology, the busbar is mostly made of copper plate with high conductivity, which has relatively strict requirements for welding precision.

[0003] When using laser welding to process busbars, the copper plate material itself has low rigidity, and the existing laser welding fixtures mostly use single-point or planar clamping to clamp and position the busbar components. This leads to uneven distribution of clamping force during the busbar welding process, resulting in some areas being clamped too loosely, causing welding displacement, while other areas are clamped too tightly, causing pre-deformation. Furthermore, the local high temperature during laser welding causes the copper plate to expand due to heat. Under uneven clamping constraints, the free release path of thermal deformation will be disrupted, further aggravating deformation problems such as warping and wrinkling after the busbar is laser welded.

[0004] To address these issues, a welding device and process for processing busbars of vehicle-mounted thin-film capacitors are proposed. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies where uneven clamping force distribution can affect welding quality when using laser welding to process busbars. Therefore, this invention proposes a welding device and process for processing busbars of vehicle-mounted thin-film capacitors.

[0006] To address the problems existing in the prior art, the present invention adopts the following technical solution: A welding apparatus and process for processing busbars of vehicle-mounted thin-film capacitors includes a machine base with a welding area above it and a laser welding head above the welding area. A clamping mechanism is provided within the welding area, and the clamping mechanism includes a base with a groove inside. A clamp is placed within the groove, and the clamp is composed of two clamping blocks joined together. A clamping cavity is formed at the center of the clamp between the two clamping blocks for placing busbar components. A first through groove is formed on each clamping block, communicating with the clamping cavity. The splicing seams are aligned, and the two ends of the platform are provided with through holes corresponding to the clamping cavity. A cover plate covering the fixture is placed on the top of the platform, and a second through groove communicating with the first through groove is provided on the cover plate. An inner support mechanism is provided on the outside of the welding area, and the inner support mechanism includes a bidirectional hydraulic push rod. A cylindrical air bladder is fixedly installed on one end of the bidirectional hydraulic push rod and sleeved on the outside of its piston rod. The inner wall of the cylindrical air bladder is fixedly connected to the piston rod end of the bidirectional hydraulic push rod. A first air pipe is fixedly installed on the cylindrical air bladder and an air pump is connected to the outside of the first air pipe.

[0007] Preferably, a protective cover is fixedly installed on the top of the machine, and an XYZ robotic arm is fixedly installed at the upper position inside the protective cover. The laser welding head is fixedly installed on the XYZ robotic arm, the welding area is set inside the protective cover, and an electric slide rail located outside the protective cover is fixedly installed on the machine, extending into the welding area. The base is fixedly installed on the sliding end of the electric slide rail.

[0008] Preferably, a galvanometer mechanism is fixedly installed on the laser welding head. The galvanometer mechanism drives the laser emitted from the laser welding head to oscillate back and forth at high frequency along the splice seam on the busbar component, and the power of the laser emitted from the laser welding head is intermittently adjusted.

[0009] Preferably, the groove has a U-shaped cross-section, the fixture has a cylindrical outer structure, and the fixture is rotatably mounted in the groove.

[0010] Preferably, the inner support mechanism is provided with two bidirectional hydraulic push rods, which are symmetrically arranged on both sides of the welding area. A pressure sensor located on the outer end wall of the cylindrical airbag is fixedly installed on the end of the piston rod of one of the bidirectional hydraulic push rods near the welding area.

[0011] Preferably, a second air tube is fixedly installed on the cylindrical airbag, and the second air tube is connected to an external air pump.

[0012] Preferably, the piston rod of the bidirectional hydraulic push rod has an airflow channel running through it, and a third air pipe connected to the airflow channel is installed inside the cylindrical air bladder. The other end of the third air pipe is connected to the outer end wall of the cylindrical air bladder. A fourth air pipe is rotatably connected to the end of the piston rod away from the welding area inside the bidirectional hydraulic push rod, and the fourth air pipe is connected to an external air pump.

