Split type welding head assembly, welding device and welding method of welding device

Abstract

The split type welding head assembly comprises a coupling rod, a welding head arranged at the bottom of the coupling rod and a holding ring fixed to the coupling rod, the bottom of the coupling rod is matched with the top of the welding head in an inserted connection mode, and a ring groove is formed in the portion, exposed out of a mounting groove, of the welding head in the circumferential direction. The split type welding head assembly has a welding state and a secondary ultrasonic demolding state, when the split type welding head assembly is in the welding state, the welding head is in interference fit with the coupling rod, and when the split type welding head assembly is in the secondary ultrasonic demolding state, the welding head is separated from the coupling rod. The resisting part abuts against the welding head in the axial direction. According to the split type welding head assembly, non-stop continuous automatic production in the welding process is achieved, and the problem that the production efficiency is low due to the fact that the welding head adheres and falls off is thoroughly solved.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic welding technology, and in particular to a split welding head assembly, a welding device, and a welding method for the welding device. Background Technology

[0002] Currently, the ultrasonic welding head and coupling rod are connected by a conical interference fit. During ultrasonic welding of aluminum, the welding head and the aluminum material tend to stick together. Existing technology attempts to separate them by adding an ultrasonic welding cycle after the normal welding, causing relative displacement between the welding head and the aluminum material. However, the conical connection between the welding head and the coupling rod is prone to failure during the second welding cycle, causing the welding head to detach from the coupling rod. Reassembly of the welding head is required before the next welding cycle can proceed, severely impacting production efficiency.

[0003] While integrated welding heads do not have the above problems, they are more expensive and more troublesome to replace than separate ones.

[0004] In view of this, it is necessary to improve the existing welding joints to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a split welding head assembly to solve the problem that the welding head and coupling rod separate during secondary ultrasonic treatment after welding in existing split welding head assemblies, which affects production efficiency.

[0006] To achieve the above objectives, the present invention provides a split-type welding head assembly, which includes a coupling rod, a welding head disposed at the bottom of the coupling rod, and a retaining ring fixed on the coupling rod. The bottom of the coupling rod is inserted into the top of the welding head. The portion of the welding head exposed outside the mounting groove has a circumferential groove. The retaining ring has a stop portion that protrudes radially into the circumferential groove. The split-type welding head assembly has a welding state and a secondary ultrasonic demolding state. When the split-type welding head assembly is in the welding state, the welding head is interference-fitted with the coupling rod. When the split-type welding head assembly is in the secondary ultrasonic demolding state, the welding head is disengaged from the coupling rod, and the stop portion abuts against the welding head axially.

[0007] As a further improvement of the present invention, when the split welding head assembly is in the welding state, the blocking part is spaced apart from the welding head along the axial direction.

[0008] As a further improvement of the present invention, when the split welding head assembly is in the welding state, the gap between the blocking part and the welding head is 0.02-0.1mm.

[0009] As a further improvement of the present invention, the bottom of the coupling rod is provided with a mounting groove, the welding head is inserted into the mounting groove, the mounting groove is conical, and the top of the welding head is conical to match the mounting groove.

[0010] As a further improvement of the present invention, the coupling rod has a vibration node along the axial direction, and the retaining ring is detachably connected to the vibration node of the coupling rod.

[0011] As a further improvement of the present invention, the cross-section of the annular groove along the axial direction is a V-shape with the opening facing outwards, and the cross-section of the abutment part is a V-shape that matches the annular groove.

[0012] The present invention also provides a welding apparatus, the welding apparatus comprising the split welding head assembly as described above, and a bottom mold disposed below the split welding head assembly.

[0013] The present invention also provides a welding method for a welding apparatus, the welding method comprising the following steps: S1: Provide the welding device as described above, wherein the split welding head assembly is in a welding state and welding material is placed on the bottom mold; S2: Adhere welding material to the welding head and weld the material; S3: Perform secondary ultrasonic testing. The split welding head assembly is in the secondary ultrasonic demolding state. The welding head is separated from the coupling rod, and the blocking part abuts against the welding head along the axial direction. S4: Remove the welded material from the bottom mold and place new welded material on the bottom mold; S5: Use air pressure to press the welding head into the coupling rod multiple times with interference fit.

