A quick positioning butt welding machine for cable processing

Abstract

The application discloses a kind of quick positioning butt welding machines for cable processing, and relate to welding equipment technical field.The application includes resistance butt welding machine, the top of resistance butt welding machine is fixedly installed with fixed clamp, the top of resistance butt welding machine is slidably connected with movable clamp, support is arranged between fixed clamp and movable clamp, welding positioning assembly is rotatably installed in the inside of support, the center of several shaping rollers can form elliptical cavity and circular cavity.The application adopts two-step automatic centering mode of large-space elliptical pre-insertion and circular clamping correction, first provides sufficient wire insertion space through elliptical cavity, reduces operation difficulty, then realizes automatic clamping centering by shrinking into circular shape through shaping roller, so that cable welding end coaxiality error is ≤0.03mm.No manual alignment is needed, operation fault tolerance is greatly improved, and problems such as uneven local stress of joint, over-molding and mold clamping caused by conductor eccentricity are avoided from the root.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, and more specifically to a rapid positioning butt welding machine for cable processing. Background Technology

[0002] With the rapid development of industries such as photovoltaic new energy, new energy vehicles, and aerospace, the demand for small-section multi-strand tin-plated copper wire has exploded. Resistance welding, as the mainstream process for connecting cable conductors, is widely used in cable manufacturing production lines due to its advantages of fast welding speed and low equipment cost.

[0003] However, existing resistance welding technology has many inherent drawbacks that are difficult to overcome in the welding of small cross-section multi-strand wires: Low positioning and centering accuracy: Traditional welding machines rely on manual alignment of cable ends, and the coaxiality error is usually greater than 0.1mm, which can easily lead to joint eccentricity, uneven local stress, and frequent problems such as mold jamming and scratching of the insulation layer during subsequent molding, which seriously affects production efficiency.

[0004] Poor metallurgical quality of the joint: The single axial upsetting process is adopted, and the upsetting force is unevenly distributed. The pressure in the central area is high and the fusion is good, while the pressure in the edge area is low and the fusion is poor. The single wire fusion rate is only 85%-90%, and there are a lot of defects such as false welding and lack of fusion. The tensile strength of the joint can only reach 70%-85% of the base material.

[0005] Incomplete removal of impurities: The oxide scale and tin plating impurities generated during the welding process can only be discharged axially to both ends. A large number of impurities remain inside the joint, which increases the joint resistance by 3%-8%. During long-term operation, local overheating may occur, and even fire accidents may be caused.

[0006] Poor forming accuracy: Axial upsetting is prone to producing axial flash and radial burrs, which must be manually ground after welding, increasing the process and cost, and the grinding quality is difficult to guarantee. Summary of the Invention

[0007] The purpose of this invention is to provide a rapid positioning butt welding machine for cable processing in order to solve the above problems.

[0008] To achieve the above objectives, the present invention specifically adopts the following technical solution: A fast positioning butt welding machine for cable processing includes a resistance butt welding machine. A fixed clamp is fixedly installed on the top of the resistance butt welding machine, and a movable clamp is slidably connected to the top of the resistance butt welding machine. A bracket is provided between the fixed clamp and the movable clamp, and a welding positioning component is rotatably installed inside the bracket. The welding positioning assembly includes a rotating frame rotatably installed inside the bracket. Two sets of closing cylinders are symmetrically installed at the top and bottom of the rotating frame. Semi-elliptical guide plates are fixedly installed at the telescopic ends of the closing cylinders. Several shaping rollers are arranged between the two semi-elliptical guide plates at the same height on the left and right. Adjacent shaping rollers are closely fitted, and when the upper and lower semi-elliptical guide plates are closed, the centers of the shaping rollers can form elliptical cavities and circular cavities.

[0009] Furthermore, the semi-elliptical guide plate is symmetrically provided with fixed shaft holes, several arc-shaped guide grooves and straight guide grooves. The fixed shaft holes, several arc-shaped guide grooves and straight guide grooves are distributed sequentially from the center of the arc edge of the semi-elliptical guide plate to the endpoint of the arc edge. A shaping roller is fixedly installed in the fixed shaft hole, and a shaping roller is slidably installed in both the arc-shaped guide groove and the straight guide groove. Adjacent shaping rollers are connected by hinges.

