A welding process and apparatus for battery connections

Abstract

The application relates to the technical field of welding, and specifically discloses a welding process and a welding device for a battery connecting piece, which comprises the following steps: step S1, placing a connecting head on a positioning column; step S2, sleeving a connecting plate on the connecting head, and positioning the connecting plate by a positioning plate; step S3, a transfer member grabbing a welding ring and sleeving the welding ring on the joint of the connecting head and the connecting plate; step S4, the movable end of a pressing member extending to press the connecting plate; step S5, a heating member heating a welding position, the welding ring melting after being heated and welding and fixing the connecting head and the connecting plate to form the battery connecting piece; and step S6, stopping heating, and after the welding position is cooled, the movable end of the pressing member is retracted, and the battery connecting piece is taken out. The welding ring is used to replace the solder paste, and automatic feeding, pressing and welding are realized, so that the production efficiency of the battery connecting piece is improved, and the consistency of the welding quality is ensured through a standardized operation process.

Description

Technical Field

[0001] This application relates to the field of welding technology, and in particular to a welding process and welding apparatus for battery connectors. Background Technology

[0002] Battery connectors are conductors used to carry current between components in a battery circuit. They are mainly used for electrical connections between individual cells, between battery terminals and battery pack terminals, or between battery pack terminals and external circuits. Their core function is to achieve current transmission. Traditional soldering processes typically involve applying solder paste to the connector head and then soldering the connector head and connecting plate together. This results in low overall production efficiency for battery connectors, and it is difficult to guarantee consistency in their production. Summary of the Invention

[0003] In order to improve the efficiency of the battery connector welding process while ensuring production consistency, this application provides a welding process and welding apparatus for battery connectors.

[0004] In a first aspect, this application provides a welding process for a battery connector, employing the following technical solution: A welding process for a battery connector includes the following steps: Step S1: Provide a welding device with a positioning element, a pressing element, a transferring element and a heating element, and place the connector on the positioning post; Step S2: Place the connecting plate onto the connecting head and use a positioning plate to position the connecting plate; Step S3: The transfer component picks up a welding ring and places the welding ring on the joint between the connector and the connecting plate; Step S4: Extend the movable end of the pressing member to press the connecting plate; Step S5: The heating element heats the welding area of ​​the welding ring, the connector and the connecting plate, so that the welding ring melts after being heated and welds and fixes the connector and the connecting plate to form a battery connector. Step S6: Stop heating and wait for the welded area to cool down. Then, retract the movable end of the pressing member and remove the battery connector.

[0005] By adopting the above technical solution, this process replaces the traditional manual application of solder paste with a solid welding ring, and through automated assembly, pressing and heating welding steps, realizes an automated process from parts assembly to welding formation, replacing inefficient and inconsistent manual work, effectively solving the technical problems of low production efficiency and difficulty in ensuring consistency pointed out in the background technology, and improving the production efficiency and product quality stability of battery connectors.

[0006] Optionally, the process further includes step S7: providing a detection mechanism with a clamping component, a pulling component, and a detection component; placing the battery connector in the detection mechanism; having the clamping component clamp the connecting plate; having the pulling component apply tension to the connector for a pull test; and having the detection component perform image detection on the battery connector after the pull test. If no cracks are found at the weld, the battery connector is collected. If cracks are found at the weld, the next battery connector undergoes pull testing and image detection, and an alarm is triggered if cracks are detected twice consecutively. Step S8: repeating steps S1-S6, welding several times consecutively, and then proceeding to step S7.

[0007] By adopting the above technical solution, this process integrates an online sampling quality inspection link that includes pull-out testing and image detection on the basis of automated welding. It can not only verify the welding strength, but also identify potential micro-crack defects. Through a continuous defect alarm mechanism, it can promptly detect systemic problems in the production process, realize closed-loop control of production and quality monitoring, and help ensure the reliability of batch products from the source.

[0008] Optionally, step S7 includes: S71. Press and fix the connecting plate with the clamping assembly; S72. The pulling assembly screws a pulling rod into the connector and threadedly connects the pulling rod to the connector. S73. The pull-out assembly applies a pulling force to the pull-out rod to perform a pull-out test on the connector. S74. The pulling assembly rotates the pulling rod out of the connector; S75. The detection component performs visual inspection on the welded area. By adopting the above technical solution and using a threaded engagement method, the pulling force is ensured to be applied stably and reliably to the connector, avoiding the slippage or uneven force problems that may occur with traditional clamps. The screwing-in process of the pulling rod and the application of pulling force to the pulling rod can both be achieved by the pulling assembly. The two processes are performed sequentially with a short time interval between them, which helps to improve the efficiency of the inspection process.

[0009] Secondly, this application provides a welding apparatus, which adopts the following technical solution: A welding apparatus, employing the welding process for battery connectors as described in any of the preceding claims, includes a welding mechanism. The welding mechanism includes a base and a positioning member, a pressing member, a transferring member, and a heating member disposed on the base. The positioning member is used to position a connector head and a connecting plate. The pressing member is used to press the connecting plate and the connector head together. The transferring member is used to place a welding ring at the joint between the connector head and the connecting plate. The heating member is used to heat the welding ring at the joint between the connecting plate and the connector head.

[0010] By adopting the above technical solution, the welding device integrates multiple automated functional units for positioning, clamping, feeding, and welding, thereby better realizing the automated welding process. The coordinated work of each functional component replaces multiple independent workstations and manual operations in traditional production, thus effectively improving production efficiency and welding consistency.

