Double-push type high-power ultrasonic welding system for wire harness welding

Abstract

The invention discloses a double-push type high-power ultrasonic welding system for wire harness welding, and belongs to the technical field of ultrasonic welding, the double-push type high-power ultrasonic welding system comprises a welding mechanism for welding a wire harness on a workpiece, and the welding mechanism is provided with a wire feeding mechanism for feeding the wire harness and a feeding mechanism for feeding the workpiece. According to the self-adaptive clamping device, flexible self-adaptive clamping of a workpiece is achieved through cooperation of a chute push block driven by an inner piezoelectric cylinder in the clamping module and a lower guide column, the surface of the workpiece can be effectively protected against damage through cooperation of the chute push block and a soft clamping block, meanwhile, a lower piezoelectric cylinder is used for driving a lower pressing slope block, a lower pressing base is driven to ascend and descend through cooperation of the slope surface, and the clamping effect is good. Precise adjustment of the welding height position of a workpiece is achieved, the supporting electric cylinder drives the lower fixing block to support the bottom of the soft clamping block after adjustment is completed, clamping rigidity and stability in the welding process are guaranteed, the device can adapt to tiny deviation of workpieces of different sizes, it can be guaranteed that the workpieces do not move in the welding process, and the welding precision and the yield are improved.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic welding technology, and in particular to a double-push high-power ultrasonic welding system for wire harness welding and its control method. Background Technology

[0002] Ultrasonic metal welding technology utilizes the principle of high-frequency vibration and friction to generate heat, enabling a strong connection between the same or different metals. It is particularly suitable for connecting workpieces such as wire harnesses and terminals, and has advantages such as fast welding speed, good conductivity, and no need to add solder. It has been widely used in automotive wire harnesses, electronic components and other fields.

[0003] With the rapid development of new energy vehicles, aerospace, and high-end manufacturing industries, higher demands are being placed on the quality, efficiency, and automation of wire harness welding. However, existing wire harness welding equipment still has some shortcomings in practical applications. On the one hand, traditional single-push ultrasonic welding machines often suffer from insufficient welding strength or poor welding consistency due to uneven energy distribution when welding large-section wire harnesses or multi-strand wire harnesses. On the other hand, in automated welding processes, the positioning, clamping, and adjustment mechanisms for workpieces are often complex or lack precision, making it difficult to achieve accurate and stable adjustment of the workpiece in multiple directions. Especially when there are slight differences in workpiece dimensions, it is difficult to balance the flexibility of adjustment with the stability of support, which can easily affect the welding quality.

[0004] Furthermore, in existing equipment, the connection between the wire harness conveying and cutting processes and the workpiece feeding and unloading processes is not tight and smooth enough. For example, after cutting the wire harness, how to stably move the welded finished product from the welding station and smoothly transfer it to the next station requires improvement in the coordination of the existing mechanism. At the same time, the wire harness is prone to bending or deviating during long-distance conveying. The lack of effective guidance and precise conveying control results in insufficient positioning accuracy when the wire harness end reaches the welding position, affecting the welding accuracy and yield. Summary of the Invention

[0005] To address the aforementioned technical problems, this invention discloses a wire harness welding system with a more rational structure, more precise control, and a higher degree of automation. The technical solution adopted by this invention is: a double-push high-power ultrasonic welding system for wire harness welding, including a welding mechanism for welding the wire harness onto a workpiece. The welding mechanism includes a main frame, and is provided with a wire feeding mechanism for feeding the wire harness and a material feeding mechanism for feeding the workpiece.

[0006] Furthermore, the welding mechanism includes a protective shell fixedly installed on the main frame, a double-push ultrasonic welding machine is installed inside the protective shell, an electric cylinder for driving the double-push ultrasonic welding machine to rise and fall is installed inside the protective shell, a placement platform is fixedly installed on the main frame, two wire clamping blocks are slidably installed on the placement platform, an electric cylinder for driving the wire clamping blocks to slide is installed inside the placement platform, and a clamping module for clamping the workpiece to be welded and a cutting module for cutting the wire harness are installed on the main frame.

[0007] Furthermore, the clamping module includes a fixed clamping platform fixedly installed on the main frame. Two lower fixed sleeves are fixedly installed on the fixed clamping platform. A lower pressure electric cylinder is fixedly installed on the lower fixed sleeve. A lower pressure ramp is fixedly installed on the output end of the lower pressure electric cylinder. A slope is provided on the lower surface of the lower pressure ramp. A lower pressure seat is slidably installed on the fixed clamping platform. A slope is provided inside the lower pressure seat. The slope of the lower pressure seat contacts the slope below the lower pressure ramp. A spring is provided between the lower pressure seat and the fixed clamping platform.