[0010] Furthermore, the outer side of the shaping roller is provided with a hinge groove, and adjacent shaping rollers are connected by a hinge member. The hinge member consists of two cylindrical sleeves and an arc-shaped member. The two cylindrical sleeves are respectively fixed at both ends of the arc-shaped member. The outer diameter of the cylindrical sleeves is the same as the outer diameter of the shaping roller, and the cylindrical sleeves are fitted into the hinge groove.

[0011] Furthermore, the shaping roller is composed of an outer layer of high borosilicate glass and a central stainless steel rod, and the cylindrical sleeve is also made of high borosilicate glass.

[0012] Furthermore, a deformation cylinder is fixedly installed on the outer side of the semi-elliptical guide plate, and a deformation drive frame is fixedly installed on the telescopic end of the deformation cylinder. The deformation drive frame is fixedly installed on the shaping roller in the linear guide groove.

[0013] Furthermore, the deformation drive frame described below is provided with a connector, and the upper square deformation drive frame can be inserted into the connector.

[0014] Furthermore, the top opening of the connector is angled outwards.

[0015] Furthermore, a drive motor is fixedly installed on the top of the resistance welding machine, and a drive wheel is installed at the output end of the drive motor. A toothed groove is annularly opened on the outer side of the rotating frame, and the drive wheel meshes with the toothed groove.

[0016] Furthermore, both the fixed fixture and the movable fixture consist of an upper resistance chuck, a lower resistance chuck, and a clamping cylinder. A guide post is provided on the top of the resistance welding machine. The lower resistance chuck in the movable fixture is slidably connected to the guide post. A drive cylinder is provided on the back of the fixed fixture. The extension end of the drive cylinder is connected to the lower resistance chuck in the movable fixture. A proximity switch is provided between the drive cylinder and the movable fixture.

[0017] The beneficial effects of this invention are as follows: This invention employs a two-step automatic centering method: large-space elliptical pre-insertion and circular clamping correction. First, an elliptical cavity provides ample space for wire insertion, reducing operational difficulty. Then, a shaping roller shrinks into a circle to achieve automatic clamping and centering, ensuring that the coaxiality error of the cable welding end is ≤0.03mm. No manual alignment is required, significantly improving operational error tolerance and fundamentally avoiding problems such as uneven local stress on the joint and mold jamming caused by conductor eccentricity.

[0018] This invention breaks through the traditional stroke limitation of welding machines. By extending the stroke of the movable clamp, a long-stroke axial pre-filling is achieved, allowing the plastic conductor to completely fill the elliptical cavity, eliminating defects such as incomplete welding and lack of fusion at the source. Subsequently, the shaping roller shrinks to form a circular cavity, applying a 360° uniform radial extrusion force to the internal plastic conductor. This forces the plastic metal to flow bidirectionally towards the center and both ends, causing all single filaments to undergo sufficient plastic deformation and form a strong metallurgical bond, greatly improving the cable splicing strength.

[0019] This invention pioneers a dual impurity removal mechanism combining directional impurity removal and dynamic rotational impurity removal. During secondary radial extrusion, oxide scale, tin-plated layer impurities, and other debris on the outer surface of the joint automatically flow to the tip space between adjacent shaping rollers, completely separating them from the core conductive area of ​​the joint. After welding, the drive motor rotates the frame, causing impurities in the tip space to completely detach from the solidified weld area, leaving no residue. Compared to the 80%-90% impurity removal rate of traditional processes, this invention completely solves the problems of increased joint resistance and localized overheating caused by internal slag inclusions, significantly improving the long-term operational reliability of the cable. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the front axle of the three-dimensional structure of the present invention; Figure 2 This is a schematic diagram of the rear axle of the three-dimensional structure of the present invention; Figure 3 This is a schematic diagram of the welding positioning component structure of the present invention; Figure 4 This is an exploded view of the semi-elliptical guide plate and shaping roller structure of the present invention; Figure 5 This is a schematic diagram of the semi-elliptical guide plate structure of the present invention; Figure 6 This is a schematic diagram of the elliptical deformation of the welding positioning component of the present invention; Figure 7 This is a schematic diagram of the circular deformation of the welding positioning component of the present invention.