[0013] Preferably, a rotating mechanism is provided on the outer side of the bidirectional hydraulic push rod, and the rotating mechanism includes a bearing fixedly mounted on the machine base, the bidirectional hydraulic push rod is rotatably mounted in the bearing, a gear ring is fixedly mounted on the bidirectional hydraulic push rod, a servo motor is fixedly mounted on the machine base, and a gear meshing with the gear ring is fixedly mounted on the drive shaft of the servo motor.

[0014] Preferably, a limiting mechanism is provided below the pedestal, and the limiting mechanism includes a column tube fixedly connected to the bottom of the pedestal, a vertically arranged pin is slidably inserted into the column tube, a spring for elastic support of the pin is fixedly installed on the column tube, a magnet is fixedly installed at the bottom end of the pin, a slot corresponding to the pin is opened on the clamping block, and an electromagnet corresponding to the magnet is fixedly installed in the welding area.

[0015] Preferably, a process for processing busbars of vehicle-mounted thin-film capacitors is provided. The process is applicable to welding equipment used for processing busbars of vehicle-mounted thin-film capacitors, and includes the following steps: Assembly and welding; S1. Assemble multiple busbar components together according to product design requirements, and align the splicing seams; S2. Place the assembled busbar components into the clamping cavity of the welding device, and use the clamping mechanism to clamp and restrict the external parts of the busbar components. S3. The clamping mechanism is fed into the welding area via an electric slide rail; S4. The cylindrical airbag is sent into the busbar component inside the clamping cavity by the bidirectional hydraulic push rod. After inflation, it provides uniform support to the inside of the busbar component. S5. Use the XYZ robotic arm to control the laser welding head to move along the splice seam and perform laser welding on one side of the splice seam of the busbar components. S6. After the single-sided splice seam is welded, the bidirectional hydraulic push rod is driven by the servo motor to rotate the cylindrical airbag and switch the welding surface of the busbar components. S7. Repeat the process in S5-S6. After completing all welding, release the cylindrical airbag and retract it. Send the clamping mechanism back to the initial position via the electric slide rail, open the cover plate, and take out the welded busbar.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. In this invention, by forming a clamping cavity in a fixture composed of two clamping blocks and installing an inflatable cylindrical airbag at the end of a bidirectional hydraulic push rod, the cylindrical airbag can be inserted into the clamping cavity. During laser welding, the fixture externally encloses and restricts the busbar components, while the cylindrical airbag provides uniform and flexible support from within the busbar components. This forms a synergistic clamping structure of external restriction and internal support, ensuring uniform force distribution on the busbar throughout the clamping process. This helps avoid pre-deformation caused by excessive tightness in certain areas and welding misalignment caused by excessive looseness in certain areas, effectively improving the welding accuracy during busbar processing. 2. In this invention, by connecting the first air pipe and the second air pipe to the cylindrical airbag, and connecting the first air pipe and the second air pipe to external air pumps respectively, under the control of inflation and deflation, while ensuring the inflation and expansion of the cylindrical airbag, the internal airflow can be flexibly controlled according to the needs, and the airflow circulation can be guided. This is beneficial to accelerate the heat dissipation inside the busbar, reduce residual thermal stress, and to a certain extent reduce the probability of deformation such as warping and wrinkling after the busbar is welded. 3. In this invention, by setting the clamp to a cylindrical structure, the clamp can rotate within the groove. With the help of a servo motor driving the bidirectional hydraulic push rod to rotate, the entire unit holding the busbar components can be precisely rotated. By rotating, the splicing seams in different directions are sequentially adjusted to be directly below the laser welding head for welding processing. There is no need to reassemble and reposition, which can greatly improve the welding efficiency of multi-faceted and multi-seam busbars and improve production efficiency to a certain extent. Attached Figure Description

[0017] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings: Figure 1 This is a perspective view of the welding apparatus of the present invention; Figure 2 For the present invention Figure 1 Front sectional view of the middle structure; Figure 3 For the present invention Figure 2 Enlarged view of point A in the middle; Figure 4 This is a perspective view of the two welding areas and two electric slide rails of the present invention; Figure 5 This is a top view of the welding area of ​​the present invention in conjunction with the electric slide rail; Figure 6 For the present invention Figure 5 Sectional view at point BB; Figure 7 For the present invention Figure 5 Sectional view at CC; Figure 8 For the present invention Figure 7 Enlarged view of point D in the middle; Figure 9 This is a three-dimensional view of the cylindrical airbag of the present invention after inflation; Figure 10 This is an exploded view of the clamping mechanism of the present invention; Figure 11 This is an exploded view of the cylindrical tube and the pin of the present invention; Figure 12 This is a flowchart of the processing technology of the present invention; Figure 13 This is a flowchart illustrating the use of the welding apparatus of the present invention.

