Process for manufacturing copper-aluminum rivet block

Abstract

The application provides a preparation process of a copper-aluminum riveting block. The preparation process of the copper-aluminum riveting block comprises the following steps: A, material preparation: the size parameters of aluminum sheets and copper rings are reviewed according to a set parameter range, and the aluminum sheets and copper rings meeting the set parameter range are temporarily stored for standby; B, ultrasonic welding: the standby aluminum sheets and copper rings are assembled to an ultrasonic welding device, after the aluminum sheets and copper rings are accurately aligned, solid-phase welding treatment is performed on the two by the ultrasonic welding device, and a riveting block product is obtained after the treatment; the ultrasonic welding device is provided with a monitoring module, and the monitoring module is used for recording welding parameters and size parameters of the riveting block product. The preparation process of the copper-aluminum riveting block is suitable for mass production operation with a high qualified rate.

Description

Technical Field

[0001] This invention relates to the field of mechanical technology, and more specifically to the manufacturing process of copper-aluminum riveting blocks. Background Technology

[0002] As the core sealing and conductive component of a battery, the performance of the battery cover directly determines the battery's safety, conductivity, and lifespan. The copper-aluminum riveting block is a key conductive connector on the battery cover, mainly used to achieve the connection between the battery terminals and the external circuit. It combines the excellent conductivity and thermal conductivity of copper with the lightweight and low-cost characteristics of aluminum, making it the mainstream structural design for current battery covers.

[0003] Currently, the manufacturing process of copper-aluminum riveting blocks for battery covers mostly adopts traditional laser welding or mechanical riveting methods. However, considering the special usage scenarios of battery covers (which need to withstand temperature changes and current surges during battery charging and discharging, and require good sealing performance and low contact resistance), existing processes have many unresolved technical pain points, which seriously affect the overall performance and safety of the battery, as follows:

[0004] 1. Insufficient conductivity and stability: Laser welding requires a high-temperature environment, which can easily lead to the formation of brittle intermetallic compounds (IMCs) at the copper-aluminum interface. This not only significantly increases contact resistance and affects the battery's conductivity, but also reduces the toughness and fatigue resistance of the joint. During long-term charge-discharge temperature cycles, the joint is prone to cracking and detachment, which can lead to safety hazards such as short circuits and leakage. Mechanical riveting achieves connection only through physical compression. The physical properties of copper and aluminum are very different (different coefficients of thermal expansion and hardness), making it difficult to form a tight interatomic bond. During long-term use, loosening can easily occur, leading to fluctuations in contact resistance and affecting the stability of battery performance.

[0005] 2. Assembly precision is difficult to meet the requirements of battery cover: The battery cover has precise dimensions and extremely high requirements for the coaxiality and assembly tolerance of the copper-aluminum riveting blocks. Traditional welding equipment lacks a dedicated positioning structure, making it difficult to achieve precise alignment between the copper ring and the aluminum sheet (battery cover substrate). After welding, coaxiality deviation is prone to occur, leading to assembly interference between the riveting block and the battery terminal and cover body. This not only affects the sealing performance of the battery cover, but may also cause the cover to deform due to uneven stress, posing a safety risk.

[0006] 3. Insufficient corrosion resistance: The battery working environment may contain electrolyte residue, humidity changes, etc., which can easily cause oxidation and corrosion on the surface of the copper ring, leading to increased contact resistance and even conductivity failure. However, the existing process does not provide targeted anti-corrosion treatment for the copper ring, making it difficult to meet the long-term use requirements of the battery.

[0007] 4. Lack of mass production quality control: Battery covers are precision parts produced in batches, with extremely high requirements for product consistency. The existing manufacturing process lacks a full-process parameter monitoring and closed-loop feedback mechanism, making it impossible to track welding parameters and product dimensions in real time. During mass production, batch-related quality problems such as cracking, bulging, and poor welding are prone to occur, making it difficult to control the pass rate stably. This increases production costs, and the entry of unqualified products into the market will seriously affect the safety of battery use.