[0011] Optionally, it also includes an inspection mechanism, which includes a clamping component, a pulling component, and an inspection component. The clamping component is used to clamp the connecting plate, the pulling component is used to apply tension to the connector welded to the connecting plate for a pull-out test, and the inspection component is used to perform visual inspection of the weld between the connecting plate and the connector.

[0012] By adopting the above technical solutions, the drawing component is used to quantify the welding strength, and the inspection component is used to detect appearance defects. The combination of the two provides a more comprehensive assessment of product quality, which moves the quality control link forward to the production equipment itself and helps to respond quickly to production anomalies.

[0013] Optionally, the pull assembly includes a screw-in component and a pull-out component; the screw-in component includes a first rotating power component, a sleeve, and a pull rod, the sleeve being connected to the output end of the first rotating power component, the first end of the pull rod having a sliding block slidably disposed inside the sleeve and capable of abutting against the end of the sleeve, the second end of the pull rod having a thread adapted to a screw hole on the connector, and the first rotating power component being used to drive the pull rod to rotate through the sleeve and cause the end of the pull rod to screw into the connector; The pull-out component includes a second rotary power component, a lead screw, and a sliding plate. The lead screw is connected to the movable end of the second rotary power component. The sliding plate is rotatably connected to the sleeve and is slidably disposed. The sliding plate is threadedly connected to the lead screw. The second rotary power component is used to drive the lead screw to rotate so that the sliding plate drives the sleeve to move.

[0014] By adopting the above technical solution, the screwing and pulling functions of the pulling component are integrated into an integrated structure. By controlling two independent power components, the screwing in and pulling action of the pulling rod can be completed at the same station. This design avoids the complex process of requiring two independent mechanisms to move and operate sequentially, simplifies the equipment structure, shortens the cycle time of a single test, and thus improves the testing efficiency.

[0015] Optionally, a connecting ring is provided at the end of the sleeve away from the first rotating power component. The connecting ring is sleeved on the outside of the pull rod, and a pressure sensor is provided on the connecting ring for abutting against the sliding block.

[0016] By adopting the above technical solution, a pressure sensor is added to the force transmission path of the pull rod. When the pulling component moves the sleeve upward, the sleeve lifts the pressure sensor through the connecting ring, so that the pressure sensor abuts against the sliding block on the pull rod, thereby accurately transmitting the pulling force to the pressure sensor. This enables the device to monitor the pulling force value in real time and quantitatively, providing objective and accurate data support for the evaluation of welding strength.

[0017] Optionally, an elastic element is connected between the sliding block and the sleeve, the elastic element being used to drive the sliding block to slide away from the first rotating power element; when the sliding block abuts against the pressure sensor, the elastic element is in an unenergized state.

[0018] By adopting the above technical solution, during the screwing-in stage, when the pull rod presses down and contacts the connector, the sleeve can continue to move downward and compress the elastic element. The pre-pressure generated by the elastic element ensures that the threaded end of the pull rod is stably aligned and reliably screwed in, thereby preventing the bottom end of the pull rod from rotating in place and ensuring the smooth progress of the screwing process. During the pulling-out stage, when the sleeve is lifted to make the pressure sensor contact the sliding block, the elastic element just returns to its natural length, and the force of the elastic element is zero. This ensures that the force measured by the pressure sensor is entirely the pulling force acting on the weld joint, avoiding interference from the elastic force of the elastic element and ensuring the accuracy of the detection data. In addition, when the bottom end of the pull rod is accidentally pulled upward from the connector, the elastic element can act as a buffer to prevent the pull rod from sliding upward rapidly, causing an impact and damaging the device.

[0019] Optionally, the end of the pull rod away from the sleeve has a conical surface, and the end of the pull rod inside the sleeve has a connecting plate with a protrusion. The sliding block has a receiving groove inside and a through hole communicating with the receiving groove. The diameter of the through hole is larger than the diameter of the pull rod, and the pull rod passes through the through hole. The connecting plate is located in the receiving groove, and the inner wall of the receiving groove has a push block for abutting against the protrusion, so that when the sliding block rotates, the push block pushes the protrusion and the connecting plate to rotate.

[0020] By adopting the above technical solution, a conical surface is provided at the end of the pull rod, and the diameter of the through hole is larger than the diameter of the pull rod, enabling the pull rod to float laterally. When there is a positional deviation between the pull rod and the threaded hole on the connector, the contact between the conical surface and the threaded hole opening during the downward movement of the pull rod generates a lateral force, thereby guiding the pull rod to automatically adjust its position and align with the center. This effectively compensates for alignment problems caused by manufacturing or installation errors, ensuring smooth thread engagement and improving the reliability of automated assembly. This solution, through the gentle guidance of the conical surface, ensures that the threads only begin to mesh after correct alignment, avoiding microscopic damage caused by hard contact and forceful engagement from the source. This effectively protects the pull rod, a critical testing component, extends the service life of the entire equipment, and ensures the testing results after multiple tests.

[0021] Optionally, the push block is provided in a plurality of positions arranged in a circular array, and the protrusion is provided in a plurality of positions arranged in a circular array, with the protrusion and the push block arranged alternately along the circumferential direction.

[0022] By adopting the above technical solution, the driving force can be applied to the connecting plate simultaneously and evenly from multiple points. Compared with single-point transmission, this multi-point distributed drive avoids tilting, shaking, or jamming of the connecting plate due to uneven force distribution, ensuring a smoother and more reliable torque transmission process and the ability to withstand greater driving torque, which helps to ensure the smooth progress of the thread engagement process. The protrusions and push blocks are arranged in a staggered circumferential direction, so that no matter what initial rotation angle the sliding block is at, its slight rotation can quickly engage the push block with the adjacent protrusion, thereby effectively reducing the rotational backlash. This allows the rotation command to be transmitted to the pull rod instantly and accurately, improving the response speed of the entire drive system.