[0018] In the picture: 1. Machine base; 11. Protective cover; 12. XYZ robotic arm; 13. Laser welding head; 14. Galvanometer mechanism; 15. Electric slide rail; 2. Base; 21. Groove; 22. Clamping block; 23. Clamping cavity; 24. First through groove; 25. Through hole; 26. Cover plate; 27. Second through groove; 3. Two-way hydraulic push rod; 31. Cylindrical airbag; 32. First air tube; 33. Second air tube; 34. Airflow channel; 35. Third air tube; 36. Fourth air tube; 4. Shaft seat; 41. Gear ring; 42. Servo motor; 43. Gear; 5. Column; 51. Pin; 52. Spring; 53. Magnet; 54. Slot; 55. Electromagnet. Detailed Implementation

[0019] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0020] Example: This example provides a welding device for processing busbars of vehicle-mounted thin-film capacitors. See [link to example]. Figure 1 - Figure 11 Specifically, the machine includes a machine base 1, a protective cover 11 fixedly installed on the top of the machine base 1, and an XYZ robotic arm 12 fixedly installed inside the upper part of the protective cover 11. A welding area is set on the machine base 1 and is located inside the protective cover 11. A laser welding head 13 is set above the welding area and is fixedly installed on the XYZ robotic arm 12. An electric slide rail 15 located outside the protective cover 11 is fixedly installed on the machine base 1 and extends into the welding area.

[0021] A clamping mechanism is provided in the welding area, and the clamping mechanism includes a base 2, which is fixedly installed on the sliding end of the electric slide rail 15. A groove 21 is provided in the base 2, and a clamp is placed in the groove 21. The clamp is composed of two clamping blocks 22. A clamping cavity 23 is formed at the center of the clamp between the two clamping blocks 22. The clamping cavity 23 is used to place busbar parts. A first through groove 24 is provided on the clamping block 22, which communicates with the clamping cavity 23. The first through groove 24 is aligned with the splice seam on the busbar parts. Through holes 25 are provided at both ends of the base 2, which communicate with the clamping cavity 23. A cover plate 26 is placed on the top of the base 2, which covers the clamp. A second through groove 27 is provided on the cover plate 26, which communicates with the first through groove 24.

[0022] An inner support mechanism is provided on the outside of the welding area, and the inner support mechanism includes a bidirectional hydraulic push rod 3. A cylindrical air bag 31 is fixedly installed on one end of the bidirectional hydraulic push rod 3 and sleeved on the outside of its piston rod. The inner wall of the cylindrical air bag 31 is fixedly connected to the piston rod end of the bidirectional hydraulic push rod 3. A first air pipe 32 is fixedly installed on the cylindrical air bag 31 and an air pump is connected to the first air pipe 32.

[0023] When using this device, the assembled and welded busbar components are first placed into the clamping cavity 23, ensuring that the splicing seam on the busbar components is precisely aligned with the first through groove 24 on the clamping block 22. Then, the assembled clamping block 22 is placed into the groove 21, and the two clamping blocks 22 are assembled to form a clamp to restrict the external of the busbar components. After the cover plate 26 is closed, the first through groove 24 on the upper clamping block 22 is precisely aligned with the second through groove 27 on the cover plate 26, and the cover plate 26 is securely connected to the base 2, so that the clamp can form a stable circumferential covering of the busbar components from the outside.