[0008] Furthermore, the clamping module also includes an internal pressure electric cylinder fixedly installed on the lower pressure seat. A slanted push block is fixedly installed on the output end of the internal pressure electric cylinder. A slanted push block is provided with a slanted groove. A clamping block is slidably installed on the lower pressure seat. A lower guide post is fixedly installed below the clamping block. The lower guide post slides in the slanted groove. A soft clamping block is fixedly installed on the inner side of the clamping block. A support electric cylinder is fixedly installed on the fixed clamping platform. A lower fixing block is fixedly installed on the output end of the support electric cylinder. A spring is provided between the clamping block and the lower pressure seat.

[0009] Furthermore, the cutting module includes a lifting electric cylinder fixedly installed on the main frame, a lifting plate fixedly installed on the output end of the lifting electric cylinder, a fixed upright plate fixedly installed on the lifting plate, two tangent cutters rotatably installed on the fixed upright plate, a tangent electric cylinder fixedly installed on the lifting plate, a lifting end block fixedly installed on the output end of the tangent electric cylinder, and two tangent rotating rods rotatably installed on the lifting end block, the two tangent rotating rods being rotatably installed with the two tangent cutters respectively.

[0010] In use, when the workpiece reaches between the two soft clamping blocks, the internal pressure electric cylinder extends, causing the inclined groove pusher block to slide within the lower pressure seat. As the inclined groove pusher block slides, it drives the lower guide post, clamping block, and soft clamping block to move inward along the lower pressure seat through the inclined groove. The spring between the clamping block and the lower pressure seat is stretched, causing the two soft clamping blocks to clamp the workpiece on both sides. Subsequently, the lower pressure electric cylinder retracts, causing the lower pressure ramp to move. Through the cooperation between the ramp surface below the lower pressure ramp and the ramp surface inside the lower pressure seat, the lower pressure seat is raised and lowered. When the lower pressure seat descends, the spring between the lower pressure seat and the fixed clamping platform is stretched, thereby causing the soft clamping block and the workpiece to rise and fall, thus adjusting the position of the workpiece. After the position of the workpiece is adjusted, the support electric cylinder extends, causing the lower fixed block to rise, so that the lower fixed block contacts the bottom of the soft clamping block, supporting the soft clamping block.

[0011] Once the wire harness is in place, the electric cylinder inside the platform drives two clamping blocks to move inward, clamping the wire harness.

[0012] After the wire harness and workpiece are welded, the lifting cylinder extends, causing the lifting plate, fixed plate, and wire cutter to rise as a whole, so that the wire cutter reaches the outside of the wire harness. The wire cutting cylinder retracts, causing the lifting end block to descend. The lifting end block drives the wire cutter to rotate relative to the fixed plate through the wire cutting rotating rod, cutting the wire harness. At this time, the lifting frame rises a short distance and the material support clamp holds the workpiece and wire harness. Then the lifting plate, fixed plate, and wire cutter descend. The wire clamping block no longer holds the welded wire harness, and the soft clamping block no longer holds the welded workpiece. Then the feeding bracket rises, bringing the workpiece and wire harness above the clamping module. Then the feeding cylinder extends, causing the feeding bracket and material support clamp to move outward. Then the workpiece and wire harness are removed. Then the wire feeding mechanism continues to transport the wire harness forward to the welding position, and then the wire clamping block clamps the wire harness.

[0013] Furthermore, the wire feeding mechanism includes a wire harness reel rotatably mounted on the side of the main frame, with a wire harness wound around the reel. An outer guide cylinder and a fixed housing are fixedly mounted on the main frame. When used for the first time, the end of the wire harness is pulled out from the wire harness reel and passes through the outer guide cylinder and the fixed housing.

[0014] Furthermore, the wire feeding mechanism also includes a conveying shell fixedly installed inside the solid housing. A conveying motor is fixedly installed on the conveying shell, and an input bevel gear is fixedly installed on the motor shaft of the conveying motor. An internal gear disk is rotatably installed on the conveying shell, and multiple helical teeth are provided on the internal gear disk. A side bevel gear is fixedly installed on the internal gear disk, and the side bevel gear meshes with the input bevel gear. Three conveying wheels are rotatably installed inside the conveying shell, and multiple helical teeth are provided on the conveying wheels. The three conveying wheels mesh with each other through the helical teeth, and the wire harness passes between the three conveying wheels, forming a frictional transmission between the conveying wheels and the wire harness.