[0023] In summary, this application includes the following beneficial technical effects: 1. By using welding rings instead of solder paste and automating feeding, pressing, and welding, the production efficiency of battery connectors is improved, and the consistency of welding quality is ensured through standardized operating procedures.

[0024] 2. It integrates online pull-out force testing and weld image inspection functions. By integrating the inspection steps with the welding steps, it can monitor and provide rapid feedback on welding quality in real time, which helps to improve the overall reliability of the product.

[0025] 3. The integrated design of the pull-out assembly allows for the screwing in and pulling out of the pull-out rod at the same station, making the testing process more convenient and efficient, thus improving testing efficiency. The elastic element applies pre-pressure to the pull-out rod during the screwing-in phase to ensure smooth screwing in; conversely, it prevents the application of elastic force to the pull-out rod during the pulling phase, ensuring accurate detection of the applied force and thus guaranteeing the accuracy of the test results. Attached Figure Description

[0026] Figure 1 This is a process flow diagram of Embodiment 1 of this application; Figure 2 This is a schematic diagram of the welding apparatus in Embodiment 1 of this application; Figure 3 This is a structural diagram used to show the welded connecting plate and connector; Figure 4 This is a process flow diagram of Embodiment 2 of this application; Figure 5 This is a schematic diagram of the testing mechanism in Embodiment 2 of this application; Figure 6 This is a cross-sectional view of Embodiment 2 of this application used to illustrate the clamping assembly; Figure 7 This is a cross-sectional view of Embodiment 2 of this application used to illustrate the pulling assembly; Figure 8 yes Figure 7 A magnified view of a portion of point A in the middle; Figure 9 yes Figure 8 A magnified view of a portion of point B in the middle; Figure 10 It is along Figure 6 A cross-sectional view along the aa direction; Figure 11 yes Figure 10 A magnified view of a portion of point C in the middle; Figure 12 This is a schematic diagram of the structure of the sliding block and the pull rod in Embodiment 2 of this application.

[0027] Reference numerals: 1. Welding mechanism; 11. Base; 12. Positioning component; 121. Positioning post; 122. Positioning plate; 13. Pressing component; 131. Pressing post; 14. Heating component; 2. Detection mechanism; 21. Clamping assembly; 211. Motor; 212. Screw; 213. Pressure plate; 22. Pulling assembly; 221. Screw engagement component; 2211. First rotational power component; 2212. Sleeve; 2212a. Connecting ring; 2212b. Pressure sensor; 2212c. Mounting ring; 2213. Pulling rod ; 2213a, conical surface; 222, pull-out component; 2221, second rotating power component; 2222, lead screw; 2223, sliding plate; 2223a, mounting groove; 2223b, mounting plate; 23, detection component; 231, cylinder; 232, CCD camera; 3, sliding block; 31, receiving groove; 311, push block; 32, perforation; 4, connecting plate; 41, protrusion; 5, elastic element; 6, connector; 7, connecting plate; 8, base plate; 81, bracket; 82, first support plate; 83, second support plate. Detailed Implementation

[0028] The following combination Figures 1-12 This application will be described in further detail.

[0029] Example 1: This application discloses a welding process for a battery connector, referring to... Figure 1 This includes the following steps: Step S1: Place the connector 6 on the positioning post 121. The positioning post 121 initially defines the position of the connector 6.

[0030] Step S2: Place the connecting plate 7 onto the connector 6, and position the connecting plate 7 with the positioning plate 122 to ensure that the relative positional relationship between the connecting plate 7 and the connector 6 meets the requirements.

[0031] Step S3: The transfer unit picks up a solid welding ring from the material area, moves it to the top of the workstation, and accurately places the welding ring onto the joint between the connector 6 and the connecting plate 7.

[0032] Step S4: The movable end of the pressing member 13 extends and applies downward force to press the connecting plate 7.

[0033] Step S5: The heating element 14 is activated to heat the welding area. The welding ring melts at high temperature, and the molten solder fills the gap between the connector 6 and the connecting plate 7, thereby firmly welding the two together to form a battery connector.

[0034] Step S6: After welding is completed, the heating element 14 stops working and waits for the welded area to cool down. After the molten solder solidifies, a strong weld is formed. At this time, the movable end of the pressing element 13 retracts, releasing the pressure on the workpiece, and the battery connector is removed.

[0035] Reference Figure 2 and Figure 3 This embodiment also discloses a welding apparatus applied in the above-mentioned process. The welding apparatus includes a welding mechanism 1, which includes a base 11 and a positioning element 12, a pressing element 13, a transfer element (not shown in the figure), and a heating element 14 disposed on the base 11. The positioning element 12 is used to accurately position the connecting plate 7 and the connector 6 before welding. The positioning element 12 includes a positioning post 121 and a positioning plate 122. The positioning post 121 is vertically arranged and can pass through the through hole in the center of the connector 6, thereby achieving accurate positioning of the connector 6. The positioning plate 122 is detachably connected to the top wall of the base 11 by bolts. The positioning plate 122 can cooperate with the connecting plate 7 so that the edge of the connecting plate 7 can engage with the positioning plate 122, thereby achieving accurate positioning of the connecting plate 7. The shape of the positioning plate 122 can be changed according to the shape of the connecting plate 7 to adapt to different shapes of connecting plates 7.