[0024] Subsequently, the workpiece-carrying platform 2 is fed into the welding area inside the protective cover 11 via the electric slide rail 15. The laser welding head 13 is positioned above the splice seam by the XYZ robotic arm 12. During this process, the bidirectional hydraulic push rod 3 on the outside of the welding area is energized and activated. Through the extension of the piston rod of the bidirectional hydraulic push rod 3, the cylindrical air bag 31, which is in a retracted state and installed at the end of the bidirectional hydraulic push rod 3, is inserted into the busbar component in the clamping mechanism through the through hole 25. It is inflated through the first air pipe 32 to provide uniform flexible support from the inside. Together with the external clamp, they form a positioning and clamping state with external restriction and internal support.

[0025] Then, the XYZ robotic arm 12 drives the laser welding head 13 to move along the splice seam for precise laser welding. After welding, the cylindrical airbag 31 is evacuated and contracted. Then, the cylindrical airbag 31 is removed from the clamping mechanism by the retraction action of the piston rod of the bidirectional hydraulic push rod 3. The clamping mechanism containing the welded busbar is sent back to its initial position by the reverse conveying of the electric slide rail 15, making it convenient for the staff to pick up the material for subsequent processing.

[0026] In the specific implementation process, such as Figure 1 - Figure 2 and Figure 4 As shown, there are two welding zones, two bases, two clamping mechanisms, and two internal support mechanisms. The two welding zones are located on the left and right sides inside the protective cover 11, respectively. The two welding zones share a single laser welding head 13. The two welding zones are used alternately. When the device is in use, the two welding zones and their associated clamping and support mechanisms operate alternately under the scheduling of two electric slide rails 15. When the busbar in one welding zone is being laser welded, the other welding zone can simultaneously perform the preceding clamping or the subsequent disassembly operation. In this operating mode, the core welding time overlaps with the auxiliary loading and unloading time, which facilitates the realization of a near-continuous production cycle and can effectively improve the utilization rate of the laser welding head 13, thereby improving the production efficiency of the device in the welding process of the busbar to a certain extent.

[0027] In the specific implementation process, such as Figure 2 As shown, a galvanometer mechanism 14 is fixedly installed on the laser welding head 13. The galvanometer mechanism 14 drives the laser emitted from the laser welding head 13 to oscillate back and forth at high frequency along the splice seam on the busbar component. The power of the laser emitted from the laser welding head 13 is intermittently adjusted. When the device is in use, the galvanometer mechanism 14 can drive the laser beam to oscillate back and forth at high frequency and small amplitude perpendicular to the welding direction. This reciprocating small amplitude oscillation can effectively expand the laser's effective area, thereby effectively improving the absorption of laser energy by the copper material, promoting the flow of the molten pool and the escape of gas, which is conducive to obtaining a weld with better shape and fewer defects.

[0028] Meanwhile, the power of the laser beam is intermittently raised and lowered during the swinging process. This allows for the use of a lower power laser beam for preheating at the beginning of the welding process and a higher power laser beam for welding during the return swing. This combination of methods prevents the busbar components from suddenly heating up to the welding temperature during laser welding, resulting in a stepped increase in welding temperature. This effectively reduces the probability of local deformation of copper busbar components due to instantaneous high heat input during welding.

[0029] In the specific implementation process, such as Figure 6 - Figure 7 and Figure 9 - Figure 10As shown, the cross-section of the groove 21 is set as a U-shaped structure, and the outside of the clamp is set as a cylindrical structure. The clamp is rotatably installed in the groove 21. A rotating mechanism is provided on the outside of the bidirectional hydraulic push rod 3, and the rotating mechanism includes a bearing 4 fixedly installed on the machine base 1. The bidirectional hydraulic push rod 3 is rotatably installed in the bearing 4. A gear ring 41 is fixedly installed on the bidirectional hydraulic push rod 3. A servo motor 42 is fixedly installed on the machine base 1, and a gear 43 that meshes with the gear ring 41 is fixedly installed on the drive shaft of the servo motor 42.

