Intelligent welding device for heat sink

Abstract

This invention discloses an intelligent welding device for radiators, comprising a welding assembly, a frame, a control module, a sensing module, and a telescopic component. The frame is used to fix a first oil collection pipe after welding several heat sink fins. The welding assembly is used to weld the heat sink fins to the first and second oil collection pipes. A second oil collection pipe is installed at the telescopic end of the telescopic component. The sensing module is electrically connected to the control module to identify the gap between each heat sink fin and the second oil collection pipe and transmit data. The control module calculates the variance based on the gap data, selects a reference heat sink based on a preset threshold, controls the telescopic component to adjust the gap between the reference heat sink fin and the second oil collection pipe to a standard value, and then controls the welding assembly to complete the welding. This invention can automatically detect and adjust the welding gap, optimize the welding sequence, and reduce welding defects, thereby improving the radiator welding pass rate and production efficiency, and adapting to the production needs of radiators of different specifications.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, and more specifically to an intelligent welding device for radiators. Background Technology

[0002] The core function of the existing radiator welding device is to accurately weld several heat sinks onto the oil collection pipe. The conventional welding process is as follows: First, one end of several heat sinks is positioned and welded to the first oil collection pipe. After the first oil collection pipe is welded to one end of all the heat sinks, the operator adjusts the first oil collection pipe with the welded heat sinks to adjust the posture of the heat sinks so that the other end of all the heat sinks is aligned with the second oil collection pipe, which is in a standard preset position. After alignment, the welding device is started to weld the second oil collection pipe to the other end of several heat sinks, thus completing the welding and assembly of the entire radiator.

[0003] However, in the aforementioned welding process: due to unavoidable processing defects such as dimensional errors and shape deviations in the heat sink, and the high temperature during welding of the first oil collection pipe to one end of the heat sink causing thermal deformation, and the differences in material uniformity and heating degree among different heat sinks resulting in inconsistent deformation, when aligning the other ends of several heat sinks with the second oil collection pipe in the standard position, the gaps between the heat sinks and the second oil collection pipe will vary. If the gap between the heat sink and the second oil collection pipe is too large, the solder cannot fully fill the gap during welding, leading to defects such as incomplete welding or poor penetration. This not only reduces the structural strength of the radiator but also affects the heat transfer efficiency between the heat sink and the oil collection pipe, thus reducing the overall heat dissipation performance of the radiator. If the gap between the heat sink and the second oil collection pipe is too small, interference and poor fit will occur.

[0004] Currently, existing radiator welding equipment typically only has basic positioning and welding functions. When welding the second oil collection pipe, it can only achieve a rough alignment between the radiator fins and the oil collection pipe, without considering the problem of inconsistent alignment gaps caused by radiator processing errors and welding deformation, nor is it equipped with corresponding gap adjustment and compensation mechanisms. Therefore, when using existing welding equipment for radiator welding, it is difficult to ensure that the welding gaps between each radiator fin and the oil collection pipe are within a reasonable range, resulting in a low radiator welding pass rate. This necessitates a significant investment of manpower for rework, increasing production costs and reducing production efficiency. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent welding device for radiators that does not have at least one of the disadvantages mentioned above.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an intelligent radiator welding device, comprising a welding assembly, a frame, and welding components. The welding components include heat sinks, a first oil collection pipe, and a second oil collection pipe. The welding assembly is used to weld the heat sinks to the first and second oil collection pipes. The frame is used to fix the first oil collection pipe after welding several heat sinks. The device also includes a control module, a sensing module electrically connected to the control module, and a telescopic component with a telescopic end for mounting the second oil collection pipe. The sensing module is used to identify the gap Ai between each heat sink and the second oil pipe, and transmit all gap Ai data to the control module. The control module calculates the variance a of several Ai based on all gap Ai data. The telescopic component is electrically connected to the control module and is used to drive the second oil collection pipe to move in a direction closer to or further away from the heat sink under the control of the control module, thereby adjusting the gap between the heat sink and the second oil collection pipe. The control module has a preset variance threshold b and a standard welding gap A0. The control module selects the reference heat sink according to the relationship between the preset variance threshold and the reference heat sink, and controls the telescopic component to adjust the gap between the second oil pipe and the reference heat sink to the standard welding gap A0. Then, the control module controls the welding assembly to complete the welding and fixing of the second oil pipe and all heat sinks.

[0007] Furthermore, the control module is used to calculate the mean T1 of all Ai; When a≤b, the control module locks the heat sink whose gap value is closest to the average value T1 as the reference heat sink; When a>b, the control module calculates the variance c of the J gap values ​​that are greater than the mean. If c≤b, the control module calculates the mean T2 of the J gap values ​​and locks the heat sink with the gap value closest to the mean T2 among the J heat sinks as the reference heat sink.

[0008] Furthermore, when a>b and c>b, the control module will lock the heatsink corresponding to the maximum value among all Ai as the reference heatsink.