[0036] The transfer device is a robotic arm used to pick up the welding ring from the feeding area and precisely place it at the joint between the connector 6 and the connecting plate 7. This design replaces the traditional manual application of solder paste, improving feeding speed and consistency. In other embodiments, the transfer device may also be a multi-axis motion module.

[0037] The pressing component 13 is a cylinder. The piston rod of the pressing component 13 is vertically downward, and two pressing columns 131 are fixedly installed at the end of the piston rod of the pressing component 13. After the connector 6 and the connecting plate 7 are positioned, the piston rod of the pressing component 13 extends, causing the pressing columns 131 to move downward. The bottom end of the pressing column 131 presses against the top wall of the connecting plate 7, thus preventing the connecting plate 7 from shifting during the heating and welding process and ensuring the stability of the welding quality.

[0038] The heating element 14 is responsible for providing the heat required for welding. In this embodiment, the heating element 14 is an electromagnetic eddy current heater, which has the advantages of fast heating speed, precise local heating, and no open flame. The above components work together to form an automated welding unit, which can efficiently and stably complete the production of battery connectors.

[0039] The implementation principle of Embodiment 1 is as follows: The connector 6 is placed on the base 11, and the positioning pin 121 passes through the through hole in the center of the connector 6, thus positioning the connector 6. Next, the connecting plate 7 is placed on the positioning plate 122, and the edge of the connecting plate 7 engages with the edge of the positioning plate 122, thus positioning the connecting plate 7. At this time, a portion of the connector 6 is located inside the opening area on the connecting plate 7, and the joint between the connector 6 and the connecting plate 7 is the area to be welded later. An annular welding groove is provided on one side of the opening area on the connecting plate 7, allowing a welding ring to be inserted.

[0040] Next, the transfer unit grabs the welding ring from the loading area and moves it above the welding groove, then places the welding ring in the welding groove. Then, the pressing member 13 applies a pre-tightening force to the connecting plate 7 to press and fix the connecting plate 7; then, the heating member 14 induction heats the welding part where the welding ring is located, melting the welding ring and completing the welding.

[0041] Example 2: Refer to Figure 4 The difference between this embodiment and embodiment 1 is that, in this embodiment, after step S6, step S7 is also included: placing the battery connector in the detection mechanism 2. The detection mechanism 2 includes a clamping component 21, a pulling component 22, and a detection component 23. The clamping component 21 clamps the connecting plate 7, the pulling component 22 applies a pulling force to the connector 6 to perform a pulling test, and the detection component 23 performs image detection on the battery connector after the pulling test. When no cracks are found at the weld, the battery connector is collected. When cracks are found at the weld, the next battery connector continues to undergo pulling test and image detection. An alarm is triggered when cracks are detected twice consecutively.

[0042] Step S7 includes: S71, the clamping assembly 21 clamps and fixes the connecting plate 7 to provide a stable test benchmark.

[0043] S72, the pulling assembly 22 starts to work, the pulling assembly 22 drives the pulling rod 2213 to rotate, so that the threaded end of the bottom of the pulling rod 2213 is screwed into the pre-set screw hole at the top of the connector 6.

[0044] S73. After the screw is securely engaged, the pull assembly 22 applies a vertical upward pulling force to the pull rod 2213 to perform a pull test, thereby verifying the mechanical strength of the weld.

[0045] S74. After the pull test is completed, the pull assembly 22 will drive the pull rod 2213 to rotate in the opposite direction, so that the bottom end of the pull rod 2213 is unscrewed from the screw hole on the connector 6.

[0046] S75, the detection component 23 acquires images of the welding area of ​​the battery connector after the pull-out test, and the system uses image analysis algorithms to detect whether there are micro-cracks in the weld.

[0047] If the inspection results show that the weld is intact, the battery connector is deemed a qualified product and accepted. If a crack is detected, the same pull-out and image inspection is immediately performed on the next welded battery connector. If a crack is found again in this additional inspection, i.e., a crack is detected twice consecutively, the system will trigger an alarm signal, such as an audible and visual alarm, to alert the operator that there may be a systemic problem in the production process, requiring immediate intervention for inspection and adjustment.

[0048] The aforementioned closed-loop feedback quality inspection process, which combines mechanical testing and visual inspection, enables the process not only to produce but also to intelligently monitor itself, thus helping to improve the reliability of products leaving the factory.

[0049] Step S8: Repeat steps S1-S6, welding several times in succession, and then proceed to step S7.

[0050] Step S7 described above is not performed on every welded battery connector, but rather serves as a sampling inspection mechanism. For example, the device can be programmed to automatically transfer a finished battery connector to inspection facility 2 for quality inspection after every 10 consecutive welds. This effectively monitors production quality without excessively impacting the overall production cycle.

[0051] Reference Figure 5 This embodiment also discloses a welding device applied to the above-described process. The welding device in this embodiment differs from the welding device in Embodiment 1 in that it further includes a base plate 8 and a detection mechanism 2 disposed on the base plate 8. The detection mechanism 2 includes a clamping component 21, a pulling component 22, and a detection component 23. The clamping component 21 is used to firmly clamp the connecting plate 7 in the battery connector during testing; the pulling component 22 is used to apply tension to the connector 6 to simulate extreme working conditions that may be encountered in actual use; and the detection component 23 is responsible for visually inspecting the weld after testing.