[0030] When in use, the device uses a cylindrical structure for the clamp, allowing it to rotate within the groove 21. The central axis of the clamp and the bidirectional hydraulic push rod 3 are on the same straight line. When welding seams in different directions on the busbar components is required, the servo motor 42 is powered on and started, ensuring that the cylindrical airbag 31 is tightly supported inside the busbar components. With the meshing of the gear 43 and the gear ring 41, the bidirectional hydraulic push rod 3 can be rotated. The friction between the cylindrical airbag 31 and the inner wall of the busbar components allows the busbar components and the clamp wrapped around them to rotate synchronously, thus adjusting the orientation of the seams in different directions on the busbar components.

[0031] The above-mentioned structural design allows the busbar components to be precisely rotated after a single clamping, adjusting the weld seams in each direction to the ideal welding position below the laser welding head 13. This eliminates the need for repeated disassembly and assembly of the fixture to manually adjust the orientation of the joints, effectively improving the efficiency of laser welding and ensuring the integrity and consistency of the multi-faceted busbar after welding, thus further enhancing the precision of the welding process.

[0032] In the specific implementation process, such as Figure 4 and Figure 7 As shown, the internal support mechanism is equipped with two bidirectional hydraulic push rods 3, which are symmetrically arranged on both sides of the welding area. A pressure sensor located on the outer wall of the cylindrical airbag 31 is fixedly installed on the end of the piston rod of one of the bidirectional hydraulic push rods 3 near the welding area. When the device is in use, by symmetrically arranging the two bidirectional hydraulic push rods 3 on both sides of the welding area, when the cylindrical airbags 31 on both sides are sent into the busbar component in the clamping mechanism, the piston rods of the two bidirectional hydraulic push rods 3 can be driven to extend synchronously towards the center. By monitoring the contact force in real time through the pressure sensor installed at the end of the piston rod, it can be determined whether the two cylindrical airbags 31 meet and dock at the center position inside the busbar component. Through the synchronous extension and retraction of the two bidirectional hydraulic push rods 3, the efficiency of the cylindrical airbags 31 entering and exiting the busbar component in the clamping mechanism can be effectively improved, thereby helping to improve the overall welding production efficiency.

[0033] Meanwhile, during the process of inflating the cylindrical airbag 31 to form internal support, the pressure reading of the pressure sensor can be used to determine the support force of the internal support mechanism on the busbar components, so as to flexibly adjust the support effect inside the busbar components according to the actual needs during welding.

[0034] In the specific implementation process, such as Figure 3 and Figure 7 As shown, a second air pipe 33 is fixedly installed on the cylindrical airbag 31, and an air pump is connected to the second air pipe 33. When the device is in use, the air pump connected to the first air pipe 32 can inflate the airbag by injecting dry inert gas into the cylindrical airbag 31 through the first air pipe 32, causing it to expand and fit against the inner wall of the busbar component. The air pump connected to the second air pipe 33 can evacuate the airbag. When the cylindrical airbag 31 needs to enter or exit the workpiece, it can be quickly evacuated through the second air pipe 33 to contract it, thus ensuring the smooth entry and exit of the cylindrical airbag 31.

[0035] During the welding process, the airflow in the first air pipe 32 and the second air pipe 33 can be flexibly adjusted by the linkage control of the two air pumps. While ensuring the internal pressure of the cylindrical air bag 31 is supported, dynamic flow control can not only compensate for the thermal expansion generated during the welding of the busbar components, but also guide the gas circulation inside the cylindrical air bag 31 after welding, which is conducive to accelerating the uniform cooling of the busbar after welding.

[0036] In the specific implementation process, such as Figure 3 , Figure 6 - Figure 7 and Figure 9 As shown, an airflow channel 34 is provided through the piston rod of the bidirectional hydraulic push rod 3. A third air pipe 35 connected to the airflow channel 34 is installed inside the cylindrical airbag 31, and the other end of the third air pipe 35 is connected to the outer end wall of the cylindrical airbag 31. A fourth air pipe 36 is rotatably connected to the end of the piston rod away from the welding area inside the bidirectional hydraulic push rod 3, and the fourth air pipe 36 is connected to an air pump. When the device is in use, the fourth air pipe 36 is connected to the third air pipe 35 at the outer end of the cylindrical airbag 31 through the airflow channel 34 inside the piston rod. When the cylindrical airbag 31 is inflated to form uniform support for the internal parts of the busbar components, the third air pipe 35 can be used for air extraction. The negative pressure adsorption formed by air extraction allows the internal parts of the busbar components to be tightly connected to the outer surface of the cylindrical airbag 31. This not only ensures the stability of the internal support, but also ensures the precise stability of the device's rotation adjustment of the busbar components driven by the rotation of the cylindrical airbag 31.