[0015] For first-time use, pull the wire harness to be used out from the end, then pass the wire harness through the outer guide cylinder and the solid housing in sequence. The outer guide cylinder straightens and guides the wire harness. The wire harness passes between the three conveyor wheels, and the wire harness is in close contact with the three conveyor wheels. When feeding the wire, the conveyor motor drives the input bevel gear to rotate. The input bevel gear drives the side bevel gear and the internal gear disk to rotate. The internal gear disk drives the three conveyor wheels to rotate synchronously through the helical teeth. The wire harness is conveyed by 310. The wire harness first passes above the wire cutter, and then the wire harness enters between the two clamping blocks. When the end of the wire harness reaches the designated position, the clamping blocks hold the wire harness.

[0016] Furthermore, the feeding mechanism includes a feeding frame fixedly installed on the main frame, a lifting frame slidably installed on the feeding frame, a lifting electric cylinder fixedly installed on the feeding frame, the output end of the lifting electric cylinder fixedly installed on the lifting frame, an infeed electric cylinder fixedly installed on the lifting frame, an infeed bracket fixedly installed on the output end of the infeed electric cylinder, the infeed bracket slidably installed on the lifting frame, and two material holders fixedly installed on the infeed bracket, with workpieces placed on the material holders.

[0017] After the wire harness end is clamped, the lifting cylinder extends first, causing the lifting frame to rise. Then, the feeding cylinder retracts, causing the feeding bracket and the material holder to move the workpiece inward. When the part of the workpiece to be welded reaches above the soft clamping block, the lifting cylinder retracts, causing the lifting frame, the feeding bracket, and the workpiece to fall, so that the part of the workpiece to be welded is between the two soft clamping blocks. After the soft clamping blocks have clamped the workpiece, the lifting cylinder retracts, causing the lifting frame to fall, so that the material holder is disengaged from the workpiece.

[0018] A control method for a double-push high-power ultrasonic welding system for wire harness welding, characterized by the following steps: S1, the operator sets welding parameters via an integrated industrial control computer on the main frame; S2, the wire harness is placed on the wire feeding mechanism; S3, the workpiece is placed into the feeding mechanism; S4, the wire harness end is fed into the welding mechanism via the wire feeding mechanism; S5, the workpiece is fed into the welding mechanism via the feeding mechanism and connected to the wire harness; S6, the double-push ultrasonic welding machine descends and completes the welding; S7, the industrial control system collects welding energy, time, and pressure data in real time; S8, the cutting module cuts the wire harness; S9, the feeding mechanism delivers the welded workpiece and wire harness.

[0019] The beneficial effects of this invention compared with the prior art are: (1) This invention achieves flexible adaptive clamping of the workpiece by using the inclined groove push block driven by the internal pressure electric cylinder in the clamping module and cooperating with the lower guide post. The soft clamping block can effectively protect the workpiece surface from damage. At the same time, the lower pressure electric cylinder drives the lower pressure ramp, and the ramp surface cooperates to drive the lower pressure seat to lift and lower, thereby achieving precise adjustment of the workpiece welding height position. After the adjustment is completed, the support electric cylinder drives the lower fixing block to provide bottom support for the soft clamping block, ensuring the rigidity and stability of the clamping during the welding process. This design of first flexible clamping and then rigid support can not only adapt to the small deviations of workpieces of different sizes, but also ensure that the workpiece does not shift during welding, thus improving the welding accuracy and yield rate; (2) This invention performs time-coordinated control of the actions of the cutting module, the feeding mechanism, and the wire feeding mechanism. The cutting module adopts a lifting electric cylinder. The linkage structure of the overall lifting and shearing and the electric cylinder driving the rotating rod to achieve shearing is compact and reliable. After welding, the finished product is automatically lifted by the material support card and sent to the bracket to transport the finished product outward. The continuous action realizes the fully automatic seamless connection from welding completion to finished product removal, reduces manual intervention, and improves the overall automation level and production efficiency of wire harness welding; (3) The present invention adopts a double-push high-power ultrasonic welding machine, which can provide more balanced and higher power welding energy output compared with the traditional single-side drive. It is especially suitable for welding large cross-section or multi-strand wire harnesses and workpieces, effectively solving the problems of insufficient welding strength and uneven energy distribution. At the same time, the two clamping blocks driven by the electric cylinder in the placement table accurately position and clamp the wire harness, ensuring that the wire harness end is accurately aligned with the workpiece during the welding process, and improving the firmness and consistency of the welded joint. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0021] Figure 2 This is a schematic diagram of the welding mechanism structure of the present invention. Figure 1 .

[0022] Figure 3 This is a schematic diagram of the welding mechanism structure of the present invention. Figure 2 .

[0023] Figure 4 This is a schematic diagram of the clamping module structure of the present invention. Figure 1 .

[0024] Figure 5 This is a schematic diagram of the clamping module structure of the present invention. Figure 2 .