[0052] Reference Figure 6The clamping assembly 21 includes a motor 211, a screw 212, and a pressure plate 213. A bracket 81 is provided on the base plate 8, and the motor 211 is fixedly mounted on the bracket 81 with its output shaft pointing vertically downwards. The screw 212 is coaxially connected to the end of the output shaft of the motor 211, and the motor 211 can drive the screw 212 to rotate. The pressure plate 213 is vertically slidable and has a through threaded hole. The pressure plate 213 is threadedly connected to the screw 212, so when the motor 211 drives the screw 212 to rotate, the pressure plate 213 can move up and down vertically. When the pressure plate 213 moves downwards, it can press against the top wall of the connecting plate 7, clamping and fixing the connecting plate 7; when the pressure plate 213 moves upwards, it can release the clamping of the connecting plate 7, thus facilitating the insertion or removal of the connecting plate 7. Two screws 212 are provided, symmetrically arranged on both sides of the pressure plate 213, thus improving the stability of the pressure plate 213 during sliding. Two motors 211 are provided, each threadedly connected to one of the two screws 212. The equivalent friction angle of the threads on the screws 212 is greater than the thread helix angle, thus the screws 212 have self-locking capability, allowing the pressure plate 213 to stably maintain its current position after the motors 211 stop operating.

[0053] Reference Figure 5 The detection component 23 includes a cylinder 231 and a CCD camera 232. A first support plate 82 is fixedly mounted on the base plate 8, and the cylinder body of the cylinder 231 is fixedly mounted on the first support plate 82. The cylinder 231 is horizontally positioned, with its piston rod facing towards the side closest to the clamping component 21. The CCD camera 232 is fixedly mounted on the end of the piston rod of the cylinder 231, with its detection end facing downwards. Therefore, after the pull-out test is completed, the pressure plate 213 moves upwards, exposing the welded area. Then, the cylinder 231 can drive the CCD camera 232 to move horizontally above the connector 6, thereby enabling better visual identification of the welded area.

[0054] It should be noted that, regardless of which side of the connector 6 the welding ring is located on, as long as the position of the battery connector is adjusted so that the side where the welding ring is located faces upward, the weld seam at the location of the welding ring can be easily visually identified by the detection component 23 to ensure the smooth progress of the detection process.

[0055] Reference Figure 7 and Figure 8The pulling assembly 22 includes a screw-in component 221 and a pull-out component 222, which are integrated into one unit. The screw-in component 221 includes a first rotating power component 2211, a sleeve 2212, and a pulling rod 2213. The first rotating power component 2211 is a servo motor, located above the sleeve 2212. The output shaft of the first rotating power component 2211 is vertically downward and connected to the top end of the sleeve 2212, thus the first rotating power component 2211 can drive the sleeve 2212 to rotate around a vertical axis. The pulling rod 2213 is vertically arranged, and a sliding block 3 is connected to the top end of the pulling rod 2213. The cross-sectional shape of the sliding block 3 is the same as the cross-sectional shape of the internal groove of the sleeve 2212, so the sliding block 3 can slide along the axial direction of the sleeve 2212 and is connected to the inside of the sleeve 2212. In this embodiment, the cross-sectional shape of the inner groove of the sleeve 2212 is hexagonal, and the cross-section of the sliding block 3 is also hexagonal, which matches the cross-section of the inner groove of the sleeve 2212. Therefore, when the sleeve 2212 rotates, it can drive the sliding block 3 to rotate, and axial relative sliding can occur between the sliding block 3 and the sleeve 2212. Thus, the top end of the pull rod 2213 can slide axially inside the sleeve 2212. The bottom end of the pull rod 2213 is located outside the sleeve 2212, and the outer wall of the bottom end of the pull rod 2213 is machined with an external thread that matches the screw hole on the connector 6.

[0056] During operation, the first rotating power component 2211 drives the sleeve 2212 to rotate, the sleeve 2212 drives the sliding block 3 to rotate, and the sliding block 3 drives the pull rod 2213 to rotate. As a result, the bottom end of the pull rod 2213 can be gradually screwed into the screw hole on the connector 6. As the screwing process proceeds, the pull rod 2213 will gradually move downward. At this time, the pull rod 2213 and the sliding block 3 will move downward relative to the sleeve 2212, thereby ensuring the smooth progress of the screwing process of the pull rod 2213.

[0057] Reference Figure 9Furthermore, the pull rod 2213 and the sliding block 3 can slide laterally relative to each other. A connecting disc 4 is fixedly connected to the top of the pull rod 2213; the connecting disc 4 is a circular disc. Multiple protrusions 41 are fixedly connected to the outer wall of the connecting disc 4, arranged in a circumferential array. A circular receiving groove 31 is provided inside the sliding block 3, and a through hole 32 communicating with the receiving groove 31 is provided on the bottom wall of the sliding block 3. The through hole 32 is a circular hole, and its diameter is larger than the diameter of the pull rod 2213. The top of the pull rod 2213 passes through the through hole 32, thus allowing the pull rod 2213 to move laterally relative to the through hole 32. The diameter of the connecting plate 4 is larger than the diameter of the through hole 32, and the diameter of the connecting plate 4 is smaller than the diameter of the receiving groove 31. Therefore, the connecting plate 4 cannot slide out of the through hole 32 and can only move inside the receiving groove 31. The thickness of the connecting plate 4 is the same as the depth of the receiving groove 31. Therefore, when the sliding block 3 moves vertically, it will drive the connecting plate 4 to move vertically as well.