[0037] Furthermore, during the operation of the device, as the cylindrical airbag 31 contracts and exits from the inside of the busbar component by being driven by air extraction, forced convection can be formed in the cavity inside the busbar component by the airflow in the third air pipe 35. This achieves direct cooling of the high-temperature area inside the busbar component, which can effectively reduce the peak temperature and cooling rate of the welding heat-affected zone and reduce the impact of thermal stress on the busbar to a certain extent.

[0038] In the specific implementation process, such as Figure 3 and Figure 5 As shown, a limiting mechanism is provided below the base 2, and the limiting mechanism includes a column 5 fixedly connected to the bottom of the base 2. A vertically arranged pin 51 is slidably inserted into the column 5. A spring 52 for elastic support of the pin 51 is fixedly installed on the column 5. A magnet 53 is fixedly installed at the bottom end of the pin 51. A slot 54 corresponding to the pin 51 is opened on the clamping block 22. An electromagnet 55 corresponding to the magnet 53 is fixedly installed in the welding area. When the device is in use, during the stage of installing the busbar parts inside the fixture and transporting the clamping mechanism through the electric slide rail 15, the pin 51 is pushed upward under the elastic force of the spring 52 on the column 5, and its lower end naturally inserts into the corresponding slot 54 on the clamping block 22, thereby rotating and locking the fixture and the base 2. This helps to prevent the fixture from accidentally deflecting due to vibration or inertia during the transport process, and effectively ensures the accuracy of the initial positioning angle of the workpiece.

[0039] After the internal support of the busbar components is completed using the cylindrical airbag 31, the electromagnet 55 is controlled to be electrically actuated. With the magnetic attraction generated by the electromagnet 55, the magnet 53 at the bottom of the pin 51 is driven to move downward, so that the elastic support of the spring 52 is overcome. The magnet 53 pulls the pin 51 downward, so that the upper end of the pin 51 is disengaged from the slot 54, thereby releasing the rotation lock of the clamp. After that, the servo motor 42 can drive the bidirectional hydraulic push rod 3 to rotate, thereby driving the busbar components to make precise angle changes and realize flexible switching of the welding surface.

[0040] In the specific implementation process, such as Figure 12 and Figure 13 As shown, a processing technology for the busbar of an automotive thin-film capacitor is provided. The processing technology is applicable to a welding device for processing the busbar of an automotive thin-film capacitor, and the processing technology includes the following steps: Step 1: Material preparation; After the high conductivity copper plate coil is unwound and leveled, it is cut into copper strips of the required length and width according to the design dimensions using a cutting machine.

[0041] Step 2: Stamping and forming; On a stamping press, dies are used to punch, stretch, and fold copper strips to form a blank of a busbar component with specific connection terminals.

[0042] Step 3: Deburr; The edges and corners, as well as the perimeter of holes, of the stamped busbar parts blanks are polished using a grinding machine to remove burrs and sharp edges.

[0043] Step 4: Bending; The busbar component blank is three-dimensionally bent using a bending machine to form a busbar component with a three-dimensional frame structure.