[0014] The present invention also provides a welding method for a welding apparatus, the welding method comprising the following steps: T1: Provide a welding device as described above, wherein the split welding head assembly is in a welding state and welding material is placed on the bottom mold; T2: Welding material is attached to the welding head, and the welding material is welded. The welding parameters are energy A, power B, and air pressure C. T3: Perform secondary ultrasonic testing. The split welding head assembly is in the secondary ultrasonic demolding state. The welding head is separated from the coupling rod, and the blocking part abuts against the welding head along the axial direction. T4: Remove the welded material from the bottom mold and place new welded material on the bottom mold; T5: Welding new welding materials. This welding process is divided into a first stage and a second stage according to time. The welding parameters of the first stage are energy A', power B', and air pressure C', where A' = 1.2-1.4A and B' = 1-1.2B.

[0015] As a further improvement of the present invention, the time of the first segment is (A'-A) / B.

[0016] The beneficial effects of the present invention are as follows: The split welding head assembly, welding device and welding method of the present invention, by setting a retaining ring and forming an axial limit with the annular groove of the welding head, successfully endows the split welding head with the reliability of automatic reset after the welding head falls off due to secondary ultrasonic impact, while retaining the advantages of low cost and easy replacement of the split welding head. This realizes continuous automated production without stopping the welding process and completely solves the problem of low production efficiency caused by welding head falling off. Attached Figure Description

[0017] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments of this application and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a three-dimensional structural schematic diagram of the welding device of the present invention; Figure 2 This is a cross-sectional structural schematic diagram of the welding device of the present invention; Figure 3 yes Figure 2 A magnified structural diagram of region A in the middle; Figure 4 This is a flowchart of the welding method of the welding apparatus according to Embodiment 1 of the present invention; Figure 5 This is a flowchart of the welding method of the welding apparatus according to Embodiment 2 of the present invention. Detailed Implementation

[0018] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0020] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Furthermore, the technical features involved in the different embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0021] like Figures 1 to 3 As shown, the split welding head assembly 1 of the present invention includes a coupling rod 11, a welding head 12 disposed at the bottom of the coupling rod 11, and a retaining ring 13 fixed on the coupling rod 11.

[0022] The bottom of the coupling rod 11 is inserted into the top of the welding head 12.

[0023] The portion of the welding head 12 exposed outside the mounting groove 111 has a circumferential groove 121.

[0024] The retaining ring 13 is provided with a stop portion 131 that protrudes radially into the annular groove 121. The retaining ring 13 is disposed outside the welding head 12 and the coupling rod 11. In this embodiment, the retaining ring 13 is made of a lightweight metal such as aluminum or a non-metallic material.

[0025] The split welding head assembly 1 has a welding state and a secondary ultrasonic demolding state. When the split welding head assembly 1 is in the welding state, the welding head 12 and the coupling rod 11 are interference-fitted. When the split welding head assembly 1 is in the secondary ultrasonic demolding state, if the welding head 12 is separated from the coupling rod 11, the blocking part 131 abuts against the welding head 12 along the axial direction.

[0026] The secondary ultrasonic demolding state refers to the process of adding an ultrasonic demolding after the first welding is completed, so that the welding head and the aluminum material being welded are separated by relative displacement.

[0027] This embodiment completely solves the problem of manual pickup and reinstallation required if the welding head 12 completely detaches after secondary ultrasonic treatment. The welding head 12 is limited by the retaining ring 13 and can be reset in the next work cycle without interrupting the production process for manual intervention, greatly improving equipment production efficiency.

[0028] In addition, the split welding head assembly 1 of this embodiment successfully introduces the anti-drop reliability that is only available in the integrated welding head 12 on the basis of low cost and easy replacement split structure. Users no longer need to bear the high cost and inconvenient replacement of the integrated welding head 12 for the sake of stability, and achieve a significant cost-performance advantage.