[0008] Therefore, given the specific application requirements of copper-aluminum riveting blocks for battery covers, there is an urgent need for a manufacturing process that can solve the above-mentioned pain points, achieve high precision, high stability, and high pass rate, and is compatible with industrial mass production, so as to ensure the safe and reliable operation of battery covers. Summary of the Invention

[0009] The purpose of this invention is to address the aforementioned problems in existing technologies by providing a manufacturing process for copper-aluminum riveting blocks that offers high precision, high yield, and is suitable for industrial mass production.

[0010] To achieve the above objectives, the present invention can be implemented through the following technical solutions:

[0011] A manufacturing process for a copper-aluminum riveting block, the copper-aluminum riveting block comprising an aluminum sheet and a copper ring, wherein the aluminum sheet has a through hole, the copper ring is embedded in the through hole of the aluminum sheet and is fixedly connected to the aluminum sheet, the through hole comprises a hole segment one located at the upper part and a hole segment two located at the lower part, both hole segment one and hole segment two are straight holes, the outer diameter of hole segment one is larger than the outer diameter of hole segment two, and the two are arranged on the same axis;

[0012] The copper ring includes a ring body one located at its upper part and a ring body two located at its lower part. The outer diameter of ring body one is larger than the outer diameter of ring body two, and the two are arranged coaxially. The manufacturing process includes the following steps:

[0013] A. Material preparation: Check the size parameters of aluminum sheets and copper rings according to the set parameter range, and temporarily store aluminum sheets and copper rings that meet the set parameter range for later use;

[0014] B. Ultrasonic welding: Assemble the spare aluminum sheet and copper ring onto the ultrasonic welding equipment. After the aluminum sheet and copper ring are precisely aligned, perform solid-state welding on them using the ultrasonic welding equipment. The finished riveted block is then obtained.

[0015] The ultrasonic welding equipment is equipped with a monitoring module, which is used to record welding parameters and the dimensional parameters of the finished riveted block.

[0016] In the above-mentioned manufacturing process of copper-aluminum riveting blocks, in step A, the copper ring undergoes electroplating to form a protective layer on its outer side.

[0017] In the above-mentioned manufacturing process of copper-aluminum riveting blocks, in step A, the protective layer on the outside of the copper ring is electroplated nickel, and the thickness of the protective layer is 3-7 μm.

[0018] In the above-mentioned copper-aluminum riveting block preparation process, in step B, the ultrasonic welding equipment includes a frame, an anvil and a welding head. The anvil is fixedly connected to the lower part of the frame, and the welding head is movably connected to the upper part of the frame. The welding head is located directly above the anvil and can move up and down relative to the anvil. The upper end of the anvil is provided with a convex and concave positioning part one, and the center of the positioning part one has a recessed clearance notch. The lower end of the welding head is provided with a convex and concave positioning part two.

[0019] In the above-mentioned manufacturing process of copper-aluminum riveting blocks, when the aluminum sheet is placed on the anvil, the through hole of the aluminum sheet is aligned with the relief notch, and the diameter of the through hole is smaller than the outer diameter of the relief notch. After the copper ring is inserted into the through hole of the aluminum sheet, the ring body one of the copper ring abuts against the step between the hole segment one and the hole segment two. After the welding head moves down, the positioning part two on it can abut against the upper end of the copper ring. After the aluminum sheet and the copper ring are pressed tightly between the welding head and the anvil, ultrasonic welding is performed.

[0020] In the above-mentioned manufacturing process of copper-aluminum riveting blocks, in step B, the centerline of the positioning notch coincides with the centerline of the through hole in the aluminum sheet.

[0021] In the above-mentioned manufacturing process of copper-aluminum rivet blocks, after step B is completed, the finished rivet block is obtained. The finished rivet block needs to be inspected for appearance, size, resistance, force and cross-section. The test data is recorded in the database. Multiple set number of rivet block test data are selected. If the test results are all within the tolerance range, the set parameter range is used as the standard to enter the subsequent mass production.

