Torque converter welding protection tool and anti-splashing control method

Abstract

The invention discloses a torque converter welding protection tool and an anti-splashing control method, and belongs to the technical field of stud type hydraulic torque converter production. A shielding assembly; the bottom of the shielding assembly is connected with the top of the welding table, and a stud of the torque converter is connected into the shielding assembly in a sleeved mode. The shielding assembly comprises a first protection mechanism and a second protection mechanism. The first protection mechanism is connected with the top end face of the welding table. The second protection mechanism is embedded in the top end face of the first protection mechanism. The torque converter is connected with the top of the first protection mechanism, and a gap is reserved between the bottom of the torque converter and the top of the first protection mechanism. The shielding assembly composed of the wrapping type first protection mechanism and the blowing type second protection mechanism is arranged and matched with the adjustable rotating mechanism and the telescopic rod, so that welding spatter is effectively prevented from making contact with a stud thread of the torque converter, the thread is prevented from being burnt and damaged, and it is ensured that the torque converter meets the assembling and using requirements.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of stud hydraulic torque converter production, in particular to a torque converter welding protection tool and a splash control method. BACKGROUND

[0002] In the production and manufacturing process of the stud hydraulic torque converter, there is a key process, namely assembly welding. The existing welding process and supporting mode currently used in the industry do not have special protection measures for the connecting threads of this type of torque converter.

[0003] However, during actual welding operation, welding splashes are inevitable. These splashes will directly contact the connecting thread part of the stud hydraulic torque converter, which is extremely easy to cause the thread to be burned or damaged. Once the connecting thread is damaged, the entire stud hydraulic torque converter will not meet the assembly and use requirements. SUMMARY

[0004] On the one hand, in order to solve the problems of the prior art, the present application provides a torque converter welding protection tool, comprising: a welding table, which is a platform for welding operation of the torque converter; a shielding assembly for shielding the splashing welding slag during the welding process of the torque converter, thereby protecting the stud of the torque converter; the bottom of the shielding assembly is connected to the top of the welding table, and the stud of the torque converter is sleeved in the shielding assembly; the shielding assembly comprises a first protection mechanism and a second protection mechanism; the first protection mechanism is connected to the top end surface of the welding table; the second protection mechanism is embedded on the top end surface of the first protection mechanism; the torque converter is connected to the top of the first protection mechanism, and a space is left between the bottom of the torque converter and the top of the first protection mechanism; the first protection mechanism protects the stud of the torque converter by wrapping, and the second protection mechanism protects the stud of the torque converter by blowing.

[0005] Further, the first protection mechanism comprises a protection disc and a protection sleeve; the protection disc is hexagonal in shape, and a center hole is arranged at the center of the protection disc, the protection disc is sleeved on the center shaft at the center position of the welding table, and is connected by a fastener; a protection sleeve is arranged on each corner of the protection disc, and the top end surface of the protection sleeve is higher than the top end surface of the protection disc; a slot hole is arranged on the top end surface of the protection sleeve for accommodating the stud of the torque converter; The top end surface of the protection disc is provided with a groove, and the second protection mechanism is arranged in the groove. The bottom center rod sleeve of the torque converter is sleeved in the deep hole at the top of the center shaft of the welding table, and the stud at the top of the torque converter is sleeved in the slot hole on the protective sleeve.

[0006] Further, the second protection mechanism comprises a gas pipe and a gas nozzle. The gas pipe comprises a main gas pipe and a plurality of branch gas pipes. The main gas pipe is arranged around the center hole, and the main gas pipe is connected with the gas supply assembly through the gas inlet pipe. The branch gas pipes are arranged along the circumferential direction of the main gas pipe, and the branch gas pipes respectively extend along the angular direction of the protection disc. One end of the branch gas pipe is sealingly connected with the main gas pipe, and the other end of the branch gas pipe is arranged to be inclined to the corresponding angle of the protection disc. A plurality of gas nozzles are arranged on the branch gas pipe.