[0025] Figure 6 This is a schematic diagram of the clamping module structure of the present invention. Figure 3 .

[0026] Figure 7This is a schematic diagram of the cutting module structure of the present invention.

[0027] Figure 8 This is a schematic diagram of the clamping module structure of the present invention. Figure 4 .

[0028] Figure 9 This is a schematic diagram of the wire feeding mechanism of the present invention. Figure 1 .

[0029] Figure 10 This is a schematic diagram of the wire feeding mechanism of the present invention. Figure 2 .

[0030] Figure 11 This is a schematic diagram of the wire feeding mechanism of the present invention. Figure 3 .

[0031] Figure 12 This is a schematic diagram of the wire feeding mechanism of the present invention. Figure 4 .

[0032] Figure 13 This is a schematic diagram of the feeding mechanism of the present invention. Figure 1 .

[0033] Figure 14 This is a schematic diagram of the feeding mechanism of the present invention. Figure 2 .

[0034] Reference numerals: 101-Main frame; 102-Protective shell; 103-Double-push ultrasonic welding machine; 104-Fixed clamping platform; 105-Lower fixed sleeve; 106-Lower pressure electric cylinder; 107-Lower pressure ramp block; 108-Lower pressure seat; 109-Internal pressure electric cylinder; 110-Slanted groove push block; 111-Clamping block; 112-Lower guide column; 113-Soft clamping block; 114-Lower fixed block; 115-Fixed upright plate; 116-Tangulating electric cylinder; 117-Lifting end block; 118-Tangulating cutter; 119-Tangulating rotating rod; 120-Slanted groove; 12 1-Wire clamping block; 122-Placement platform; 123-Lifting electric cylinder; 124-Lifting plate; 125-Supporting electric cylinder; 201-Wire harness reel; 202-Outer guide cylinder; 203-Fixed outer shell; 204-Conveyor motor; 205-Input bevel gear; 206-Conveyor shell; 207-Side bevel gear; 208-Internal gear disc; 209-Helical gear; 210-Conveyor wheel; 301-Feeding rack; 302-Lifting frame; 303-Lifting electric cylinder; 304-Feeding electric cylinder; 305-Feeding bracket; 306-Material holder; 4-Workpiece; 5-Wire harness. Detailed Implementation

[0035] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings.

[0036] Example: Reference Figures 1-14A double-push high-power ultrasonic welding system for wire harness welding includes a welding mechanism for welding wire harness 5 onto workpiece 4. The welding mechanism includes a main frame 101, and is provided with a wire feeding mechanism for feeding wire harness 5 and a feeding mechanism for feeding workpiece 4.

[0037] like Figures 2-8 As shown, the welding mechanism includes a protective shell 102 fixedly installed on the main frame 101. A double-push ultrasonic welding machine 103 is installed inside the protective shell 102. An electric cylinder for driving the double-push ultrasonic welding machine 103 to rise and fall is installed inside the protective shell 102. A placement platform 122 is fixedly installed on the main frame 101. Two wire clamping blocks 121 are slidably installed on the placement platform 122. An electric cylinder for driving the wire clamping blocks 121 to slide is installed inside the placement platform 122. A clamping module for clamping the workpiece 4 to be welded and a cutting module for cutting the wire harness 5 are provided on the main frame 101.

[0038] like Figures 2-8 As shown, the clamping module includes a fixed clamping platform 104 fixedly installed on the main frame 101. Two lower fixed sleeves 105 are fixedly installed on the fixed clamping platform 104. A lower pressure electric cylinder 106 is fixedly installed on the lower fixed sleeve 105. A lower pressure ramp 107 is fixedly installed on the output end of the lower pressure electric cylinder 106. A slope is provided on the lower surface of the lower pressure ramp 107. A lower pressure seat 108 is slidably installed on the fixed clamping platform 104. A slope is provided inside the lower pressure seat 108. The slope of the lower pressure seat 108 contacts the slope below the lower pressure ramp 107. A spring is provided between the lower pressure seat 108 and the fixed clamping platform 104.

[0039] like Figures 2-8 As shown, the clamping module also includes an internal pressure electric cylinder 109 fixedly installed on the lower pressure seat 108. A slanted push block 110 is fixedly installed on the output end of the internal pressure electric cylinder 109. A slanted groove 120 is provided on the slanted push block 110. A clamping block 111 is slidably installed on the lower pressure seat 108. A lower guide post 112 is fixedly installed below the clamping block 111. The lower guide post 112 slides in the slanted groove 120. A soft clamping block 113 is fixedly installed on the inner side of the clamping block 111. A support electric cylinder 125 is fixedly installed on the fixed clamping platform 104. A lower fixing block 114 is fixedly installed on the output end of the support electric cylinder 125. A spring is provided between the clamping block 111 and the lower pressure seat 108.