[0022] In the above-mentioned manufacturing process of copper-aluminum riveting blocks, the appearance inspection is carried out by taking pictures of the welded joint with a CCD camera and observing whether the product in the picture has cracks, bulges, overflow, or severe discoloration.

[0023] In the aforementioned manufacturing process of copper-aluminum riveting blocks, during mass production, the finished riveting blocks are randomly inspected at set intervals. If the inspection is satisfactory, normal operation proceeds; if it fails, the following two operations are performed:

[0024] First, check if the welding parameters at the monitoring module are normal. If not, adjust and maintain the ultrasonic welding equipment accordingly.

[0025] Secondly, assuming the monitoring module is functioning normally, adjust the set parameter range values ​​for the aluminum sheet and copper ring.

[0026] When the monitoring module malfunctions and the ultrasonic welding equipment is adjusted and maintained, or when the monitoring module is normal and the set parameter range values ​​of the aluminum sheet and copper ring are adjusted, mass production will resume. However, the sampling inspection time for subsequent mass production operations will be shortened, and so on.

[0027] In the above-mentioned manufacturing process of copper-aluminum riveting blocks, the first sampling inspection interval is 1 hour, and the subsequent sampling inspection time is halved after a defective product is found, and so on.

[0028] In the above-mentioned manufacturing process of copper-aluminum riveting blocks, the outer diameter of the first ring is A, the outer diameter of the second ring is B, and the height of the second ring is C.

[0029] The diameter of the first hole segment is D, the diameter of the second hole segment is E, and the depth of the second hole segment is E;

[0030] The above-mentioned parameter settings are within the range of values ​​for A, B, C, D, and E.

[0031] In the above-mentioned manufacturing process of copper-aluminum riveting blocks, the lower limit of dimensions A, B, D, and E in the set parameter range affects the vibration during the welding process, and the upper limit of dimensions A, B, D, and E in the set parameter range affects the coaxiality assembly dimensions of the aluminum sheet and copper sheet in the finished riveting block after welding.

[0032] Compared with existing technologies, the manufacturing process of this copper-aluminum riveting block is specifically designed for the unique application requirements of copper-aluminum riveting blocks for battery covers, and has the following significant advantages: it precisely addresses the core pain points of existing processes and ensures the overall performance of the battery cover and the battery:

[0033] 1. Improved conductivity and reduced battery safety hazards: The ultrasonic solid-state welding process utilizes ultrasonic energy to cause plastic deformation of the copper-aluminum contact surface at low temperatures, forming a tight interatomic bond. This completely avoids the brittle intermetallic compounds (IMC) produced by the high temperatures of traditional laser welding, effectively reducing the contact resistance of the rivet block, improving conductivity efficiency and stability, and meeting the current surge requirements of long-term battery charging and discharging. At the same time, the solid-state connection joint has strong toughness and good fatigue resistance, and can withstand temperature cycling changes during battery charging and discharging, preventing joint cracking and detachment. This reduces the risk of battery short circuits and leakage from the source, ensuring battery safety.

[0034] 2. Ensuring high-precision assembly to meet the precision requirements of battery cover plates: Through the special positioning structure of the ultrasonic welding equipment (concave-convex positioning part one, positioning part two, and coaxial avoidance notch), micron-level precise alignment of the copper ring and aluminum sheet (battery cover plate substrate) is achieved, ensuring high coaxiality of the rivet block after welding, avoiding assembly interference with the battery terminal and cover plate body, while ensuring the fit between the rivet block and the battery cover plate, improving the sealing performance of the battery cover plate, solving the pain point of large coaxiality deviation in traditional processes, and meeting the precision dimensional requirements of the battery cover plate.

[0035] After welding, uneven indentations will remain on the surface of the rivet block. However, since the rivet block is covered by other parts when assembled on the battery cover, it will not be exposed, and the indentations will not affect the assembly of the battery cover.