[0007] Further, the groove comprises an annular groove and an inclined groove. The annular groove is concentrically arranged with the center hole, and the diameter of the annular groove is greater than the diameter of the center hole. The inclined groove is inclined downward, the number of the inclined grooves is matched with the number of the angles of the protection disc, one end of the inclined groove is in communication with the annular groove, and the other end of the inclined groove extends toward the angle of the protection disc. The branch gas pipe is arranged to closely contact the bottom of the inclined groove, the shape of the main gas pipe is matched with the annular groove, and the main gas pipe is arranged in the annular groove.

[0008] Further, a plurality of sliding grooves are arranged on the top surface of the welding table, a mounting seat is arranged in the sliding groove, and an extension rod is arranged on the mounting seat. The extension rod is located between the adjacent two angles of the protection disc.

[0009] Further, the bottom of the welding table is connected with the base. The welding table and the base are connected through a rotating mechanism, and the rotating mechanism is used for adjusting the rotation angle of the welding table in the horizontal direction.

[0010] Further, the driving mechanism comprises a servo motor, a lead screw and a toothed disc. The upper end surface of the toothed disc is fixedly connected with the bottom end surface of the welding table, and the center point of the toothed disc and the center point of the welding table are on the same axis. The bottom end surface of the toothed disc is rotationally connected with the top end surface of the base. The bottom center of the welding table is fixedly connected with a connecting shaft, and the connecting shaft is rotationally connected with the base through the center of the toothed disc; The outer side of the toothed disc is provided with continuous teeth in the axial direction; The screw rod is located between the welding table and the base, and the screw rod is engaged with the toothed disc; The servo motor is located below the welding table and is connected with the top end surface of the base; One end of the screw rod is connected with the output end of the servo motor, and the other end of the screw rod is rotationally connected with a base plate, and the base plate is fixedly connected with the top end surface of the base.

[0011] In another aspect, the application provides a splash-proof control method, which realizes maximum protection of the stud by dynamically monitoring the welding process and adaptively adjusting the protection parameters, and the steps include: Real-time collection of splash particle characteristics, welding electrical parameters and stud surface temperature data through multi-dimensional sensors; Comparing the real-time data with the early warning threshold, dividing low, medium and high risk levels, and adjusting the airflow pressure of the gas supply assembly and the welding table angle of the rotating mechanism, maintaining the baseline parameters for low risk, increasing the airflow pressure by 1.2-1.5 times for medium risk and fine-tuning the angle; Further, the strengthened protection adjustment for high-risk state includes: The gas supply assembly increases the airflow pressure to 1.5-2.0 times of the baseline pressure, starts all the gas nozzle high-intensity directional blowing and shortens the jet interval; The rotating mechanism quickly adjusts the welding table angle with the maximum step length to avoid the stud area from the splash concentration path; The telescopic rod extends the preset stroke, lifts the bottom of the torque converter to form a gap between the stud and the protective sleeve slot hole, and enhances the airflow circulation effect.

[0012] Further, real-time collection of adjusted splash data and stud state, comparison with target protection threshold, and repetition of risk determination and adjustment steps if not reaching the target; After welding is completed, reset each execution component, and detect the stud surface state; Record parameter adjustment log to provide reference for subsequent similar torque converter welding.

[0013] The beneficial effects of the application are: The first protective mechanism is a wrapping type protective mechanism composed of a protective disc and a protective sleeve, the torque converter stud is accurately sleeved in the protective sleeve slot hole, the physical isolation protection of the stud is realized, the welding spatter is directly blocked from contacting the thread, and the thread is prevented from being burned; the second protective mechanism is a blowing type protective mechanism composed of a main gas pipe, a branch gas pipe and an inclined air nozzle, the annular groove and the inclined groove matched with the gas pipe are arranged, the airflow is accurately blown to the stud area, the welding slag splashed to the stud is blown away in time, and the stud is further protected; the servo motor driven screw rod and the gear disc rotating mechanism are arranged, the welding table angle can be flexibly adjusted, and the torque converter can be conveniently taken off from the welding table by the telescopic rod in the sliding groove. BRIEF DESCRIPTION OF DRAWINGS

[0014] Figure 1 A perspective structural schematic view of the welding tool provided by the present application is provided. Figure 2 A side structural schematic view of the welding tool provided by the present application is provided. Figure 3 A top view structural schematic view of the welding tool provided by the present application is provided. Figure 4 A shielding assembly structural schematic view of the welding tool provided by the present application is provided. Figure 5 A gas pipe connecting structural schematic view provided by the present application is provided.