[0021] Reference numerals: 1. Resistance welding machine; 2. Fixed fixture; 3. Movable fixture; 4. Drive cylinder; 5. Guide post; 6. Proximity switch; 7. Bracket; 8. Welding positioning assembly; 81. Closing cylinder; 82. Semi-elliptical guide plate; 821. Fixed shaft hole; 822. Arc-shaped guide groove; 823. Straight guide groove; 83. Shaping roller; 831. Hinge groove; 84. Hinge component; 85. Deformation cylinder; 86. Deformation drive frame; 87. Connector; 88. Rotating frame. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0023] Example 1, as Figures 1-7 As shown, a fast positioning butt welding machine for cable processing includes a resistance butt welding machine 1, a fixed clamp 2 is fixedly installed on the top of the resistance butt welding machine 1, a movable clamp 3 is slidably connected to the top of the resistance butt welding machine 1, a bracket 7 is provided between the fixed clamp 2 and the movable clamp 3, and a welding positioning component 8 is rotatably installed inside the bracket 7. The welding positioning assembly 8 includes a rotating frame 88 rotatably installed inside the bracket 7. Two sets of closing cylinders 81 are symmetrically installed on the top and bottom of the rotating frame 88. Semi-elliptical guide plates 82 are fixedly installed on the telescopic ends of the closing cylinders 81. Several shaping rollers 83 are arranged between the two semi-elliptical guide plates 82 at the same height on the left and right, preferably 10. Adjacent shaping rollers 83 are closely fitted, and when the upper and lower semi-elliptical guide plates 82 are closed, the center of the several shaping rollers 83 can form an elliptical cavity and a circular cavity.

[0024] A drive motor is fixedly mounted on the top of the resistance welding machine 1. A drive wheel is installed at the output end of the drive motor. A toothed groove is formed on the outer side of the rotating frame 88, and the drive wheel meshes with the toothed groove. Both the fixed clamp 2 and the movable clamp 3 consist of an upper resistance chuck, a lower resistance chuck, and a clamping cylinder. A guide post 5 is provided on the top of the resistance welding machine 1. The lower resistance chuck in the movable clamp 3 is slidably connected to the guide post 5. A drive cylinder 4 is provided on the back of the fixed clamp 2. The telescopic end of the drive cylinder 4 is connected to the lower resistance chuck in the movable clamp 3. A proximity switch 6 is provided between the drive cylinder 4 and the movable clamp 3.

[0025] Welding steps: (1) Cable positioning and clamping: The upper and lower closing cylinder 81 drives the upper and lower semi-elliptical guide plates 82 to close together, and an elliptical cavity is formed between the shaping rollers 83. At this time, the space is large, and the two cable heads that need to be welded are inserted from both ends of the elliptical cavity. After the insertion is completed, several shaping rollers 83 deform, and a circular cavity is formed between the shaping rollers 83. The circular cavity plays a clamping and correction function, so that the welding ends of the two cables are aligned. After alignment, the upper resistance clamp is driven to descend by the clamping cylinder. The upper resistance clamp and the lower resistance clamp clamp the cable. The fixed clamp 2 and the movable clamp 3 clamp the two cables respectively to clamp and fix the cables.

[0026] Cable butt welding: After the cable is clamped and fixed, several shaping rollers 83 deform again, and elliptical cavities are formed between the shaping rollers 83 again. The space is relatively large. Then, the movable clamp 3 is driven by the driving cylinder 4 to approach the fixed clamp 2, and the resistance butt welding machine 1 is supplied with low voltage and high current. The contact resistance of the cable conductor contact surface and the volume resistance of the conductor itself generate concentrated heat, which quickly heats the end face to a plastic state (copper about 600-800℃, not completely melted). In this invention, the stroke of the movable clamp 3 is greater than that of the prior art, so that the elliptical cavity is filled with plastic conductor. When the movable clamp 3 moves to form a switch, it stops moving, which is the initial axial extrusion butt welding. At this time, several shaping rollers 83 deform again, and circular cavities are formed between the shaping rollers 83 again. The circular cavity is smaller than the elliptical cavity, so it generates extrusion force on the plastic conductor in the middle, causing it to flow to the middle and both ends. This is a secondary radial diffusion extrusion method. During the secondary extrusion process, impurities on the outer surface of the cable joint will flow to the outermost side under the extrusion action. Therefore, most of them will flow into the tip space between adjacent shaping rollers 83. At the same time, the rotating frame 88 is driven by the drive motor to rotate, and the welding positioning component 8 rotates relative to the cable with the rotation center on the cable axis. The shaping rollers 83 rotate relative to the cable joint to roll the welding position to keep it cylindrical. The impurities in the tip space are separated from the welding part as the shaping rollers 83 rotate. After the equipment is powered off, the welding positioning component 8 continues to rotate rapidly to ensure that the impurities are completely separated from the solidified welding part, thereby improving the quality of cable welding.