[0036] 3. Enhanced corrosion resistance and extended battery life: Electroplating the copper ring with nickel (3-7μm thick protective layer) not only effectively isolates it from corrosive media such as air and electrolyte, preventing oxidation and corrosion, but also improves the compatibility of copper-aluminum welding, further enhancing the connection strength and stability of the joint. Improved corrosion resistance of the copper ring avoids problems such as increased contact resistance and conductivity failure caused by corrosion, extending the lifespan of the rivet block and battery cover, thereby improving the overall battery lifespan.

[0037] 4. Achieve end-to-end quality control and ensure mass production consistency: A closed-loop quality control system has been established, encompassing "material preparation verification - welding monitoring - finished product full inspection - dynamic sampling inspection during mass production." The monitoring module records welding parameters and product dimensions in real time, and combined with multi-dimensional inspections of appearance, dimensions, resistance, top force, and cross-section, ensures product quality traceability. Simultaneously, the dynamic sampling inspection mechanism (shortening the sampling interval after non-compliance) can promptly identify equipment or parameter issues during mass production and make rapid adjustments, ensuring that product test results are within tolerance limits. This meets the consistency requirements for mass production of battery cover plates, reduces production costs, and improves production efficiency.

[0038] 5. Strong process adaptability, balancing performance and cost: This process has simple steps, and the ultrasonic welding equipment is highly versatile, adaptable to the production of copper-aluminum riveting blocks for battery cover plates of different specifications; the design cost of the electroplated nickel protective layer is controllable, improving product performance without significantly increasing production costs. Compared with traditional laser welding and mechanical riveting processes, it is more suitable for industrial mass production, providing battery cover plate manufacturers with an efficient, high-quality, and low-cost manufacturing solution. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the three-dimensional structure of the aluminum sheet.

[0040] Figure 2 This is a schematic diagram of the three-dimensional structure of a copper ring.

[0041] Figure 3 This is a cross-sectional structural diagram of the copper-aluminum riveting block.

[0042] Figure 4 This is a structural diagram of the ultrasonic welding operation area.

[0043] In the picture:

[0044] 1. Aluminum sheet; 11. Hole section one; 3. Hole section two; 2. Copper ring; 21. Ring body one; 22. Ring body two; 3. Frame; 4. Anvil; 41. Positioning part one; 42. Avoidance notch; 5. Welding head; 51. Positioning part two. Detailed Implementation

[0045] The following are specific embodiments of the present invention, which, together with the accompanying drawings, will further describe the technical solution of the present invention.

[0046] like Figure 1-4 As shown, the copper-aluminum riveting block includes an aluminum sheet 1 and a copper ring 2. The aluminum sheet 1 has a through hole, and the copper ring 2 is embedded in the through hole of the aluminum sheet 1 and is fixedly connected to the aluminum sheet 1. The through hole includes a hole segment 11 located at the upper part and a hole segment 3 located at the lower part. Both hole segment 11 and hole segment 3 are straight holes. The diameter of hole segment 11 is larger than that of hole segment 3, and the two are set on the same axis.

[0047] The copper ring 2 includes a ring body 21 located at the upper part and a ring body 22 located at the lower part. The outer diameter of the ring body 21 is larger than that of the ring body 22, and the two are arranged on the same axis.

[0048] The manufacturing process of this copper-aluminum riveting block includes the following steps:

[0049] A. Material preparation: Check the size parameters of aluminum sheet 1 and copper ring 2 according to the set parameter range, and temporarily store aluminum sheet 1 and copper ring 2 that meet the set parameter range for later use;

[0050] In step A, the copper ring 2 undergoes electroplating to form a protective layer on its outer side.

[0051] In step A, the protective layer on the outside of the copper ring 2 is electroplated nickel, and the thickness of the protective layer is 3μm. Depending on the actual situation, a protective layer with a thickness of 5μm or 7μm can also be used.