[0044] Step 5: Assembly and Welding; S1. Assemble multiple busbar components together according to product design requirements, and align the splicing seams; S2. Place the assembled busbar components into the clamping cavity 23 of the welding device, and use the clamping mechanism to clamp and restrict the external parts of the busbar components. S3. The clamping mechanism is fed into the welding area via the electric slide rail 15; S4. The cylindrical airbag 31 is sent into the busbar component inside the clamping cavity 23 by the bidirectional hydraulic push rod 3. After inflation, it provides uniform support to the inside of the busbar component. S5. Use the XYZ robotic arm 12 to control the laser welding head 13 to move along the splice seam and perform laser welding on one side of the splice seam of the busbar components. S6. After the single-sided splice seam is welded, the bidirectional hydraulic push rod 3 is driven by the servo motor 42 to rotate the cylindrical airbag 31 and switch the welding surface of the busbar parts. S7. Repeat the process in S5-S6. After completing all welding, release the cylindrical airbag 31 and retract it. Send the clamping mechanism back to the initial position via the electric slide rail 15, open the cover plate 26, and take out the busbar that has been welded into a whole.

[0045] Step Six: Post-treatment and Insulation; The welded busbars are cleaned and inspected, and insulating paper is then attached to the busbars using 3M adhesive.

[0046] Step 7: Packaging and warehousing; The finished busbars are packaged in dust-proof and moisture-proof packaging, then boxed and stored in the warehouse.

[0047] Specifically, the working principle of this invention is as follows: The busbar components are rigidly positioned and circumferentially wrapped by a fixture consisting of two clamping blocks 22. At the same time, a cylindrical airbag 31 is inserted into the workpiece by a bidirectional hydraulic push rod 3 and inflated to provide uniform internal support. Then, the XYZ robotic arm 12 controls the laser welding head 13 to move and perform laser welding on the splice. When it is necessary to weld splices in different directions, the servo motor 42 is powered on and started, driving the bidirectional hydraulic push rod 3 and the cylindrical airbag 31 to rotate. This causes the busbar components, along with the fixture, to rotate precisely in the groove 21 in the base 2, adjusting the orientation of the splice and achieving multi-sided welding in a single clamping.

[0048] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A welding device for processing busbars of vehicle-mounted thin-film capacitors, comprising a machine base (1), characterized in that: The machine base (1) is provided with a welding area, and a laser welding head (13) is provided above the welding area. A clamping mechanism is provided in the welding area, and the clamping mechanism includes a base (2). A groove (21) is provided in the base (2), and a clamp is placed in the groove (21). The clamp is composed of two clamping blocks (22) assembled together. A clamping cavity (23) is provided between the two clamping blocks (22). The clamping cavity (23) is used to place busbar parts. A first through groove (24) is provided on the clamping block (22), and the first through groove (24) is aligned with the splice seam on the busbar parts. The base (2) has through holes (25) at both ends. The top of the base (2) is covered with a cover plate (26), and the cover plate (26) has a second through groove (27) that communicates with the first through groove (24). An inner support mechanism is provided on the outside of the welding area, and the inner support mechanism includes a bidirectional hydraulic push rod (3). A cylindrical air bag (31) is fixedly installed on one end of the bidirectional hydraulic push rod (3), and the inner wall of the cylindrical air bag (31) is fixedly connected to the piston rod end of the bidirectional hydraulic push rod (3). A first air pipe (32) is fixedly installed on the cylindrical air bag (31), and the first air pipe (32) is connected to an external air pump.

2. The welding device for processing busbars of vehicle-mounted thin-film capacitors according to claim 1, characterized in that: A protective cover (11) is fixedly installed on the top of the machine base (1), and an XYZ robotic arm (12) is fixedly installed in the upper part of the protective cover (11). The laser welding head (13) is fixedly installed on the XYZ robotic arm (12). The welding area is set inside the protective cover (11). An electric slide rail (15) located outside the protective cover (11) is fixedly installed on the machine base (1), and the electric slide rail (15) extends into the welding area. The platform (2) is fixedly installed on the sliding end of the electric slide rail (15).

3. The welding device for processing busbars of vehicle-mounted thin-film capacitors according to claim 2, characterized in that: A galvanometer mechanism (14) is fixedly installed on the laser welding head (13). The galvanometer mechanism (14) drives the laser emitted from the laser welding head (13) to oscillate back and forth at high frequency along the splice seam on the busbar parts. The power of the laser emitted from the laser welding head (13) is intermittently adjusted.

