Convex hull positioning welding die and process

Abstract

The invention relates to the technical field of welding processes, in particular to a convex hull positioning welding die and process, the convex hull positioning welding die comprises a stamping die and a copper bar sub-piece, a fixing hole is formed in the stamping die, a positioning block is connected to the outer side of the stamping die, and the copper bar sub-piece is arranged on the back face of the stamping die. The positioning convex hull is formed at a time through die stamping, multiple procedures in traditional machining are omitted, machining allowance does not need to be reserved for a sub-part, the production period is remarkably shortened, the machining efficiency is improved, the method is suitable for mass production, the technology is simplified, and the efficiency is improved; by the adoption of the mold forming mode, the consistency and the repeated precision of the sizes of the convex hulls can be effectively guaranteed, size fluctuation caused by manual operation or equipment errors is avoided, and therefore the overall quality and reliability of welding assembly are improved.

Description

Technical Field

[0001] This invention relates to the field of welding technology, specifically to a convex hull positioning welding mold and process. Background Technology

[0002] In power transmission and distribution systems, copper busbars are critical conductive components, and their structural performance and connection reliability directly affect the overall system's operating efficiency and safety. With the development of electrical equipment towards higher density and integration, the application of irregularly shaped copper busbar assemblies is becoming increasingly widespread. These assemblies are typically composed of multiple separately processed components assembled by welding. To ensure welding quality, each component must maintain accurate relative position during the welding process; otherwise, weld deviations, decreased conductivity, or even structural failure can easily occur.

[0003] Currently, common positioning methods are mainly divided into two categories: one is to use mechanical processing to create positioning protrusions on sub-components. Although this method has high precision, it has a long processing cycle and high cost, and is particularly inefficient in mass production. The other is to use special tooling fixtures for positioning. Although this improves assembly accuracy to some extent, the tooling design and manufacturing costs are high, and its versatility is poor, making it difficult to apply flexibly to products with different structures.

[0004] Under the existing technological framework, positioning processes still face many challenges, such as high process complexity, low processing efficiency, difficulty in cost control, and insufficient versatility. These problems not only restrict the improvement of production efficiency but also create bottlenecks in manufacturing flexibility. To address these issues, we propose a convex hull positioning welding mold and process. Summary of the Invention

[0005] The purpose of this invention is to provide a convex hull positioning welding mold and process to solve the problems mentioned in the background art, such as high process complexity, low processing efficiency, difficulty in cost control, and insufficient versatility, which limit the improvement of production efficiency.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a convex hull positioning welding mold and process, comprising a stamping mold and a copper busbar component, wherein a fixing hole is provided inside the stamping mold, a positioning block is connected to the outside of the stamping mold, and a copper busbar component is provided on the back of the stamping mold.

[0007] The convex hull positioning welding process, applied to the aforementioned convex hull positioning welding mold, is characterized by including the following steps: S1: Sub-component pretreatment: According to the design drawings, process two copper busbar sub-components to be welded to ensure that their external dimensions meet the design requirements; S2: Positioning hole machining: At the preset welding position of one of the sub-components, a process circular hole is machined. The diameter of the circular hole is consistent with the design diameter of the positioning protrusion, and the tolerance is controlled at +0.1 / 0 mm. S3: Stamping of convex bulge: At the corresponding position of another sub-part, a special stamping die is used to stamp and form a positioning convex bulge with a height of 1mm. The diameter of the convex bulge matches the aforementioned process round hole, and the tolerance is controlled at 0 / -0.1 mm. At the same time, a 1mm deep pit is formed on the back of the convex bulge. S4: Assembly and Welding: The stamped convex bulge is embedded into the process round hole to achieve the initial positioning of the two parts. Then, brazing filler is added to the joint area, and welding is carried out after alignment. S5: Post-processing: After welding, the positioning holes are enlarged according to the drawing requirements to achieve the final forming size.

[0008] Compared with the prior art, the beneficial effects of the present invention are: This invention uses a die to stamp a positioning protrusion in one step, eliminating multiple steps in traditional machining. Sub-parts do not require pre-reserved machining allowances, significantly shortening the production cycle and improving processing efficiency. It is more suitable for mass production, simplifying the process and improving efficiency.

[0009] This invention features consistent dimensions and controllable quality. By employing a mold forming method, it can effectively ensure the consistency and repeatability of the convex hull dimensions, avoiding dimensional fluctuations caused by human operation or equipment errors, thereby improving the overall quality and reliability of the welding assembly.

[0010] This invention is highly versatile and cost-effective. The same set of stamping dies can be used for a variety of products with different structures. Quick switching can be achieved with simple adjustments, which greatly reduces tooling investment and maintenance costs and enhances the flexibility and economy of the process.

[0011] The present invention has a reasonable structure and is easy to assemble. The matching structure of the convex bulge and the concave pit not only realizes the precise positioning of the sub-component, but also provides a natural space for the solder to be contained during the welding process, which is beneficial to the weld formation and strength improvement. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1 This is a schematic diagram of the stamping die of the present invention; Figure 2This is a schematic diagram of the stamping process of the copper busbar component of the present invention.