[0052] B. Ultrasonic welding: Assemble the spare aluminum sheet 1 and copper ring 2 into the ultrasonic welding equipment. After the aluminum sheet 1 and copper ring 2 are precisely aligned, perform solid-state welding on them using the ultrasonic welding equipment. After the treatment, the finished riveted block is obtained.

[0053] The ultrasonic welding equipment is equipped with a monitoring module, which is used to record welding parameters and the dimensional parameters of the finished riveted block.

[0054] The stepped through-hole design serves two purposes. First, it utilizes the difference in diameter between the upper and lower holes to form an axial limiting structure, preventing axial movement of the copper ring 2 during assembly and ensuring assembly positioning accuracy. Second, the coaxial centerline setting avoids the eccentricity problem between the copper ring 2 and the aluminum sheet 1 from a structural perspective, laying a structural foundation for coaxiality control in subsequent welding processes. At the same time, the straight hole structure facilitates processing, reduces component manufacturing costs, and is suitable for mass production needs.

[0055] The stepped structure of the copper ring 2 corresponds one-to-one with the stepped structure of the through hole of the aluminum sheet 1. During assembly, the second ring 22 can be precisely embedded inside the second hole 3, while the first ring 21 abuts against the stepped surface formed by the first hole 11 and the second hole 3, realizing the pre-positioning of the copper ring 2 and the aluminum sheet 1, avoiding the copper ring 2 from shifting or tilting during welding, and ensuring the coaxiality of the two. At the same time, the non-equal diameter structure can increase the contact area between the copper ring 2 and the aluminum sheet 1, providing sufficient working surface for the solid-phase connection of ultrasonic welding and improving the welding bonding force.

[0056] Dimensional verification is to avoid welding defects caused by component dimensional deviations from the source, ensure the compatibility of subsequent assembly and welding processes, and prevent the entire finished product from being scrapped due to the non-compliance of a single component's dimensions.

[0057] The nickel-plated protective layer on the outer side of copper ring 2 can, on the one hand, isolate the galvanic corrosion caused by direct contact between copper and aluminum, and extend the service life of the rivet block. On the other hand, the nickel layer has good hardness and wear resistance, which can protect the surface of copper ring 2 from scratches and oxidation during assembly and welding. At the same time, it optimizes the ultrasonic vibration transmission effect and ensures welding stability.

[0058] The coating thickness is controlled between 3-7μm. If the thickness is too thin, it cannot provide effective protection and conductivity optimization. If the thickness is too thick, it will increase the impedance of the welding interface, affect the transmission of ultrasonic energy, and increase production costs. This thickness range balances protection performance, welding performance, and economy.

[0059] In step B, the ultrasonic welding equipment includes a frame 3, an anvil 4, and a welding head 5. The anvil 4 is fixedly connected to the lower part of the frame 3, and the welding head 5 is movably connected to the upper part of the frame 3. The welding head 5 is located directly above the anvil 4 and can move up and down relative to the anvil 4. The upper end of the anvil 4 is provided with a positioning part 41 with a concave-convex shape, and the center of the positioning part 41 has a recessed clearance notch 42. The lower end of the welding head 5 is provided with a positioning part 51 with a concave-convex shape.

[0060] When the aluminum sheet 1 is placed on the anvil 4, the through hole of the aluminum sheet 1 is aligned with the relief recess 42, and the diameter of the through hole is smaller than the outer diameter of the relief recess 42. After the copper ring 2 is inserted into the through hole of the aluminum sheet 1, the ring body 21 of the copper ring 2 abuts against the step between the hole segment 11 and the hole segment 3. After the welding head 5 moves down, the positioning part 51 on it can abut against the upper end of the copper ring 2. After the aluminum sheet 1 and the copper ring 2 are pressed tightly between the welding head 5 and the anvil 4, ultrasonic welding is performed.

[0061] In step B, the centerline of the avoidance notch 42 coincides with the centerline of the through hole of the aluminum sheet 1.