[0015] Reference signs: In the figure: 1 is a welding table, 2 is a protective disc, 3 is a protective sleeve, 4 is a slot hole, 5 is a main gas pipe, 6 is a branch gas pipe, 7 is an air nozzle, 8 is an annular groove, 9 is an inclined groove, 10 is a sliding groove, 11 is a mounting seat, 12 is a telescopic rod, 13 is a base, 14 is a servo motor, 15 is a screw rod, 16 is a gear disc, and 17 is a gas supply pipe. DETAILED DESCRIPTION

[0016] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0017] Please refer to Figures 1-5 The present application provides a torque converter welding protective tool, which comprises: A welding table 1, which is a platform for welding operation of the torque converter; A shielding assembly, which is used for shielding the splashing welding slag during the welding process of the torque converter and protecting the stud of the torque converter. The bottom of the shielding assembly is connected to the top of the welding station 1, and the stud of the torque converter is sleeved inside the shielding assembly; The shielding assembly includes: a first protective mechanism and a second protective mechanism; The first protective mechanism is connected to the top end face of the welding table 1; The second protective mechanism is embedded in the top end face of the first protective mechanism; The torque converter is connected to the top of the first protective mechanism, and there is a gap between the bottom of the torque converter and the top of the first protective mechanism. The first protective mechanism protects the torque converter studs by wrapping them in place, while the second protective mechanism protects the torque converter studs by blowing air into them.

[0018] The welding table is a circular platform adapted to the shape of the studded hydraulic torque converter, providing a stable support surface for welding the torque converter assembly. The shielding assembly is a combined structure specifically designed to protect the torque converter studs, used to block spatter from all directions during welding, preventing spatter from contacting the torque converter studs and achieving precise protection of the stud threads. The bottom of the shielding assembly is detachably connected to the top of the welding table via bolts, and the torque converter studs are correspondingly fitted into the protected area of ​​the shielding assembly, achieving full-coverage protection for the studs. The shielding assembly includes a first protective mechanism and a second protective mechanism, which work together to form dual protection. The first protective mechanism is connected to... The top end face of the welding station is fixedly connected, with high connection strength, and can withstand vibration during the welding process; the second protective mechanism is embedded in the top end face of the first protective mechanism; the torque converter is positioned and connected to the top of the first protective mechanism through the bottom center rod, and a gap of 5-10mm is left between the bottom of the torque converter and the top of the first protective mechanism as a space for airflow; the first protective mechanism provides the first layer of protection for the stud of the torque converter by physically wrapping it, isolating most of the spattered welding slag; the second protective mechanism provides the second layer of protection for the stud of the torque converter by directional air blowing, blowing away the welding slag flying towards the stud.

[0019] Furthermore, the first protective mechanism includes: a protective disc 2 and a protective sleeve 3; The protective plate 2 is hexagonal in shape and has a central hole in the center. The protective plate 2 is sleeved on the central shaft at the center of the welding table 1 and connected by fasteners. The protective sleeve 3 is provided at each corner of the protective disk 2, and the top end face of the protective sleeve 3 is higher than the top end face of the protective disk 2. The top end face of the protective sleeve 3 is provided with a slot 4 for accommodating the stud of the torque converter; A groove is provided on the top end face of the protective disc 2, and the second protective mechanism is disposed in the groove; The bottom center rod of the torque converter is sleeved in the deep hole at the top of the center shaft of the welding station 1, and the stud at the top of the torque converter is sleeved in the slot 4 on the protective sleeve 3.