[0040] like Figures 2-8As shown, the cutting module includes a lifting electric cylinder 123 fixedly installed on the main frame 101. A lifting plate 124 is fixedly installed on the output end of the lifting electric cylinder 123. A fixed upright plate 115 is fixedly installed on the lifting plate 124. Two cutting blades 118 are rotatably installed on the fixed upright plate 115. A cutting electric cylinder 116 is fixedly installed on the lifting plate 124. A lifting end block 117 is fixedly installed on the output end of the cutting electric cylinder 116. Two cutting rotating rods 119 are rotatably installed on the lifting end block 117. The two cutting rotating rods 119 are rotatably installed with the two cutting blades 118 respectively.

[0041] In use, when the workpiece 4 reaches between the two soft clamping blocks 113, the internal pressure electric cylinder 109 extends, causing the inclined groove pusher block 110 to slide within the lower pressure seat 108. As the inclined groove pusher block 110 slides, it drives the lower guide post 112, clamping block 111, and soft clamping block 113 to move inward along the lower pressure seat 108 via the inclined groove 120. The spring between the clamping block 111 and the lower pressure seat 108 is stretched, causing the two soft clamping blocks 113 to clamp the workpiece 4 on both sides. Subsequently, the lower pressure electric cylinder 106 retracts, causing the lower pressure ramp block 107 to move. The slope surface below the pressure block 107 cooperates with the inner slope surface of the pressure seat 108 to drive the pressure seat 108 to rise and fall. When the pressure seat 108 falls, the spring between the pressure seat 108 and the fixed clamping table 104 is stretched, thereby driving the soft clamping block 113 and the workpiece 4 to rise and fall, thereby adjusting the position of the workpiece 4. After the position of the workpiece 4 is adjusted, the support electric cylinder 125 extends to drive the lower fixed block 114 to rise, so that the lower fixed block 114 contacts the bottom of the soft clamping block 113 to support the soft clamping block 113.

[0042] Once the wire harness 5 is delivered to the designated position, the electric cylinder inside the placement platform 122 drives the two wire clamping blocks 121 to move inward, clamping the wire harness 5 through the wire clamping blocks 121.

[0043] After the wire harness 5 and workpiece 4 are welded, the lifting cylinder 123 extends, causing the lifting plate 124, fixed upright plate 115, and wire cutter 118 to rise as a whole, so that the wire cutter 118 reaches the outside of the wire harness 5. The wire cutting cylinder 116 retracts, causing the lifting end block 117 to descend. The lifting end block 117 drives the wire cutter 118 to rotate relative to the fixed upright plate 115 through the wire cutting rotating rod 119, and the wire harness 5 is cut by the wire cutter 118. At this time, the lifting frame 302 rises a short distance and the material support 306 supports the workpiece 4 and the wire harness 5. Then the lifting plate 124 extends. 4. The fixed upright plate 115 and the wire cutting blade 118 descend, and then the wire clamping block 121 stops clamping the welded wire harness 5, and the soft clamping block 113 stops clamping the welded workpiece 4. Then the feeding bracket 305 rises, driving the workpiece 4 and the wire harness 5 to the top of the clamping module. Then the feeding electric cylinder 304 extends, driving the feeding bracket 305 and the material holder 306 to move outward. Then the workpiece 4 and the wire harness 5 are taken away. Then the wire feeding mechanism continues to feed the wire harness 5 forward, and feeds the wire harness 5 to the position to be welded. Then the wire clamping block 121 clamps the wire harness 5.

[0044] like Figures 9-12 As shown, the wire feeding mechanism includes a wire harness reel 201 rotatably mounted on the side of the main frame 101. A wire harness 5 is wound around the wire harness reel 201. An outer guide cylinder 202 and a fixed housing 203 are fixedly mounted on the main frame 101. When used for the first time, the end of the wire harness 5 is pulled out from the wire harness reel 201 and passes through the outer guide cylinder 202 and the fixed housing 203.

[0045] like Figures 9-12 As shown, the wire feeding mechanism also includes a conveying shell 206 fixedly installed inside the fixed housing 203. A conveying motor 204 is fixedly installed on the conveying shell 206. An input bevel gear 205 is fixedly installed on the motor shaft of the conveying motor 204. An internal gear disk 208 is rotatably installed on the conveying shell 206. Multiple helical teeth 209 are provided on the internal gear disk 208. A side bevel gear 207 is fixedly installed on the internal gear disk 208. The side bevel gear 207 meshes with the input bevel gear 205. Three conveying wheels 210 are rotatably installed inside the conveying shell 206. Multiple helical teeth are provided on the conveying wheels 210. The three conveying wheels 210 mesh with the helical teeth 209 through the helical teeth. The wire harness 5 passes between the three conveying wheels 210. The conveying wheels 210 and the wire harness 5 form a friction drive.