[0062] During assembly, aluminum sheet 1 is placed stably on positioning part 41 of anvil 4, ensuring that the through hole of aluminum sheet 1 is aligned with the relief recess 42 in the center of anvil 4, and that the overall diameter of the through hole is smaller than the outer diameter of relief recess 42, to prevent the edge of aluminum sheet 1 from sinking into relief recess 42 and affecting positioning; then copper ring 2 is inserted into the through hole of aluminum sheet 1, with the second ring body 22 of copper ring 2 fully extending into the second hole segment 3, and the first ring body 21 stably abutting against the step surface between the first hole segment 11 and the second hole segment 3, completing the pre-positioning; then the welding head 5 is controlled to move down smoothly, and the positioning part 51 at the lower end of the welding head 5 precisely abuts against the upper end of copper ring 2, stably pressing aluminum sheet 1 and copper ring 2 between welding head 5 and anvil 4, maintaining coaxiality, and then the ultrasonic welding program is started to complete solid phase welding.

[0063] The concave-convex positioning part 41 and the second positioning part 51 can achieve dual precise positioning of aluminum sheet 1 and copper ring 2. Combined with the coaxial design of the avoidance notch 42, the component offset problem during welding is completely solved, ensuring the coaxiality of the finished product. The avoidance notch 42 can prevent the bottom of copper ring 2 from hard contacting the anvil 4 during welding, thus protecting the structural integrity of copper ring 2.

[0064] Ultrasonic welding uses high-frequency vibration energy to act on the contact interface between the copper ring 2 and the aluminum sheet 1, causing the metal molecules at the interface to vibrate violently, breaking the surface oxide film and impurities. Under pressure, solid bonding between metal molecules is achieved. No solder or molten metal is required, and there are no problems such as welding thermal deformation, incomplete welding, or cracks. It is suitable for high-strength and high-precision connection of dissimilar copper and aluminum metals, and has high welding efficiency, making it suitable for mass production.

[0065] After step B is completed, the finished riveting block is obtained. The finished riveting block needs to be inspected for appearance, size, resistance, force and cross-section. The test data is recorded in the database. Multiple set number of riveting block test data are selected. If the test results are all within the tolerance range, the set parameter range is used as the standard to enter the subsequent mass production.

[0066] In this embodiment, test data from 10 riveting blocks are selected, and a pass rate of 100% is acceptable.

[0067] The visual inspection involves taking photos of the welded areas with a CCD camera and observing whether the product in the photos has cracks, bulges, excess material, or severe discoloration.

[0068] During mass production, the finished riveting blocks are randomly inspected at set intervals. If the inspection is satisfactory, normal operation proceeds; otherwise, the following two operations are performed:

[0069] First, check if the welding parameters at the monitoring module are normal. If not, adjust and maintain the ultrasonic welding equipment accordingly.

[0070] Secondly, assuming the monitoring module is functioning normally, adjust the set parameter range values ​​for aluminum plate 1 and copper ring 2.

[0071] When the monitoring module malfunctions and the ultrasonic welding equipment is adjusted and maintained, or when the monitoring module is normal and the set parameter range values ​​of aluminum sheet 1 and copper ring 2 are adjusted, mass production will resume. However, the sampling inspection time for subsequent mass production operations will be shortened, and so on.

[0072] The initial sampling interval is 1 hour. Subsequent sampling intervals after a non-conforming product is found are halved, and so on.

[0073] The outer diameter of the first ring 21 is A, the outer diameter of the second ring 22 is B, and the height of the second ring 22 is C.

[0074] The diameter of the first hole segment 11 is D, the diameter of the second hole segment 3 is E, and the depth of the second hole segment 3 is E;

[0075] The above-mentioned parameter settings are within the range of values ​​for A, B, C, D, and E.

[0076] The lower limits of dimensions A, B, D, and E in the parameter range affect the vibration during the welding process, while the upper limits of dimensions A, B, D, and E in the parameter range affect the coaxiality assembly dimensions of aluminum sheet 1 and copper ring 2 in the finished riveted block after welding.