[0058] Reference Figure 10 , Figure 11 and Figure 12 A push block 311 is fixedly connected to the inner wall of the receiving groove 31. Multiple push blocks 311 are provided, the number of which is the same as the number of protrusions 41. The multiple push blocks 311 are arranged in a circumferential array. The push blocks 311 and protrusions 41 are arranged alternately in the circumferential direction, with each protrusion 41 abutting against the corresponding push block 311. When the sleeve 2212 rotates, it drives the sliding block 3 to rotate. The sliding block 3 drives the push block 311 to rotate, and the push block 311 abuts against the protrusion 41. Therefore, the push block 311 pushes the protrusion 41 to rotate, causing the connecting disc 4 and the pull rod 2213 to rotate together. That is, when the sliding block 3 rotates, it can drive the pull rod 2213 to rotate together, thus facilitating the screwing of the bottom end of the pull rod 2213 into the screw hole on the connector 6.

[0059] Reference Figure 7The bottom end of the pull rod 2213 is provided with a conical surface 2213a, which is used to abut against the wall of the opening of the screw hole on the connector 6. During operation, after the clamping assembly 21 clamps and fixes the battery connector, the pull rod 2213 moves downward. If the pull rod 2213 is aligned with the screw hole on the connector 6, the conical surface 2213a at the bottom end of the pull rod 2213 is directly inserted into the screw hole on the connector 6, and then it can be directly screwed in. If there is a slight deviation between the pull rod 2213 and the threaded hole on the connector 6, resulting in misalignment, the conical surface 2213a at the bottom of the pull rod 2213 will first abut against the wall of the opening at the top of the threaded hole on the connector 6 during the downward movement of the pull rod 2213. Then, as the pull rod 2213 moves downward, it will move laterally on its own, achieving fine-tuning of its position until the conical surface 2213a at the bottom of the pull rod 2213 is fully inserted into the threaded hole on the connector 6. Then, the threads can be screwed in. In other words, the relative sliding between the pull rod 2213 and the sliding block 3 allows the position of the pull rod 2213 to be fine-tuned according to the position of the threaded hole on the connector 6. This ensures that even if there is a deviation between the pull rod 2213 and the threaded hole on the connector 6 due to manufacturing or installation errors, the bottom of the pull rod 2213 can still be smoothly screwed in, thus guaranteeing the smooth progress of subsequent testing.

[0060] Reference Figure 7 and Figure 8The pull-out component 222 includes a second rotary power component 2221, a lead screw 2222, and a sliding plate 2223. A second support plate 83 is fixedly mounted on the base plate 8, and the second rotary power component 2221 is fixedly mounted on the second support plate 83. The second rotary power component 2221 is a servo motor, and its output shaft faces vertically downwards. The lead screw 2222 is coaxially connected to the movable end of the second rotary power component 2221, thus enabling the second rotary power component 2221 to drive the lead screw 2222 to rotate. A sliding plate 2223 is disposed on the outside of a sleeve 2212. A mounting ring 2212c is fixedly connected to the outer wall of the sleeve 2212. The mounting ring 2212c is a circular ring and is coaxially disposed with the sleeve 2212. The sliding plate 2223 is sleeved on the outside of the mounting ring 2212c. An annular mounting groove 2223a is formed inside the sliding plate 2223. The mounting ring 2212c is rotatably connected to the inside of the mounting groove 2223a, so that the mounting ring 2212c and the sliding plate 2223 are rotatably connected. Therefore, relative rotation can occur between the mounting ring 2212c and the sliding plate 2223. When the mounting ring 2212c rotates, the sliding plate 2223 can remain stationary. The sliding plate 2223 is vertically slidable and is threadedly connected to a lead screw 2222. Therefore, when the lead screw 2222 rotates, it can drive the sliding plate 2223 to slide vertically. A connecting ring 2212a is fixedly provided at the bottom end of the sleeve 2212. The connecting ring 2212a is sleeved on the outside of the pull rod 2213, and the top wall of the connecting ring 2212a is used to abut against the bottom wall of the sliding block 3 at the end of the pull rod 2213.

[0061] During operation, the first rotary power component 2211 drives the sleeve 2212 and the pull rod 2213 to rotate together, causing the bottom end of the pull rod 2213 to first screw into the threaded hole on the connector 6. Then, the second rotary power component 2221 drives the lead screw 2222 to rotate, thereby causing the slide plate 2223 and the sleeve 2212 to move upward as a whole. Since the bottom end of the pull rod 2213 is screwed into the threaded hole on the connector 6, the vertical movement of the pull rod 2213 is restricted, so the pull rod 2213 remains stationary during the upward movement of the sleeve 2212. When the connecting ring 2212a at the bottom end of the sleeve 2212 abuts against the sliding block 3 at the top end of the pull rod 2213, the continued upward movement of the sleeve 2212 will apply an upward pulling force to the pull rod 2213, which in turn applies an upward pulling force to the connector 6. Maintaining this state for a period of time is sufficient to achieve the pull test of the connector 6.

[0062] Therefore, the process of screwing the bottom end of the pull rod 2213 into the screw hole on the connector 6 and the process of applying an upward pulling force to the screwed-in pull rod 2213 can be performed quickly in sequence. The two processes are completed in the same position, so the time interval between the two processes is short, the structure is more compact and the working efficiency is higher.

[0063] The equivalent friction angle of the thread on the lead screw 2222 is greater than the thread helix angle, so the lead screw 2222 has a self-locking capability, which allows the slide plate 2223 to be stably maintained in the current position after the second rotating power component 2221 stops operating, and can also better apply tension for detection.