[0046] When using it for the first time, first pull out the wire harness 5 from the end, then pass the wire harness 5 through the outer guide cylinder 202 and the solid housing 203 in sequence. The outer guide cylinder 202 straightens and guides the wire harness 5. The wire harness 5 passes between the three conveyor wheels 210, and the wire harness 5 is in close contact with the three conveyor wheels 210. When feeding the wire, the conveyor motor 204 drives the input bevel gear 205 to rotate. The input bevel gear 205 drives the side bevel gear 207 and the internal gear disk 208 to rotate. The internal gear disk 208 drives the three conveyor wheels 210 to rotate synchronously through the helical teeth 209. The wire harness 5 is conveyed through 310. The wire harness 5 first passes above the wire cutter 118, and then the wire harness 5 enters between the two clamping blocks 121. When the end of the wire harness 5 reaches the designated position, the clamping blocks 121 clamp the wire harness 5.

[0047] like Figure 13 , Figure 14 As shown, the feeding mechanism includes a feeding frame 301 fixedly installed on the main frame 101, a lifting frame 302 slidably installed on the feeding frame 301, a lifting electric cylinder 303 fixedly installed on the feeding frame 301, the output end of the lifting electric cylinder 303 fixedly installed with the lifting frame 302, an infeed electric cylinder 304 fixedly installed on the lifting frame 302, an infeed bracket 305 fixedly installed on the output end of the infeed electric cylinder 304, the infeed bracket 305 slidably installed with the lifting frame 302, and two material holders 306 fixedly installed on the infeed bracket 305, on which workpieces 4 are placed.

[0048] After the wire harness 5 is clamped at the end, the lifting cylinder 303 first extends to raise the lifting frame 302. Then, the feeding cylinder 304 retracts to move the feeding bracket 305 and the material holder 306 inward with the workpiece 4. When the part of the workpiece 4 to be welded reaches above the soft clamping block 113, the lifting cylinder 303 retracts to lower the lifting frame 302, the feeding bracket 305 and the workpiece 4, so that the part of the workpiece 4 to be welded is between the two soft clamping blocks 113. After the soft clamping block 113 has clamped the workpiece 4, the lifting cylinder 303 retracts to lower the lifting frame 302, so that the material holder 306 is disengaged from the workpiece 4.

[0049] A control method for a double-push high-power ultrasonic welding system for wire harness welding, characterized by the following steps: S1, the operator sets welding parameters via an industrial control integrated computer on the main frame 101; S2, the wire harness 5 is placed on the wire feeding mechanism; S3, the workpiece 4 is placed into the feeding mechanism; S4, the end of the wire harness 5 is fed into the welding mechanism via the wire feeding mechanism; S5, the workpiece 4 is fed into the welding mechanism via the feeding mechanism and connected to the wire harness 5; S6, the double-push ultrasonic welding machine 103 descends and completes the welding; S7, the industrial control system collects welding energy, time, and pressure data in real time; S8, the cutting module cuts the wire harness 5; S9, the feeding mechanism delivers the welded workpiece 4 and wire harness 5.

[0050] Working principle: When using for the first time, first pull out the wire harness 5 from the end, then pass the wire harness 5 through the outer guide cylinder 202 and the solid housing 203 in sequence. The outer guide cylinder 202 straightens and guides the wire harness 5. The wire harness 5 passes between the three conveyor wheels 210, and the wire harness 5 is in close contact with the three conveyor wheels 210. When feeding the wire, the conveyor motor 204 drives the input bevel gear 205 to rotate. The input bevel gear 205 drives the side bevel gear 207 and the internal gear disk 208 to rotate. The internal gear disk 208 drives the three conveyor wheels 210 to rotate synchronously through the helical teeth 209. The wire harness 5 is conveyed through 310. The wire harness 5 first passes above the wire cutter 118, and then the wire harness 5 enters between the two clamping blocks 121. When the end of the wire harness 5 reaches the designated position, the clamping blocks 121 clamp the wire harness 5.

[0051] After the wire harness 5 is clamped at the end, the lifting cylinder 303 first extends to raise the lifting frame 302. Then, the feeding cylinder 304 retracts to move the feeding bracket 305 and the material holder 306 inward with the workpiece 4. When the part of the workpiece 4 to be welded reaches above the soft clamping block 113, the lifting cylinder 303 retracts to lower the lifting frame 302, the feeding bracket 305 and the workpiece 4, so that the part of the workpiece 4 to be welded is between the two soft clamping blocks 113. After the soft clamping block 113 has clamped the workpiece 4, the lifting cylinder 303 retracts to lower the lifting frame 302, so that the material holder 306 is disengaged from the workpiece 4.