[0020] The protective disc is hexagonal in shape, precisely matching the hexagonal distribution of the torque converter studs. The shape of the protective disc is not specifically limited; it is adapted based on the distribution and number of torque converter studs. A circular center hole is provided in the center of the protective disc, through which it is fitted onto the central shaft at the center of the welding station and secured with a nut. A protective sleeve is vertically installed at each corner of the protective disc. These sleeves are made of high-temperature and wear-resistant material, with their top surfaces 5-8mm higher than the top surface of the protective disc, ensuring the studs are fully embedded in the protected area. The protective sleeve has a circular slot on its top end face that matches the shape and size of the torque converter stud. The inner wall of the slot is smooth to completely accommodate the torque converter stud. The protective disc has a groove on its top end face for installing a second protective mechanism. The depth of the groove matches the height of the second protective mechanism, which is fixedly installed in the groove to ensure that the top surface of the protective disc is flat. The bottom center rod of the torque converter is fitted into the deep hole at the top of the center shaft of the welding station through a clearance fit. Each stud on the top of the torque converter is fitted into a corresponding slot on the protective sleeve.

[0021] Furthermore, the second protective mechanism includes: an air supply pipe and an air nozzle 7; The gas supply pipe includes: a main gas pipe 5 and multiple branch gas pipes 6; The main air pipe 5 is arranged around the central hole, and the main air pipe 5 is connected to the air supply pipe 17 of the air supply assembly through the air inlet pipe. The air supply pipe passes through the center of the central axis of the welding table. One end of the air supply pipe is connected to the main air pipe, and the other end of the air supply pipe is rotatably and sealed to the air outlet of the air supply assembly. The air supply assembly is located directly below the central axis. The gas distribution pipe 6 is arranged along the circumferential direction of the main gas pipe 5, and the gas distribution pipe 6 extends along the angular direction of the protective disc 2 respectively; One end of the gas distribution pipe 6 is sealed to the main gas pipe 5, and the other end of the gas distribution pipe 6 is inclined to the corner of the corresponding protective plate 2. Multiple air nozzles 7 are spaced apart on the air distribution pipe 6.

[0022] The system comprises an air supply pipe and an air nozzle, which together form a directional airflow purging system to remove welding slag flying towards the studs within the protected area. The main air pipe has a ring structure, concentrically arranged around the central hole of the protective plate, and an air inlet pipe is connected to one side of the main air pipe. The air inlet pipe is sealed to an external air supply component (such as an air compressor) via a quick connector. The number of branch air pipes is the same as the number of corners of the protective plate (i.e., 6), evenly distributed along the circumference of the main air pipe, and the branch air pipes extend radially along the corners of the protective plate. One end of the branch air pipe is sealed to the main air pipe by welding or clamping, with no airflow leakage at the connection. The other end of the branch air pipe is inclined towards the corresponding corner of the protective plate at an angle of 15-30°.

[0023] Furthermore, the groove includes: an annular groove 8 and an inclined groove 9; The annular groove 8 is concentrically arranged with the central hole, and the diameter of the annular groove 8 is larger than the diameter of the central hole; The inclined groove 9 is inclined downward, and the number of inclined grooves 9 is adapted to the number of corners of the protective disk 2. One end of the inclined groove 9 is connected to the annular groove 8, and the other end of the inclined groove 9 extends toward the corner of the protective disk 2. The gas distribution pipe is positioned close to the bottom of the inclined groove 9, and the shape of the main gas pipe 5 is adapted to the annular groove 8. The main gas pipe 5 is positioned inside the annular groove 8.

[0024] The inclined groove is tilted downwards, with the tilt angle being the same as that of the air distribution pipe (15-30°). The air distribution pipe is positioned close to the bottom of the inclined groove, and the bottom of the groove is provided with positioning buckles or slots to fix the air distribution pipe and prevent displacement caused by airflow impact.