[0077] The lower limits of parameters A, B, D, and E directly affect the vibration transmission efficiency during ultrasonic welding. If the lower limit is too small, the welding contact area will be too small, and the ultrasonic vibration energy cannot be effectively transmitted to the welding interface, which can easily lead to weak welding and incomplete welding. The upper limits of parameters A, B, D, and E directly determine the coaxiality assembly accuracy of aluminum sheet 1 and copper ring 2 in the finished product after welding. If the upper limit is too large, the fit gap between copper ring 2 and the through hole of aluminum sheet 1 will be too large. During the welding process, copper ring 2 is easily affected by vibration and becomes eccentric, which cannot guarantee the coaxiality requirement. At the same time, an excessive gap will reduce the tightness of the welded joint.

[0078] If the random inspection is qualified, it means that the current material preparation parameters and welding equipment parameters are normal, and mass production operations can continue to be carried out according to the original process and random inspection frequency.

[0079] If the random inspection fails, mass production should be immediately suspended, and two troubleshooting operations should be performed simultaneously:

[0080] First, retrieve the welding parameters recorded by the monitoring module and check whether parameters such as vibration frequency, pressure, and time deviate from the standard range. If the parameters are abnormal, immediately debug, maintain, and calibrate the ultrasonic welding equipment until the parameters return to normal.

[0081] Secondly, if the monitoring module shows that the welding parameters are completely normal, it means that the reason for the failure is due to the deviation of the raw material size. It is necessary to finely adjust the parameter range of A, B, C, D and E of aluminum sheet 1 and copper ring 2 to reduce the size tolerance and improve the accuracy of the raw material.

[0082] Once the equipment debugging is completed or the parameter range is adjusted, mass production will resume. At the same time, the subsequent sampling inspection interval will be halved from the original level to strengthen quality control. If unqualified products are found again, the sampling inspection interval will be halved again, and so on, until the product quality is consistently stable, and then the regular sampling inspection frequency will be gradually restored.

[0083] By adopting a dynamic sampling inspection and hierarchical control model, the root cause of quality abnormalities in the mass production process can be quickly located, distinguishing between equipment failures and raw material deviations, and targeted solutions can be implemented to avoid blind adjustments. Gradually shortening the sampling inspection interval allows for rapid verification of the rectification effect after anomaly repair, preventing the production of batches of unqualified products, reducing production losses, and enabling rapid traceability of quality problems through full-process data monitoring, ensuring the stability and consistency of mass production.

[0084] The technical solutions of the present invention described above provide solutions that are significantly different from those of the prior art, addressing the problem that existing technical solutions are too simplistic. The parts not covered in this application are the same as or can be implemented using existing technologies, and will not be described in detail here.

[0085] The technical solutions in the above embodiments have clearly and completely described the content of the present invention. 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.

Claims

1. A manufacturing process for a copper-aluminum riveting block, the copper-aluminum riveting block comprising an aluminum sheet and a copper ring, wherein the aluminum sheet has a through hole, the copper ring is embedded in the through hole of the aluminum sheet and is fixedly connected to the aluminum sheet, the through hole comprising a hole segment one located at its upper part and a hole segment two located at its lower part, both hole segment one and hole segment two being straight holes, the outer diameter of hole segment one being larger than the outer diameter of hole segment two, and both being arranged on the same axis; The copper ring includes a ring body one located at its upper part and a ring body two located at its lower part. The outer diameter of ring body one is larger than the outer diameter of ring body two, and the two are arranged coaxially. Its characteristic is that... This preparation process includes the following steps: A. Material preparation: Check the size parameters of aluminum sheets and copper rings according to the set parameter range, and temporarily store aluminum sheets and copper rings that meet the set parameter range for later use; B. Ultrasonic welding: Assemble the spare aluminum sheet and copper ring onto the ultrasonic welding equipment. After the aluminum sheet and copper ring are precisely aligned, perform solid-state welding on them using the ultrasonic welding equipment. The finished riveted block is then obtained. The ultrasonic welding equipment is equipped with a monitoring module, which is used to record welding parameters and the dimensional parameters of the finished riveted block.