[0064] Reference Figure 8 Furthermore, a pressure sensor 2212b is installed on the top wall of the connecting ring 2212a located at the bottom end of the sleeve 2212, and the pressure sensor 2212b is directly below the sliding block 3. When the pulling action is performed, the sleeve 2212 moves upward, and the sleeve 2212 drives the connecting ring 2212a to move upward. The pressure sensor 2212b on the connecting ring 2212a comes into contact with the sliding block 3. Therefore, during the process of pulling the pull rod 2213 outward, the pressure sensor 2212b can detect the pulling force on the pull rod 2213, thereby ensuring the accuracy of the detection results.

[0065] In addition, an elastic element 5, which is a spring, is installed between the top wall of the sliding block 3 and the inner wall of the upper part of the sleeve 2212. When the pull rod 2213 is screwed in, when the lowered pull rod 2213 contacts the connector 6, the sleeve 2212 can continue to move down a certain distance. During this process, the elastic element 5 will be compressed, thereby generating a continuous downward pressure on the pull rod 2213, which helps the threaded end of the pull rod 2213 to be stably aligned and smoothly screwed into the threaded hole on the connector 6.

[0066] Under normal conditions, the elastic element 5 is at its original length, and the sliding block 3 is exactly abutting against the pressure sensor 2212b. After screwing the bottom end of the pull rod 2213 onto the connector 6, the pull rod 2213 needs to be pulled upwards; the sleeve 2212 moves upwards, and the sleeve 2212 drives the connecting ring 2212a to move upwards. The pressure sensor 2212b on the connecting ring 2212a contacts the sliding block 3. At this time, the elastic element 5 returns to its original length, without applying any additional force to the pull rod 2213. Therefore, the pressure sensor 2212b can accurately detect the tensile force applied to the weld point by the pulling component 222, avoiding interference from the force of the elastic element 5 on the measurement results and ensuring the accuracy of the detection data.

[0067] The top wall of the slide plate 2223 is fixedly connected to the mounting plate 2223b, and the first rotating power component 2211 is fixedly installed on the mounting plate 2223b, thus providing better support for the first rotating power component 2211.

[0068] The implementation principle of Example 2 is as follows: The welding process of connector 6 and connecting plate 7 is the same as that of Example 1. After welding, the welded battery connector is transferred to the testing mechanism 2. The clamping assembly 21 first clamps and fixes the connecting plate 7, and then the second rotating power component 2221 drives the lead screw 2222 to rotate, which drives the slide plate 2223 to move downward. The slide plate 2223 drives the sleeve 2212 and the pull rod 2213 to move downward. Under the action of the conical surface 2213a at the bottom of the pull rod 2213, the pull rod 2213 can automatically make micro-adjustments so that the pull rod 2213 is aligned with the screw hole on the connector 6, until the cylindrical surface at the bottom of the pull rod 2213 is completely inserted into the screw hole on the connector 6. Then the slide plate 2223 continues to move downward, causing the sleeve 2212 to move downward a certain distance relative to the pull rod 2213. The elastic element 5 is compressed, and the elastic element 5 applies continuous downward pressure to the pull rod 2213, pressing the threaded end of the bottom of the pull rod 2213 against the threaded hole opening on the connector 6.

[0069] Then, the second rotating power component 2221 stops operating, and the first rotating power component 2211 drives the sleeve 2212 to rotate. The sleeve 2212 drives the sliding block 3 to rotate, and the sliding block 3, through the cooperation of the push block 311 and the protrusion 41, drives the pull rod 2213 to rotate, so that the bottom end of the pull rod 2213 gradually screws into the screw hole on the connector 6. During the screwing process, the sliding block 3 and the pull rod 2213 continuously move downward relative to the sleeve 2212, thereby ensuring the smooth screwing process between the pull rod 2213 and the connector 6.

[0070] Next, the first rotating power component 2211 stops operating, and the second rotating power component 2221 drives the lead screw 2222 to rotate in the opposite direction, causing the slide plate 2223 to move upward. The slide plate 2223 drives the sleeve 2212 to move upward until the pressure sensor 2212b on the connecting ring 2212a at the bottom of the sleeve 2212 abuts against the sliding block 3 at the top of the pull rod 2213. At this time, the elastic element 5 returns to its original length. Then, the slide plate 2223 continues to move upward, which applies an upward pulling force to the pull rod 2213. The pull rod 2213 applies a pulling force to the connector 6, thereby realizing the pull test of the connector 6. After a period of time, the pulling force is stopped, and then the bottom end of the pull rod 2213 is unscrewed from the screw hole on the connector 6. Then, the welded part is visually inspected by the detection component 23 to identify whether there are cracks in the welded part.

[0071] This device achieves seamless integration and closed-loop control from production to quality inspection through dual verification of pull-out force testing and image detection, as well as intelligent logic for continuous non-compliance alarms, thereby ensuring the safety and reliability of battery connectors for long-term use.

[0072] The above are optional embodiments of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made to the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A welding process for a battery connector, characterized in that, Includes the following steps: Step S1: Provide a welding device with a positioning element (12), a pressing element (13), a transfer element and a heating element (14), and place the connector (6) on the positioning post (121); Step S2: Place the connecting plate (7) onto the connector (6) and use a positioning plate (122) to position the connecting plate (7); Step S3: The transfer component grabs a welding ring and places the welding ring on the joint between the connector (6) and the connecting plate (7); Step S4: Extend the movable end of the pressing member (13) to press the connecting plate (7). Step S5: The heating element (14) heats the welding parts of the welding ring, the connector (6), and the connecting plate (7) so that the welding ring melts after being heated and welds the connector (6) and the connecting plate (7) together to form a battery connector. Step S6: Stop heating and wait for the welded part to cool down. Then, retract the movable end of the pressing part (13) and remove the battery connector.