[0025] Furthermore, a plurality of sliding grooves 10 are provided on the top surface of the welding table 1, and a mounting base 11 is provided in the sliding groove 10, and a telescopic rod 12 is provided on the mounting base 11; The telescopic rod 12 is located between two adjacent corners of the protective disc 2.

[0026] The welding table has multiple grooves evenly arranged along the circumference on its top surface, with 3-6 grooves to match the number of corners of the protective plate. The grooves are T-shaped or dovetail grooves. An adjustable mounting seat is slidably installed in the groove, and the mounting seat is fixed in position by locking bolts, which facilitates flexible adjustment according to the size of the torque converter. A telescopic rod is vertically installed on the mounting seat. The telescopic rod is hydraulic or electric and its extension stroke is adjustable. It is used to push the torque converter out of the protective sleeve after welding. The end of the telescopic rod is equipped with an anti-slip rubber pad with anti-slip texture to avoid damaging the torque converter housing.

[0027] Furthermore, the bottom of the welding station 1 is connected to the base 13; The welding table 1 and the base 13 are connected by a rotating mechanism, which is used to adjust the rotation angle of the welding table 1 in the horizontal direction.

[0028] The bottom of the welding table is detachably connected to the base by bolts; the welding table and the base are connected by a rotating mechanism, which is a high-precision transmission structure used to adjust the rotation angle of the welding table in the horizontal plane to meet the welding requirements of different positions; the connection of the rotating mechanism is equipped with bearings and sealing rings.

[0029] Furthermore, the drive mechanism includes: a servo motor 14, a lead screw 15, and a gear 16; The upper end face of the gear disk 16 is fixedly connected to the bottom end face of the welding table 1, and the center point of the gear disk 16 and the center point of the welding table 1 are on the same axis. The bottom end face of the toothed disc 16 is rotatably connected to the top end face of the base; A connecting shaft is fixedly connected to the center of the bottom of the welding table 1, and the connecting shaft passes through the center of the gear plate 16 and is rotatably connected to the base 13. The outer side of the toothed disc 16 is provided with continuous teeth along the axial direction. The lead screw 15 has a helical thread on its surface that meshes with the teeth. The lead screw 15 is located between the welding table 1 and the base 13, and the lead screw 15 meshes with the gear disc 16. The servo motor 14 is located below the welding table 1 and is connected to the top end face of the base 13; One end of the lead screw 15 is connected to the output end of the servo motor 14, and the other end of the lead screw 15 is rotatably connected to the base plate. The base plate is fixedly connected to the top end face of the base 13.

[0030] The gear disk is a ring gear structure, with its upper end face fixedly connected to the bottom end face of the welding platform by bolts. The center point of the gear disk and the center point of the welding platform are on the same axis to ensure no eccentricity during rotation. The bottom end face of the gear disk is rotatably connected to the top end face of the base through a thrust bearing. A connecting shaft is fixedly connected to the bottom center of the welding platform by welding or keying. The connecting shaft passes through the center of the gear disk and is rotatably connected to the base through a deep groove ball bearing. The lead screw has a helical thread on its surface that precisely meshes with the teeth of the gear. The lead screw is horizontally positioned between the welding platform and the base, meshing with the gear disk to form a transmission pair. The servo motor is located below the welding platform and is fixedly connected to the top end face of the base through a motor mount. One end of the lead screw is fixedly connected to the output end of the servo motor through a coupling, and the other end of the lead screw is rotatably connected to the base plate through a bearing. The base plate is fixedly connected to the top end face of the base by bolts. The base plate is a thickened steel plate structure.