4. The welding device for processing busbars of vehicle-mounted thin-film capacitors according to claim 1, characterized in that: The cross-section of the groove (21) is set as a U-shaped structure, the outside of the clamp is set as a cylindrical structure, and the clamp is rotatably installed in the groove (21).

5. The welding device for processing busbars of vehicle-mounted thin-film capacitors according to claim 1, characterized in that: The inner support mechanism is provided with two bidirectional hydraulic push rods (3). The two bidirectional hydraulic push rods (3) are symmetrically arranged on both sides of the welding area. A pressure sensor located on the outer wall of the cylindrical airbag (31) is fixedly installed on the end of the piston rod of one of the bidirectional hydraulic push rods (3) near the welding area.

6. The welding device for processing busbars of vehicle-mounted thin-film capacitors according to claim 1, characterized in that: A second air tube (33) is fixedly installed on the cylindrical airbag (31), and the second air tube (33) is connected to an external air pump.

7. The welding device for processing busbars of vehicle-mounted thin-film capacitors according to claim 1, characterized in that: An airflow channel (34) is provided through the piston rod of the bidirectional hydraulic push rod (3). A third air pipe (35) connected to the airflow channel (34) is installed inside the cylindrical airbag (31), and the other end of the third air pipe (35) is connected to the outer end wall of the cylindrical airbag (31). A fourth air pipe (36) is rotatably connected to the end of the piston rod away from the welding area inside the bidirectional hydraulic push rod (3), and the fourth air pipe (36) is connected to an external air pump.

8. The welding device for processing busbars of vehicle-mounted thin-film capacitors according to claim 4, characterized in that: A rotating mechanism is provided on the outside of the bidirectional hydraulic push rod (3), and the rotating mechanism includes a bearing seat (4) fixedly installed on the machine base (1). The bidirectional hydraulic push rod (3) is rotatably installed in the bearing seat (4). A gear ring (41) is fixedly installed on the bidirectional hydraulic push rod (3). A servo motor (42) is fixedly installed on the machine base (1), and a gear (43) meshing with the gear ring (41) is fixedly installed on the drive shaft of the servo motor (42).

9. The welding device for processing busbars of vehicle-mounted thin-film capacitors according to claim 8, characterized in that: A limiting mechanism is provided below the pedestal (2), and the limiting mechanism includes a column (5) fixedly connected to the bottom of the pedestal (2). A vertically arranged pin (51) is slidably inserted into the column (5). A spring (52) for elastic support of the pin (51) is fixedly installed on the column (5). A magnet (53) is fixedly installed at the bottom end of the pin (51). A slot (54) corresponding to the pin (51) is opened on the clamping block (22). An electromagnet (55) corresponding to the magnet (53) is fixedly installed in the welding area.

10. A process for processing busbars of vehicle-mounted thin-film capacitors, characterized in that: The processing technology is applicable to the welding apparatus for processing busbars of vehicle-mounted thin-film capacitors as described in any one of claims 1-9, and the processing technology includes the following steps: Assembly and welding; S1. Assemble multiple busbar components together according to product design requirements, and align the splicing seams; S2. Place the assembled busbar parts into the clamping cavity (23) of the welding device and use the clamping mechanism to clamp and restrict the external parts of the busbar parts. S3. The clamping mechanism is fed into the welding area via the electric slide rail (15); S4. The cylindrical airbag (31) is sent into the busbar component inside the clamping cavity (23) by the bidirectional hydraulic push rod (3). After inflation, it provides uniform support to the inside of the busbar component. S5. Using the XYZ robotic arm (12), the laser welding head (13) is moved along the splice seam to perform laser welding on one side of the busbar component splice seam. S6. After the single-sided splice seam is welded, the bidirectional hydraulic push rod (3) is driven by the servo motor (42) to rotate the cylindrical airbag (31) and switch the welding surface of the busbar parts. S7. Repeat the process in S5-S6. After completing all welding, release the cylindrical airbag (31) and retract it. Send the clamping mechanism back to the initial position through the electric slide rail (15), open the cover plate (26), and take out the busbar that has been welded into a whole.

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