2. The welding process for a battery connector according to claim 1, characterized in that, Also includes: Step S7: Provide a detection mechanism (2) with a clamping component (21), a pulling component (22), and a detection component (23). Place the battery connector in the detection mechanism (2), and make the clamping component (21) clamp the connecting plate (7). Make the pulling component (22) apply a pulling force to the connector (6) to perform a pulling test. Make the detection component (23) perform image detection on the battery connector after the pulling test. When no cracks are generated at the weld, the battery connector is collected. When cracks are generated at the weld, the next battery connector is subjected to a pulling test and image detection. An alarm is triggered when cracks are detected twice in a row. Step S8: Repeat steps S1-S6, welding several times consecutively, and then proceed to step S7.

3. The welding process for a battery connector according to claim 2, characterized in that, Step S7 includes: S71, Press the connecting plate (7) with the clamping assembly (21); S72, the pulling assembly (22) screws a pulling rod (2213) into the connector (6) and the pulling rod (2213) is threadedly connected to the connector (6); S73, The pull assembly (22) applies a pulling force to the pull rod (2213) to achieve a pull test on the connector (6); S74, the pulling assembly (22) is used to unscrew the pulling rod (2213) from the connector (6); S75, the detection component (23) performs visual inspection on the welded area.

4. A welding apparatus, characterized in that: The welding device using the welding process of the battery connector as described in any one of claims 1 to 3 includes a welding mechanism (1), the welding mechanism (1) including a base (11) and a positioning member (12), a pressing member (13), a transfer member and a heating member (14) disposed on the base (11), the positioning member (12) being used to position the connector (6) and the connecting plate (7), the pressing member (13) being used to press the connecting plate (7) and the connector (6) together, the transfer member being used to place the welding ring at the joint between the connector (6) and the connecting plate (7), and the heating member (14) being used to heat the welding ring at the joint between the connecting plate (7) and the connector (6).

5. The welding apparatus according to claim 4, characterized in that: It also includes a testing mechanism (2), which includes a clamping assembly (21), a pull-out assembly (22) and a testing assembly (23). The clamping assembly (21) is used to clamp the connecting plate (7), the pull-out assembly (22) is used to apply a pulling force to the connector (6) welded to the connecting plate (7) for a pull-out test, and the testing assembly (23) is used to visually inspect the weld between the connecting plate (7) and the connector (6).

6. The welding apparatus according to claim 5, characterized in that: The pull assembly (22) includes a screw-in component (221) and a pull-out component (222); the screw-in component (221) includes a first rotating power component (2211), a sleeve (2212) and a pull rod (2213), the sleeve (2212) is connected to the output end of the first rotating power component (2211), the first end of the pull rod (2213) is provided with a sliding block (3), the sliding block (3) is slidably disposed inside the sleeve (2212), and the sliding block (3) can abut against the end of the sleeve (2212), the second end of the pull rod (2213) is provided with a thread for matching the screw hole on the connector (6), the first rotating power component (2211) is used to drive the pull rod (2213) to rotate through the sleeve (2212) and cause the end of the pull rod (2213) to be screwed into the connector (6); The pull-out component (222) includes a second rotary power component (2221), a lead screw (2222), and a sliding plate (2223). The lead screw (2222) is connected to the movable end of the second rotary power component (2221). The sliding plate (2223) is rotatably connected to the sleeve (2212). The sliding plate (2223) is slidably disposed and threadedly connected to the lead screw (2222). The second rotary power component (2221) is used to drive the lead screw (2222) to rotate so that the sliding plate (2223) drives the sleeve (2212) to move.

7. A welding apparatus according to claim 6, characterized in that: The sleeve (2212) has a connecting ring (2212a) at one end away from the first rotating power component (2211). The connecting ring (2212a) is sleeved on the outside of the pull rod (2213). The connecting ring (2212a) is provided with a pressure sensor (2212b), which is used to abut against the sliding block (3).

8. The welding apparatus according to claim 7, characterized in that: An elastic element (5) is connected between the sliding block (3) and the sleeve (2212). The elastic element (5) is used to drive the sliding block (3) to slide away from the first rotating power element (2211). When the sliding block (3) is in contact with the pressure sensor (2212b), the elastic element (5) is in an unenergized state.

9. A welding apparatus according to claim 6, characterized in that: The end of the pull rod (2213) away from the sleeve (2212) is provided with a conical surface (2213a). The end of the pull rod (2213) located inside the sleeve (2212) is provided with a connecting plate (4). The connecting plate (4) is provided with a protrusion (41). The sliding block (3) is provided with a receiving groove (31). The sliding block (3) is provided with a through hole (32) communicating with the receiving groove (31). The diameter of the through hole (32) is larger than the diameter of the pull rod (2213). The pull rod (2213) passes through the through hole (32). The connecting plate (4) is located in the receiving groove (31). The inner wall of the receiving groove (31) is provided with a push block (311) for abutting against the protrusion (41), so that when the sliding block (3) rotates, the push block (311) pushes the protrusion (41) and the connecting plate (4) to rotate.

10. A welding apparatus according to claim 9, characterized in that: The push block (311) is provided in multiple and arranged in a circular array, and the protrusion (41) is provided in multiple and arranged in a circular array. The protrusion (41) and the push block (311) are arranged alternately along the circumferential direction.

Images