[0031] In addition, this application provides a spatter prevention control method, which achieves maximum stud protection by dynamically monitoring the welding process and adaptively adjusting protection parameters. The steps include: Multi-dimensional data acquisition and preprocessing: A monitoring network consisting of a spatter particle sensor, a welding electrical parameter monitoring module, a stud surface temperature sensor, and an environmental sensor is set up. The spatter particle sensor uses a high-speed vision acquisition unit and an infrared detection component to work together to capture the particle size distribution (0.1-5mm), flight speed (0.5-10m / s), and trajectory direction of spatter particles in real time, with a sampling frequency of no less than 100Hz. The welding electrical parameter monitoring module simultaneously acquires welding current (50-500A), voltage (10-40V), welding speed (5-50mm / s), and arc stability parameters. The stud surface temperature sensor uses a combination of a contact thermocouple and a non-contact infrared thermometer to accurately acquire temperature data (room temperature - 800℃) of key areas of the stud thread (crest, flank, root), with a temperature measurement error ≤ ±5℃. The environmental sensor assists in acquiring air pressure (95-105kPa) and humidity (30%-70%RH) data of the welding area to correct the protection parameter calculation model. After noise interference is removed from the collected multi-source data by filtering algorithms, the data is transmitted to the central control unit for data fusion processing.

[0032] Intelligent risk level determination: The central control unit has a built-in machine learning-based risk assessment model. This model is trained and optimized using historical data from over 1000 different welding conditions, and compares the pre-processed real-time data with preset warning thresholds from multiple dimensions. Warning thresholds are stored according to welding materials (steel, aluminum, alloys, etc.), stud specifications, and welding processes.

[0033] The risk level classification criteria are as follows: Low risk: Spatter particle size ≤1mm, velocity ≤2m / s, welding electrical parameter fluctuation range ≤±5%, stud surface temperature ≤300℃, and no abnormal data for 3 consecutive sampling cycles; Medium risk: Spatter particle size 1-3mm, velocity 2-5m / s, welding electrical parameter fluctuation range 5%-10%, stud surface temperature 300-500℃, or abnormal data in 3-5 sampling cycles; High risk: Spatter particle size ≥3mm, velocity ≥5m / s, welding electrical parameter fluctuation ≥10%, stud surface temperature ≥500℃, or abnormal data in more than 5 consecutive sampling cycles.

[0034] Graded protection parameters adaptive adjustment: Based on the risk level assessment, the central control unit sends precise control commands to the air supply components and rotating mechanism. Low-risk condition: Maintain baseline protection parameters, including maintaining the air supply component airflow pressure at 0.3-0.5MPa, the air nozzle spray interval at 200ms, and locking the current angle of the welding table with the rotating mechanism to ensure stable welding process; Medium-risk status: Automatically increase the airflow pressure to 1.2-1.5 times the reference pressure (0.36-0.75MPa), adjust the nozzle spray interval to 150ms, and enhance the airflow purging force; the rotating mechanism finely adjusts the welding table angle at a speed of 5° / s (adjustment range ±5°), and disperses the impact area of ​​spatter particles by changing the relative position of the stud and the welding arc; at the same time, the welding electrical parameters are adjusted in real time (such as reducing the welding current by 5%-10%) to suppress the amount of spatter particles generated.

[0035] Enhanced protective measures for high-risk situations include: Enhanced airflow protection: The air supply component activates the boost mode, rapidly increasing the airflow pressure to 1.5-2.0 times the reference pressure (0.45-1.0MPa). Simultaneously, the nozzle operating mode is switched to high-frequency pulse injection, shortening the injection interval to 50-100ms. The nozzle injection direction is finely adjusted in real time by a servo motor, focusing the airflow according to the trajectory data of splashed particles to form an "air curtain" protective wall for the stud area. At the same time, the backup air path is opened, adding 2-4 emergency nozzles to focus on blowing the key stress parts of the stud threads, ensuring that splashed particles cannot adhere.

[0036] Rapid adjustment of welding table angle: After receiving a high-risk signal, the rotation mechanism immediately adjusts the welding table angle with the maximum step size (10° / step) and the highest speed (15° / s), with an adjustment range of ±15°. At the same time, the operating device of the welding torch rotates synchronously with the welding head at the same angle. The central control unit predicts the concentrated path of spatter in advance based on the spatter particle trajectory prediction algorithm, and drives the welding table to drive the torque converter to quickly avoid the high-risk area. During the angle adjustment process, the precise meshing control between the gear plate and the lead screw ensures that the rotation error of the welding table is ≤±0.5°, avoiding the impact of sudden angle changes on the welding quality.