[0014] In the figure: 1. Stamping die; 101. Fixing hole; 102. Positioning block; 2. Copper busbar. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] Please see Figure 1-2 The present invention provides an embodiment of a convex hull positioning welding mold and process, including a stamping mold 1 and a copper busbar 2. The stamping mold 1 has a fixing hole 101 inside, a positioning block 102 connected to the outside of the stamping mold 1, and a copper busbar 2 on the back of the stamping mold 1. This device utilizes a die-stamping method to achieve efficient and precise forming of positioning protrusions. This innovation not only optimizes the process flow and significantly improves production efficiency but also substantially reduces manufacturing costs, while enhancing the versatility and adaptability of the process. Its superior performance and broad application potential provide the industry with a highly valuable solution, demonstrating a promising future for widespread application. It solves the problems of high process complexity, low processing efficiency, difficulty in cost control, and insufficient versatility, which have limited the improvement of production efficiency.

[0017] The convex hull positioning welding process, applied to convex hull positioning welding molds, includes the following steps: S1: Sub-component pretreatment: According to the design drawings, process two copper busbar sub-components 2 to be welded to ensure that their external dimensions meet the design requirements; S2: Positioning hole machining: At the preset welding position of one of the sub-components, a process circular hole is machined. The diameter of the circular hole is consistent with the design diameter of the positioning protrusion, and the tolerance is controlled at +0.1 / 0 mm. S3: Stamping of convex bulge: At the corresponding position of another sub-part, a special stamping die 1 is used to stamp and form a positioning convex bulge with a height of 1mm. The diameter of the convex bulge matches the aforementioned process hole, and the tolerance is controlled at 0 / -0.1 mm. At the same time, a 1mm deep pit is formed on the back of the convex bulge. S4: Assembly and Welding: The stamped convex bulge is embedded into the process round hole to achieve the initial positioning of the two parts. Then, brazing filler is added to the joint area, and welding is carried out after alignment. S5: Post-processing: After welding, the positioning holes are enlarged according to the drawing requirements to achieve the final forming size.

[0018] Working principle: First, according to the product drawings, two copper busbar components 2 to be welded are prepared to ensure that their outline dimensions and material properties meet the design standards.

[0019] Secondly, at the welding position of the first sub-component, a circular hole with a diameter of ΦD is machined using a drilling process. The specific size of the hole depends on the product specifications, and the tolerance is strictly controlled within the range of +0.1 / 0 mm.

[0020] Subsequently, stamping die 1 is installed and used for stamping at the corresponding position of the second sub-part. During the stamping process, the upper and lower dies of the die work together to stamp a convex bulge with a height of 1 mm and a diameter the same as the process hole on the surface of the sub-part, while forming a 1 mm deep recess on the back. The diameter tolerance of the convex bulge is controlled within 0 / -0.1 mm to ensure clearance fit with the process hole.

[0021] After completing the above processing, the convex hull is embedded into the process circular hole to achieve the initial positioning of the two sub-components. Then, silver-based brazing filler is filled into the joint interface, and the sub-components are aligned with the aid of tooling and slight pressure is applied to ensure that the sub-components are correctly aligned before brazing.

[0022] After welding, the original circular holes are enlarged according to the final product size requirements to achieve the forming dimensions specified in the drawings, thus completing the entire component processing flow. The above describes the entire working principle of this invention.

[0023] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A convex hull positioning welding mold, characterized in that: It includes a stamping die (1) and a copper busbar (2). The stamping die (1) has a fixing hole (101) inside, a positioning block (102) is connected to the outside of the stamping die (1), and a copper busbar (2) is provided on the back of the stamping die (1).

2. The convex hull positioning welding process, as described in claim 1, is characterized in that: Includes the following steps: S1: Sub-component pretreatment: According to the design drawings, process two copper busbar sub-components to be welded (2) respectively to ensure that their external dimensions meet the design requirements; S2: Positioning hole machining: At the preset welding position of one of the sub-components, a process circular hole is machined. The diameter of the circular hole is consistent with the design diameter of the positioning protrusion, and the tolerance is controlled at +0.1 / 0 mm. S3: Stamping of convex bulge: At the corresponding position of another sub-part, a special stamping die (1) is used to stamp and form a positioning convex bulge with a height of 1mm. The diameter of the convex bulge matches the aforementioned process round hole, and the tolerance is controlled at 0 / -0.1 mm. At the same time, a 1mm deep pit is formed on the back of the convex bulge. S4: Assembly and Welding: The stamped convex bulge is embedded into the process round hole to achieve the initial positioning of the two parts. Then, brazing filler is added to the joint area, and welding is carried out after alignment. S5: Post-processing: After welding, the positioning holes are enlarged according to the drawing requirements to achieve the final forming size.

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