[0027] This invention breaks through the traditional stroke limitation of welding machines, allowing the plastic conductor to completely fill the elliptical cavity, eliminating defects such as incomplete welding and lack of fusion from the root. Furthermore, the 360° uniform radial extrusion force compels the plastic metal to flow bidirectionally towards the center and both ends, causing all single wires to undergo sufficient plastic deformation and form a metallurgical bond.

[0028] During the secondary radial extrusion, oxide scale, tin plating impurities, and other contaminants on the outer surface of the joint automatically flow to the tip space between adjacent shaping rollers 83, completely separating them from the core conductive area of ​​the joint. Dynamic rotation is then used for impurity removal, ensuring that impurities in the tip space are completely removed from the solidified weld area, leaving no residue. This effectively improves the situation where slag inclusions cause increased joint resistance and localized overheating. Furthermore, after welding, because the adjacent shaping rollers 83 are movable, impurities in the tip space can be quickly discharged, requiring only simple cleaning, making cleaning convenient.

[0029] In embodiment two, based on the above embodiment, it further includes a semi-elliptical guide plate 82 symmetrically provided with a fixed shaft hole 821, a plurality of arc-shaped guide grooves 822 and straight guide grooves 823. The fixed shaft hole 821, the plurality of arc-shaped guide grooves 822 and straight guide grooves 823 are distributed sequentially from the center of the arc edge of the semi-elliptical guide plate 82 to the endpoint of the arc edge. A shaping roller 83 is fixedly installed in the fixed shaft hole 821. A shaping roller 83 is slidably installed in both the arc-shaped guide grooves 822 and the straight guide grooves 823. Adjacent shaping rollers 83 are connected by a hinge 84.

[0030] The outer side of the shaping roller 83 is provided with a hinge groove 831. Adjacent shaping rollers 83 are connected by a hinge member 84. The hinge member 84 consists of two cylindrical sleeves and an arc-shaped member. The two cylindrical sleeves are fixed at both ends of the arc-shaped member. The outer diameter of the cylindrical sleeves is the same as the outer diameter of the shaping roller 83. The cylindrical sleeves are fitted into the hinge groove 831.

[0031] The shaping roller 83 consists of an outer layer of high borosilicate glass and a central stainless steel rod, with the cylindrical sleeve also made of high borosilicate glass. The softening point of the high borosilicate 3.3 glass is 820±10℃, providing a safety margin of 70-220℃ compared to the copper ductile welding temperature (600-750℃), preventing softening and deformation during welding. The stainless steel mandrel (304 / 316 material) provides sufficient bending and impact resistance. The outer glass layer only bears uniform radial extrusion pressure, while bending and shear stresses are entirely borne by the mandrel.

[0032] A deformation cylinder 85 is fixedly installed on the outer side of the semi-elliptical guide plate 82. A deformation drive frame 86 is fixedly installed on the telescopic end of the deformation cylinder 85. The deformation drive frame 86 is fixedly installed on the shaping roller 83 in the linear guide groove 823.

[0033] This embodiment provides a specific deformation structure. During elliptical deformation, the deformation cylinder 85 extends, and the deformation cylinder 85 drives the deformation drive frame 86 away from the semi-elliptical guide plate 82. The deformation drive frame 86 drives the outermost shaping roller 83 to slide linearly along the straight guide groove 823. The outermost shaping roller 83 drives other shaping rollers 83 to unfold outward through the hinge 84. Several shaping rollers 83 form a chain under the action of the hinge 84, and adjacent shaping rollers 83 are always in close contact. Under the guidance of the arc-shaped guide groove 822, an elliptical cavity is formed between the shaping rollers 83.

[0034] The circular deformation causes the deformation cylinder 85 to retract, which in turn drives the deformation drive frame 86 to approach the semi-elliptical guide plate 82. The deformation drive frame 86 then drives the outermost shaping roller 83 to slide linearly along the straight guide groove 823. The outermost shaping roller 83 applies inward squeezing force to the other shaping rollers 83 through the hinge 84. Under the guidance of the arc-shaped guide groove 822, a circular cavity is formed between the shaping rollers 83.

[0035] In embodiment three, based on the above embodiments, a connector 87 is provided on the lower square drive frame 86, and the upper square drive frame 86 can be inserted into the connector 87. The top opening of the connector 87 is inclined outward.