[0037] Stud protection clearance optimization: The central control unit sends an extension command to the telescopic rod, which lifts the bottom of the torque converter at a uniform speed according to the preset stroke (3-8mm), so that a uniform gap (1-3mm) is formed between the stud and the protective sleeve slot. This gap ensures that the airflow can flow smoothly and completely discharge the tiny splashing particles remaining in the slot, while avoiding direct friction between the stud and the inner wall of the slot, which would cause thread damage. At the same time, the airflow channel formed by the gap and the air nozzle injection direction have a synergistic effect, further improving the protection effect.

[0038] Emergency cooling assistance: When the surface temperature of the stud exceeds 600℃, the cooling assistance system is automatically activated. Cooling gas (temperature 5-15℃) is introduced through the micro cooling channel built into the protective sleeve to indirectly cool the stud, control the surface temperature of the stud to not exceed 550℃, and prevent the performance of the thread material from deteriorating due to high temperature.

[0039] After the protection parameters are adjusted, multi-dimensional sensors continuously collect the characteristics of spatter particles, the surface condition of the stud, and welding quality parameters, with the collection cycle shortened to 50ms / time. The central control unit compares the adjusted data with the target protection threshold in real time. If the target threshold is not reached, the risk level determination process is re-triggered, and the protection parameters are iteratively adjusted according to the new monitoring data until the protection requirements are met. The number of iterative adjustments does not exceed 3 times to avoid excessive adjustment affecting welding efficiency.

[0040] Post-welding reset and inspection: After the welding process is completed, the central control unit controls the reset of each actuator in a preset sequence: the telescopic rod retracts to its initial position at a uniform speed, the welding table rotates to its initial angle, the air pressure of the air supply component returns to the reference value, and the cooling auxiliary system is shut down; then the automated inspection process is started, and the thread surface of each stud is scanned 360° by a high-definition vision inspection module to identify defects such as spatter residue, burns, and deformation; at the same time, a thread gauge is used to perform a go / no-go test to verify whether the thread size accuracy meets the requirements; the inspection data automatically generates an inspection report, and if a non-conforming stud is found, the system automatically marks it and triggers an alarm.

[0041] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A torque converter welding shield tool, comprising: include: A welding table is a platform used for welding torque converters. The shielding assembly is used to shield the spatter from welding slag during the torque converter welding process, thereby protecting the torque converter studs. The bottom of the shielding assembly is connected to the top of the welding station, and the stud of the torque converter is sleeved inside the shielding assembly; The shielding assembly includes: a first protective mechanism and a second protective mechanism; The first protective mechanism is connected to the top end face of the welding table; The second protective mechanism is embedded in the top end face of the first protective mechanism; The torque converter is connected to the top of the first protective mechanism, and there is a gap between the bottom of the torque converter and the top of the first protective mechanism. The first protective mechanism protects the torque converter studs by wrapping them in place, while the second protective mechanism protects the torque converter studs by blowing air into them.

2. The variator weld shield tooling of claim 1, wherein, The first protective mechanism includes: a protective disc and a protective sleeve; The protective plate is hexagonal in shape and has a central hole in the center. The protective plate is sleeved on the central shaft at the center of the welding station and connected by fasteners. The protective sleeve is provided at each corner of the protective disk, and the top end face of the protective sleeve is higher than the top end face of the protective disk. The top end face of the protective sleeve is provided with a slot for accommodating the stud of the torque converter; A groove is provided on the top end face of the protective disc, and the second protective mechanism is disposed in the groove; The bottom center rod of the torque converter is sleeved in the deep hole at the top of the center shaft of the welding station, and the stud at the top of the torque converter is correspondingly sleeved in the slot on the protective sleeve.