[0029] When the split welding head assembly 1 is in the welding state, the blocking part 131 is spaced apart from the welding head 12 along the axial direction. The axial spacing forms a physical isolation zone, ensuring that the welding head 12 vibrates at high frequency in a pure state without external interference during normal welding. All energy is transferred along the path of coupling rod 11, welding head 12, and workpiece, thereby ensuring the stability of welding energy and the repeatability of the process.

[0030] This embodiment eliminates continuous hard contact between the blocking part 131 and the welding head 12 by setting a gap, avoiding rapid wear and fatigue damage to the welding head 12 and the blocking part 131 themselves, avoiding harsh high-frequency noise caused by collision, improving the working environment, and avoiding metal debris generated by friction, which may contaminate the welding area or damage the equipment.

[0031] Furthermore, in this embodiment, when the split welding head assembly 1 is in the welding state, the gap between the blocking part 131 and the welding head 12 is 0.02-0.1mm, which includes a gap in the vertical direction and a gap in the horizontal direction. The normal amplitude of the welding head 12 is 0.005-0.02mm. In this embodiment, the gap is greater than the amplitude of the welding head 12, thereby preventing the welding head 12 from contacting the blocking part 131 during the welding process.

[0032] In this embodiment, a mounting groove 111 is provided at the bottom of the coupling rod 11, and the welding head 12 is inserted into the mounting groove 111. The mounting groove 111 is conical, and the top of the welding head 12 is conical to match the mounting groove 111. Driving the welding head 12 in the vertical direction will make the welding head 12 and the coupling rod 11 have an interference fit.

[0033] In other embodiments, a mounting groove may be provided on the top of the welding head 12, and the bottom of the coupling rod 11 may be inserted into the mounting groove.

[0034] The coupling rod 11 has a vibration node along its axial direction, and the retaining ring 13 is detachably connected to the vibration node of the coupling rod 11. The vibration node has almost no movement, making it the ideal location for installing the retaining ring 13. Installing the retaining ring 13 here provides reliable mechanical support for the falling welding head 12 without affecting the effective transmission of ultrasonic energy. The retaining ring 13 and the coupling rod 11 can be detachably fixed using screws, bolts, or other methods, facilitating the replacement of the welding head 12.

[0035] There are at least two methods for obtaining vibration nodes. One is theoretical calculation / simulation estimation, where the vibration of the coupling rod 11 can be considered as one-dimensional longitudinal wave propagation. The node position is directly related to the sound velocity of the material and the frequency of the ultrasonic wave. For a simple-shaped coupling rod 11, the node position can be theoretically calculated using the wave equation. For a complex-shaped coupling rod 11, modal analysis and harmonic response analysis are typically performed using specialized finite element analysis software. This allows the identification of the inherent vibration mode of the coupling rod 11 at a specific frequency, and directly visualizes the positions of antinodes and nodes, which are usually represented as a plane. Simulation can very accurately predict the axial and radial positions of the nodes, providing a theoretical basis for the design and installation of the retaining ring 13.

[0036] The second method is experimental measurement, which is the most direct and reliable method used to verify theoretical / simulation results, or when simulation conditions are not available. For example, using a non-contact laser vibrometer, the vibration amplitude distribution of the entire rod surface can be accurately measured by irradiating the surface of the coupling rod 11 with a laser, and a contour map can be generated. On the contour map, the area with zero or close to zero amplitude is the node location.

[0037] The annular groove 121 has an outward-opening V-shaped cross-section along its axial direction, and the abutment part 131 has a V-shaped cross-section that matches the annular groove 121. The V-shaped fit design serves an automatic correction function. When the welding head 12 detaches from the coupling rod 11 and falls, it is supported by the abutment part 131. This inclined surface guides the welding head 12 to automatically return to the center position, preventing it from shifting due to tilting, and preparing for subsequent automatic reset pressing.

[0038] The present invention also provides a welding device 100, including a split welding head assembly 1, a bottom mold disposed below the split welding head assembly 1, a counterweight 2 and a transducer 3, wherein the counterweight 2 is disposed at the top end of a coupling rod 11 and the transducer 3 is connected to the middle part of the coupling rod 11.