[0036] With the connector 87 configured in this embodiment, when the upper and lower semi-elliptical guide plates 82 are brought together, the upper square deformation drive frame 86 is inserted into the connector 87, so that the upper and lower deformation drive frames 86 can move synchronously, making the deformation more stable, and eliminating the need to set the deformation cylinder 85 on the upper semi-elliptical guide plate 82, thus reducing costs.

[0037] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A rapid positioning butt welding machine for cable processing, comprising a resistance butt welding machine (1), characterized in that, A fixed clamp (2) is fixedly installed on the top of the resistance welding machine (1), and a movable clamp (3) is slidably connected to the top of the resistance welding machine (1). A bracket (7) is provided between the fixed clamp (2) and the movable clamp (3), and a welding positioning component (8) is rotatably installed inside the bracket (7). The welding positioning assembly (8) includes a rotating frame (88) rotatably installed inside the bracket (7). Two sets of closing cylinders (81) are symmetrically installed on the top and bottom of the rotating frame (88). Semi-elliptical guide plates (82) are fixedly installed on the telescopic ends of the closing cylinders (81). Several shaping rollers (83) are arranged between the two semi-elliptical guide plates (82) at the same height on the left and right. The adjacent shaping rollers (83) are closely fitted, and when the upper and lower semi-elliptical guide plates (82) are closed, the center of the several shaping rollers (83) can form an elliptical cavity and a circular cavity.

2. The rapid positioning butt welding machine for cable processing according to claim 1, characterized in that, The semi-elliptical guide plate (82) is symmetrically provided with a fixed shaft hole (821), several arc-shaped guide grooves (822) and straight guide grooves (823). The fixed shaft hole (821), several arc-shaped guide grooves (822) and straight guide grooves (823) are distributed sequentially from the center of the arc edge of the semi-elliptical guide plate (82) to the endpoint of the arc edge. A shaping roller (83) is fixedly installed in the fixed shaft hole (821). A shaping roller (83) is slidably installed in both the arc-shaped guide grooves (822) and the straight guide grooves (823). Adjacent shaping rollers (83) are connected by a hinge (84).

3. The rapid positioning butt welding machine for cable processing according to claim 2, characterized in that, The outer side of the shaping roller (83) is provided with a hinge groove (831). Adjacent shaping rollers (83) are connected by a hinge (84). The hinge (84) consists of two cylindrical sleeves and an arc-shaped part. The two cylindrical sleeves are fixed at both ends of the arc-shaped part. The outer diameter of the cylindrical sleeves is the same as the outer diameter of the shaping roller (83). The cylindrical sleeves are fitted into the hinge groove (831).

4. A rapid positioning butt welding machine for cable processing according to claim 3, characterized in that, The shaping roller (83) is composed of an outer layer of high borosilicate glass and a central stainless steel rod, and the cylindrical sleeve is also made of high borosilicate glass.

5. A rapid positioning butt welding machine for cable processing according to claim 4, characterized in that, A deformation cylinder (85) is fixedly installed on the outer side of the semi-elliptical guide plate (82), and a deformation drive frame (86) is fixedly installed on the telescopic end of the deformation cylinder (85). The deformation drive frame (86) is fixedly installed on the shaping roller (83) in the linear guide groove (823).

6. A rapid positioning butt welding machine for cable processing according to claim 5, characterized in that, The deformation drive frame (86) below is provided with a connector (87), and the upper square deformation drive frame (86) can be inserted into the connector (87).

7. A rapid positioning butt welding machine for cable processing according to claim 6, characterized in that, The top opening of the connector (87) is inclined outward.

8. A rapid positioning butt welding machine for cable processing according to any one of claims 1-7, characterized in that, The top of the resistance welding machine (1) is fixedly equipped with a drive motor, and the output end of the drive motor is equipped with a drive wheel. The outer side of the rotating frame (88) is provided with a toothed groove, and the drive wheel meshes with the toothed groove.

9. A rapid positioning butt welding machine for cable processing according to claim 8, characterized in that, Both the fixed clamp (2) and the movable clamp (3) consist of an upper resistance chuck, a lower resistance chuck and a clamping cylinder. The top of the resistance welding machine (1) is provided with a guide post (5). The lower resistance chuck in the movable clamp (3) is slidably connected to the guide post (5). The back of the fixed clamp (2) is provided with a driving cylinder (4). The extension end of the driving cylinder (4) is connected to the lower resistance chuck in the movable clamp (3). A proximity switch (6) is provided between the driving cylinder (4) and the movable clamp (3).

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