[0052] When workpiece 4 reaches between the two soft clamping blocks 113, the internal pressure electric cylinder 109 extends, causing the inclined groove pusher block 110 to slide within the lower pressure seat 108. As the inclined groove pusher block 110 slides, it drives the lower guide post 112, clamping block 111, and soft clamping block 113 to move inward along the lower pressure seat 108 via the inclined groove 120. The spring between the clamping block 111 and the lower pressure seat 108 is stretched, causing the two soft clamping blocks 113 to clamp workpiece 4 on both sides. Subsequently, the lower pressure electric cylinder 106 retracts, driving the lower pressure ramp block 107 to move, passing through the lower... The slope surface below the pressure block 107 cooperates with the inner slope surface of the pressure seat 108 to drive the pressure seat 108 to rise and fall. When the pressure seat 108 falls, the spring between the pressure seat 108 and the fixed clamping table 104 is stretched, thereby driving the soft clamping block 113 and the workpiece 4 to rise and fall, thereby adjusting the position of the workpiece 4. After the position of the workpiece 4 is adjusted, the support electric cylinder 125 extends to drive the lower fixed block 114 to rise, so that the lower fixed block 114 contacts the bottom of the soft clamping block 113 to support the soft clamping block 113.

[0053] After the wire harness 5 and workpiece 4 are welded, the lifting cylinder 123 extends, causing the lifting plate 124, fixed upright plate 115, and wire cutter 118 to rise as a whole, so that the wire cutter 118 reaches the outside of the wire harness 5. The wire cutting cylinder 116 retracts, causing the lifting end block 117 to descend. The lifting end block 117 drives the wire cutter 118 to rotate relative to the fixed upright plate 115 through the wire cutting rotating rod 119, and the wire harness 5 is cut by the wire cutter 118. At this time, the lifting frame 302 rises a short distance and the material support 306 supports the workpiece 4 and the wire harness 5. Then the lifting plate 124 extends. 4. The fixed upright plate 115 and the wire cutting blade 118 descend, and then the wire clamping block 121 stops clamping the welded wire harness 5, and the soft clamping block 113 stops clamping the welded workpiece 4. Then the feeding bracket 305 rises, driving the workpiece 4 and the wire harness 5 to the top of the clamping module. Then the feeding electric cylinder 304 extends, driving the feeding bracket 305 and the material holder 306 to move outward. Then the workpiece 4 and the wire harness 5 are taken away. Then the wire feeding mechanism continues to feed the wire harness 5 forward, and feeds the wire harness 5 to the position to be welded. Then the wire clamping block 121 clamps the wire harness 5.

[0054] The above description is only a preferred embodiment 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 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 double-push high-power ultrasonic welding system for wire harness welding, comprising a welding mechanism for welding a wire harness (5) onto a workpiece (4), characterized in that: The welding mechanism includes a main frame (101), and is provided with a wire feeding mechanism for feeding the wire harness (5) and a material feeding mechanism for feeding the workpiece (4).

2. The double-push high-power ultrasonic welding system for wire harness welding according to claim 1, characterized in that: The welding mechanism includes a protective shell (102) fixedly installed on the main frame (101). A double-push ultrasonic welding machine (103) is installed inside the protective shell (102). An electric cylinder for driving the double-push ultrasonic welding machine (103) to rise and fall is installed inside the protective shell (102). A placement platform (122) is fixedly installed on the main frame (101). Two wire clamping blocks (121) are slidably installed on the placement platform (122). An electric cylinder for driving the wire clamping blocks (121) to slide is installed inside the placement platform (122). A clamping module for clamping the workpiece (4) to be welded and a cutting module for cutting the wire harness (5) are provided on the main frame (101).

3. A double-push high-power ultrasonic welding system for wire harness welding according to claim 2, characterized in that: The clamping module includes a fixed clamping platform (104) fixedly installed on the main frame (101). Two lower fixed sleeves (105) are fixedly installed on the fixed clamping platform (104). A lower pressure electric cylinder (106) is fixedly installed on the lower fixed sleeve (105). A lower pressure ramp (107) is fixedly installed on the output end of the lower pressure electric cylinder (106). A slope is provided on the lower surface of the lower pressure ramp (107). A lower pressure seat (108) is slidably installed on the fixed clamping platform (104). A slope is provided inside the lower pressure seat (108). The slope of the lower pressure seat (108) contacts the slope below the lower pressure ramp (107). A spring is provided between the lower pressure seat (108) and the fixed clamping platform (104).