[0039] This embodiment provides two different welding methods, the main difference being the different ways of fixing the welding head 12 and the coupling rod 11, as detailed below: Example 1: like Figure 4 As shown, in this embodiment, the welding method of the welding apparatus 100 includes the following steps: S1: Welding device 100 is provided, the split welding head assembly 1 is in the welding state, and welding material is placed on the bottom mold; S2: Adhere the welding material to the welding head 12, press the welding head 12 against the welding material, and weld the welding material; S3: Perform secondary ultrasonic treatment. The split welding head assembly 1 is in the secondary ultrasonic demolding state. When the welding head 12 is separated from the coupling rod 11, the blocking part 131 abuts against the welding head 12 along the axial direction. S4: Remove the completed welding material and place new welding material on the bottom mold; S5: Use air pressure to press the welding head 12 into the coupling rod 11 through multiple presses.

[0040] In normal welding, the gas pressure is 20-65 psi, and in step S5, the gas pressure is 50-86 psi, and the number of presses is 2-5. In step S5, the welding head 12 can be press-fitted into the coupling rod 11. Then, steps S2-S5 can be repeated to complete multiple welding operations.

[0041] This embodiment successfully achieves continuous automated operation of the welding production line through a simple, reliable, and easily automated operating procedure, completely solving the downtime problem caused by welding head detachment. The reset method utilizes only the existing drive mechanism (cylinder) and control system of the equipment, and can be completed by a simple command of temporarily increasing the air pressure and pressing down multiple times. No complex dedicated reset mechanism is required, reducing system complexity and cost. The welding method in this embodiment combines the passive protection of the retaining ring 13 with the active recovery of high-pressure reset in the process flow, forming a complete solution. This allows the low-cost, split welding head 12 to be applied to production scenarios requiring high continuity, demonstrating significant industrial application value.

[0042] Example 2: like Figure 5 As shown, in this embodiment, the welding method of the welding apparatus 100 includes the following steps: T1: Welding device 100 is provided, the split welding head assembly 1 is in the welding state, and welding materials are placed on the bottom mold; T2: Welding material is attached to welding head 12. Welding head 12 is pressed against the welding material to weld the material. The welding parameters are energy A, power B, and air pressure C. T3: Perform secondary ultrasonic treatment. The split welding head assembly 1 is in the secondary ultrasonic demolding state. When the welding head 12 is separated from the coupling rod 11, the blocking part 131 abuts against the welding head 12 along the axial direction. T4: Remove the completed welding material and place new welding material on the bottom mold; T5: Welding new welding materials. This welding process is divided into a first stage and a second stage according to time. The welding parameters of the first stage are energy A', power B', and air pressure C', where A' = 1.2-1.4A and B' = 1-1.2B.

[0043] Furthermore, the time for the first part is (A'-A) / B.

[0044] This method, by optimizing control logic rather than adding mechanical steps, brings significant operational efficiency and system integration advantages. It integrates the reset function of welding head 12 into the initial stage of the next welding cycle, meaning that both "welding head 12 pressing in" and "material welding" are completed simultaneously within a single welding cycle. This method eliminates a separate reset step, simplifies the operation process, and theoretically can further shorten the production cycle time, achieving a faster cycle speed than the previous method and maximizing production efficiency.

[0045] Furthermore, this method sets precise enhancement parameters, namely A'=1.2-1.4A, B'=1-1.2B, and the crucial time calculation formula (A'-A) / B. This indicates that the system will release the excess energy (A'-A) beyond the energy required for normal welding at a specific power (B'), and the release time is exactly equal to the time required to complete this extra work. This allows the excess energy to be precisely used to generate the interference fit force between the welding head 12 and the coupling rod 11. Once the reset is complete, the system immediately switches to the normal welding mode, avoiding energy waste and ensuring the stability and controllability of the process.

[0046] The entire reset welding process is achieved solely through changes in software parameters, reducing frequent impacts on the actuators and the burden on the control system, thus improving the equipment's response speed and long-term operational reliability. All operations are integrated into a single, coherent welding command, resulting in simpler system logic and potentially lower failure rates. Furthermore, this controlled, transient parameter enhancement prevents over-welding or damage to the workpiece, while ensuring stable and consistent process parameters from the end of the current weld until the next weld, thereby guaranteeing a high degree of uniformity in the quality of all welded products.