2. The manufacturing process of the copper-aluminum riveting block according to claim 1, characterized in that, In step A, the copper ring undergoes electroplating to form a protective layer on its outer side.

3. The manufacturing process of the copper-aluminum riveting block according to claim 2, characterized in that, In step A, the protective layer on the outside of the copper ring is electroplated nickel, and the thickness of the protective layer is 3-7 μm.

4. The manufacturing process of the copper-aluminum riveting block according to claim 1, 2, or 3, characterized in that, In step B, the ultrasonic welding equipment includes a frame, an anvil, and a welding head. The anvil is fixedly connected to the lower part of the frame, and the welding head is movably connected to the upper part of the frame. The welding head is located directly above the anvil and can move up and down relative to the anvil. The upper end of the anvil is provided with a convex and concave positioning part one, and the center of the positioning part one has a recessed clearance notch. The lower end of the welding head is provided with a convex and concave positioning part two. When the aluminum sheet is placed on the anvil, the through hole of the aluminum sheet is aligned with the relief notch, and the diameter of the through hole is smaller than the outer diameter of the relief notch. After the copper ring is inserted into the through hole of the aluminum sheet, the first ring of the copper ring rests against the step between the first and second hole segments. After the welding head moves down, the second positioning part on it can rest against the upper end of the copper ring. After the aluminum sheet and the copper ring are pressed tightly between the welding head and the anvil, ultrasonic welding is performed.

5. The manufacturing process of the copper-aluminum riveting block according to claim 4, characterized in that, In step B, the centerline of the positioning notch coincides with the centerline of the through hole in the aluminum sheet.

6. The manufacturing process of the copper-aluminum riveting block according to claim 1, 2, or 3, characterized in that, After step B is completed, the finished riveting block is obtained. The finished riveting block needs to be inspected for appearance, size, resistance, force and cross-section. The test data is recorded in the database. Multiple set number of riveting block test data are selected. If the test results are all within the tolerance range, the set parameter range is used as the standard to enter the subsequent mass production.

7. The manufacturing process of the copper-aluminum riveting block according to claim 6, characterized in that, The visual inspection involves taking photos of the welded joints with a CCD camera and observing whether the product in the photos has cracks, bulges, excess material, or severe discoloration.

8. The manufacturing process of the copper-aluminum riveting block according to claim 6, characterized in that, During mass production, the finished riveting blocks are randomly inspected at set intervals. If the inspection is satisfactory, normal operation proceeds; otherwise, the following two operations are performed: First, check if the welding parameters at the monitoring module are normal. If not, adjust and maintain the ultrasonic welding equipment accordingly. Secondly, assuming the monitoring module is functioning normally, adjust the set parameter range values ​​for the aluminum sheet and copper ring. When the monitoring module malfunctions and the ultrasonic welding equipment is adjusted and maintained, or when the monitoring module is normal and the set parameter range values ​​of the aluminum sheet and copper ring are adjusted, mass production will resume. However, the sampling inspection time for subsequent mass production operations will be shortened, and so on.

9. The manufacturing process of the copper-aluminum riveting block according to claim 8, characterized in that, The initial sampling interval is 1 hour. Subsequent sampling intervals after a non-conforming product is found are halved, and so on.

10. The manufacturing process of the copper-aluminum riveting block according to claim 1, 2, or 3, characterized in that, The outer diameter of the first ring is A, the outer diameter of the second ring is B, and the height of the second ring is C; The diameter of the first hole segment is D, the diameter of the second hole segment is E, and the depth of the second hole segment is E; The above-mentioned parameter settings are within the range of values ​​for A, B, C, D, and E.

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