4. A double-push high-power ultrasonic welding system for wire harness welding according to claim 3, characterized in that: The clamping module also includes an internal pressure electric cylinder (109) fixedly installed on the lower pressure seat (108). A slanted push block (110) is fixedly installed on the output end of the internal pressure electric cylinder (109). A slanted groove (120) is provided on the slanted push block (110). A clamping block (111) is slidably installed on the lower pressure seat (108). A lower guide post (112) is fixedly installed below the clamping block (111). The lower guide post (112) slides in the slanted groove (120). A soft clamping block (113) is fixedly installed on the inner side of the clamping block (111). A support electric cylinder (125) is fixedly installed on the fixed clamping platform (104). A lower fixing block (114) is fixedly installed on the output end of the support electric cylinder (125). A spring is provided between the clamping block (111) and the lower pressure seat (108).

5. A double-push high-power ultrasonic welding system for wire harness welding according to claim 4, characterized in that: The cutting module includes a lifting electric cylinder (123) fixedly installed on the main frame (101). A lifting plate (124) is fixedly installed on the output end of the lifting electric cylinder (123). A fixed upright plate (115) is fixedly installed on the lifting plate (124). Two tangent cutters (118) are rotatably installed on the fixed upright plate (115). A tangent electric cylinder (116) is fixedly installed on the lifting plate (124). A lifting end block (117) is fixedly installed on the output end of the tangent electric cylinder (116). Two tangent rotating rods (119) are rotatably installed on the lifting end block (117). The two tangent rotating rods (119) are rotatably installed with the two tangent cutters (118) respectively.

6. A double-push high-power ultrasonic welding system for wire harness welding according to claim 1, characterized in that: The wire feeding mechanism includes a wire harness reel (201) rotatably mounted on the side of the main frame (101). A wire harness (5) is wound around the wire harness reel (201). An outer guide cylinder (202) and a fixed outer shell (203) are fixedly mounted on the main frame (101). When used for the first time, the end of the wire harness (5) is pulled out from the wire harness reel (201) and passes through the outer guide cylinder (202) and the fixed outer shell (203).

7. A double-push high-power ultrasonic welding system for wire harness welding according to claim 6, characterized in that: The wire feeding mechanism also includes a conveying shell (206) fixedly installed inside the solid housing (203). A conveying motor (204) is fixedly installed on the conveying shell (206). An input bevel gear (205) is fixedly installed on the motor shaft of the conveying motor (204). An internal gear disk (208) is rotatably installed on the conveying shell (206). Multiple helical teeth (209) are provided on the internal gear disk (208). A side bevel gear (207) is fixedly installed on the internal gear disk (208). The side bevel gear (207) meshes with the input bevel gear (205). Three conveying wheels (210) are rotatably installed inside the conveying shell (206). Multiple helical teeth are provided on the conveying wheels (210). The three conveying wheels (210) mesh with the helical teeth (209) through the helical teeth. The wire harness (5) passes between the three conveying wheels (210). The conveying wheels (210) and the wire harness (5) form a friction drive.

8. A double-push high-power ultrasonic welding system for wire harness welding according to claim 1, characterized in that: The feeding mechanism includes a feeding frame (301) fixedly installed on the main frame (101), a lifting frame (302) slidably installed on the feeding frame (301), a lifting electric cylinder (303) fixedly installed on the feeding frame (301), the output end of the lifting electric cylinder (303) fixedly installed on the lifting frame (302), an infeed electric cylinder (304) fixedly installed on the lifting frame (302), an infeed bracket (305) fixedly installed on the output end of the infeed electric cylinder (304), the infeed bracket (305) slidably installed on the lifting frame (302), two material holders (306) fixedly installed on the infeed bracket (305), and a workpiece (4) is placed on the material holders (306).

9. The control method for a double-push high-power ultrasonic welding system for wire harness welding according to claim 1, characterized in that: The steps are as follows: S1, the operator sets the welding parameters through the industrial control all-in-one computer on the main frame (101); S2, the wire harness (5) is placed on the wire feeding mechanism; S3, the workpiece (4) is placed into the feeding mechanism; S4, the end of the wire harness (5) is fed into the welding mechanism through the wire feeding mechanism; S5, the workpiece (4) is fed into the welding mechanism through the feeding mechanism and connected with the wire harness (5); S6, the double-push ultrasonic welding machine (103) descends and completes the welding; S7, the industrial control system collects welding energy, time and pressure data in real time; S8, the cutting module cuts the wire harness (5); S9, the feeding mechanism sends out the welded workpiece (4) and wire harness (5).

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