[0047] The present invention relates to a split welding head assembly 1, a welding device 100, and a welding method thereof. By setting a retaining ring 13 and forming an axial limit with the annular groove 121 of the welding head 12, the split welding head 12 is given anti-detachment reliability against secondary ultrasonic impact while retaining its advantages of low cost and easy replacement. This enables continuous automated production without stopping the welding process and completely solves the problem of low production efficiency caused by the adhesion and detachment of the welding head 12. At the same time, the unique gap design and node fixing ensure the high efficiency and stability of ultrasonic energy transmission and the long service life of the components, achieving significant cost-effectiveness and industrial application value.

[0048] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0049] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A split welding head assembly, characterized by: The split welding head assembly comprises a coupling rod, a welding head arranged at the bottom of the coupling rod, and a clamping ring fixed on the coupling rod, the bottom of the coupling rod is inserted into the top of the welding head, the part of the welding head exposed outside the mounting groove is provided with a ring groove in the circumferential direction, the clamping ring is provided with a resisting portion protruding into the ring groove in the radial direction, the split welding head assembly has a welding state and a secondary ultrasonic demolding state, when the split welding head assembly is in the welding state, the welding head is in interference fit with the coupling rod, when the split welding head assembly is in the secondary ultrasonic demolding state, the welding head is separated from the coupling rod, and the resisting portion is in abutment with the welding head in the axial direction.

2. The split weld head assembly of claim 1, wherein: When the split welding head assembly is in the welding state, the resisting portion is arranged in the axial direction and spaced from the welding head.

3. The split weld head assembly of claim 2, wherein: When the split welding head assembly is in the welding state, the gap between the resisting portion and the welding head is 0.02-0.1 mm.

4. The split weld head assembly of claim 1, wherein: The bottom of the coupling rod is provided with a mounting groove, the welding head is inserted into the mounting groove, the mounting groove is tapered, and the top of the welding head is tapered and matched with the mounting groove.

5. The split weld head assembly of claim 1, wherein: The coupling rod has a vibration node in the axial direction, and the clamping ring is detachably connected to the vibration node of the coupling rod.

6. The split weld head assembly of claim 1, wherein: The cross section of the ring groove in the axial direction is V-shaped with an opening outward, and the cross section of the resisting portion is V-shaped and matched with the ring groove.

7. A welding device characterized by: The welding device comprises the split welding head assembly according to any one of claims 1-6, and a bottom die arranged below the split welding head assembly.

8. A welding method of a welding apparatus, characterized by: The welding method of the welding device comprises the following steps: S1: providing the welding device according to claim 7, the split welding head assembly is in the welding state, and welding materials are placed on the bottom die; S2: sticking welding materials on the welding head, waiting for the welding head to abut against the welding materials, and welding the welding materials; S3: performing secondary ultrasonic, the split welding head assembly is in the secondary ultrasonic demolding state, when the welding head is separated from the coupling rod, the resisting portion is in abutment with the welding head in the axial direction; S4: taking away the welding materials after welding, and placing new welding materials on the bottom die; S5: using air pressure to press the welding head into the coupling rod multiple times.

9. A welding method of a welding apparatus, characterized by: The welding method of the welding device comprises the following steps: T1: providing the welding device according to claim 7, the split welding head assembly is in the welding state, and welding materials are placed on the bottom die; T2: sticking welding materials on the welding head, waiting for the welding head to abut against the welding materials, and welding the welding materials, the welding parameters are energy A, power B, and air pressure C; T3: performing secondary ultrasonic, the split welding head assembly is in the secondary ultrasonic demolding state, when the welding head is separated from the coupling rod, the resisting portion is in abutment with the welding head in the axial direction; T4: taking away the welding materials after welding, and placing new welding materials on the bottom die; T5: welding the new welding materials, and dividing the current welding into a previous front section and a subsequent rear section according to time, wherein the welding parameters of the front section are energy A', power B', and air pressure C', wherein A'=1.2-1.4A, and B'=1-1.2B.

10. The welding method of a welding apparatus according to claim 9, characterized by: The time of the preceding paragraph is (A'-A) / B.

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