3. The variator weld shield tooling of claim 2, wherein, The second protective mechanism includes: an air supply pipe and an air nozzle; The gas supply pipe includes: a main gas pipe and multiple branch gas pipes; The main air pipe is arranged around the central hole, and the main air pipe is connected to the air supply assembly through an air inlet pipe; The gas distribution pipe is arranged along the circumferential direction of the main gas pipe, and the gas distribution pipes extend along the angular direction of the protective disc respectively; One end of the gas distribution pipe is sealed to the main gas pipe, and the other end of the gas distribution pipe is inclined to the corner of the corresponding protective plate. Each of the gas distribution pipes is provided with multiple air nozzles at intervals.

4. The variator weld shield tooling of claim 3, wherein, The groove includes: an annular groove and an inclined groove; The annular groove is concentrically arranged with the central hole, and the diameter of the annular groove is larger than the diameter of the central hole; The inclined groove is inclined downwards, the number of inclined grooves is adapted to the number of corners of the protective plate, one end of the inclined groove is connected to the annular groove, and the other end of the inclined groove extends toward the corner of the protective plate. The gas distribution pipe is positioned close to the bottom of the inclined groove, and the shape of the main gas pipe is adapted to the annular groove, with the main gas pipe positioned inside the annular groove.

5. The variator weld shield tooling of claim 1, wherein, The top surface of the welding table is provided with multiple sliding grooves, and a mounting base is provided in the sliding grooves. A telescopic rod is provided on the mounting base. The telescopic rod is located between two adjacent corners of the protective disc.

6. The variator weld shield tooling of claim 1, wherein, The bottom of the welding station is connected to the base; The welding table and the base are connected by a rotating mechanism, which is used to adjust the rotation angle of the welding table in the horizontal direction.

7. The variator weld shield tooling of claim 6, wherein, The driving mechanism comprises a servo motor, a screw rod and a toothed disc; The upper end surface of the toothed disc is fixedly connected with the bottom end surface of the welding table, and the center point of the toothed disc is on the same axis as the center point of the welding table; The bottom end surface of the toothed disc is rotationally connected with the top end surface of the base; The bottom center position of the welding table is fixedly connected with a connecting shaft, and the connecting shaft is rotationally connected with the base through the center position of the toothed disc; The outer side of the toothed disc is provided with continuous teeth in the axial direction; The surface of the screw rod is provided with inclined threads engaged with the teeth, the screw rod is located between the welding table and the base, and the screw rod is engaged with the toothed disc; The servo motor is located below the welding table and is connected with the top end surface of the base; One end of the screw rod is connected with the output end of the servo motor, and the other end of the screw rod is rotationally connected with a base plate, and the base plate is fixedly connected with the top end surface of the base.

8. A method of splash control, characterized in that The method is applied to the variable torque device welding protection tooling according to any one of the preceding items, and the method realizes maximum protection of the stud by dynamically monitoring the welding process and adaptively adjusting the protection parameters, and the steps include: Real-time acquisition of splash particle characteristics, welding electrical parameters and stud surface temperature data by multi-dimensional sensors; Comparing the real-time data with the early warning threshold, dividing low, medium and high risk levels, and adjusting the airflow pressure of the gas supply assembly and the welding table angle of the rotating mechanism, maintaining the reference parameters for low risk, and increasing the airflow pressure by 1.2-1.5 times and slightly adjusting the angle for medium risk.

9. The splash control method according to claim 7, characterized by, The reinforcement protection adjustment for high risk state includes: The gas supply assembly increases the airflow pressure to 1.5-2.0 times of the reference pressure, starts all gas nozzle high-intensity directional blowing and shortens the jet interval; The rotating mechanism quickly adjusts the welding table angle with the maximum step length to avoid the stud area from the splash concentration path; The telescopic rod extends the preset stroke, lifts the variable torque device bottom to form a gap between the stud and the protective sleeve slot hole, and enhances the airflow circulation effect.

10. The splash control method according to claim 7, characterized by, Real-time acquisition of adjusted splash data and stud state, comparison with target protection threshold, and repetition of risk determination and adjustment steps if the target is not reached; After the welding is completed, reset each execution component, and detect the stud surface state; Record parameter adjustment log to provide reference basis for subsequent similar variable torque device welding.

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