[0009] Furthermore, the control module sorts all Ai values ​​from largest to smallest and creates a mapping table between the gap values ​​and the heat sinks based on this sorting. The control module then creates a welding table based on the sorting of the heat sinks in the mapping table, and the welding assembly welds the heat sinks and the second oil pipe according to the welding table.

[0010] Furthermore, if the distance between any two adjacent heat sinks in the welding table is less than the safety threshold, the welding assembly will be welded according to the order of the heat sinks in the welding table.

[0011] Furthermore, if there is a distance between adjacent heat sinks in the welding table that is greater than the safety threshold, the welding assembly will choose to weld in either the order of expanding from the center to both ends or symmetrically converging from both ends to the center after determining whether the heat sink with the gap value closest to the average value T1 is located in the central safety area E.

[0012] Furthermore, when the heat sink closest to the mean T1 is located within the central safe area E, the welding assembly adopts a welding method that expands outward from the heat sink as the center; otherwise, the welding assembly adopts a welding method that converges symmetrically from both ends to the center.

[0013] Furthermore, the control module has a preset standard width M0 for the central safety area E. The control module adjusts the actual width M1 of the central safety area E based on the actual equidistant dimension d between the equally spaced heat sinks, the actual total number of heat sinks Z, and the actual thickness t of the heat sinks. M1 = e * M0 * (k1 * d / d0 + k2 * Z / Z0 + k3 * t0 / t). Here, d0, Z0, and t0 are the standard equidistant dimension, the standard total number of heat sinks, and the standard thickness of the heat sinks, respectively, when the width is the standard width M0. k1, k2, and k3 are weighting coefficients, and k1 + k2 + k3 = 1. e is the adjustment coefficient.

[0014] Furthermore, it also includes a control panel for inputting the values ​​of b, A0, M0, d0, Z0, t0, e, k1, k2, and k3.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. Based on the existing welding device, the present invention adds a control module, a sensing module and a telescopic component, which realizes the detection, analysis and adjustment of welding gap, effectively solves the problem of uneven gap caused by heat sink processing error and welding thermal deformation, and avoids the problems of incomplete welding and incomplete penetration caused by excessive gap; 2. By performing variance analysis on the gap data through the control module, a reference heat sink is selected according to different scenarios to ensure the rationality of the reference selection. This ensures that the gap between all heat sinks and the second oil pipe is within a reasonable range, thereby improving the structural strength and heat dissipation performance of the radiator and increasing the product welding qualification rate. 3. Optimize the welding sequence and select appropriate welding methods based on the gap arrangement and the distance between adjacent heat sinks to reduce secondary deformation during the welding process and further improve welding stability; at the same time, by dynamically adjusting the width of the central safety area, it can adapt to heat sinks of different specifications, making it highly versatile. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0018] The components include: 1. Adjustable clamping mechanism; 2. First oil collection pipe; 3. Heat sink; 4. Welding assembly; 5. Second oil collection pipe; 6. Telescopic component. Detailed Implementation

[0019] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0020] The existing radiator welding device is designed to accurately weld several heat sinks onto the oil collection pipe. The conventional welding process is as follows: First, one end of several heat sinks is positioned and welded to the first oil collection pipe. After the first oil collection pipe is welded to one end of all the heat sinks, the operator adjusts the first oil collection pipe with the welded heat sinks to adjust the posture of the heat sinks, so that the other end of all the heat sinks is aligned with the second oil collection pipe, which is in a standard preset position. After alignment, the welding device is started to weld the second oil collection pipe to the other end of several heat sinks, thus completing the welding and assembly of the entire radiator.

[0021] However, in the aforementioned welding process: due to unavoidable processing defects such as dimensional errors and shape deviations in the heat sink, and the high temperature during welding of the first oil collection pipe to one end of the heat sink causing thermal deformation, and the differences in material uniformity and heating degree among different heat sinks resulting in inconsistent deformation, when aligning the other ends of several heat sinks with the second oil collection pipe in the standard position, the gaps between the heat sinks and the second oil collection pipe will vary. If the gap between the heat sink and the second oil collection pipe is too large, the solder cannot fully fill the gap during welding, leading to defects such as incomplete welding or poor penetration. This not only reduces the structural strength of the radiator but also affects the heat transfer efficiency between the heat sink and the oil collection pipe, thus reducing the overall heat dissipation performance of the radiator. If the gap between the heat sink and the second oil collection pipe is too small, interference and poor fit will occur.

[0022] Currently, existing radiator welding equipment typically only has simple positioning and welding functions. When welding the second oil collection pipe, it can only achieve a rough alignment between the heat sink and the oil collection pipe, without considering the problem of inconsistent alignment gaps caused by heat sink processing errors and welding deformation, and it also lacks corresponding gap adjustment and compensation mechanisms. Therefore, when using existing welding equipment for radiator welding, it is difficult to ensure that the welding gap between each heat sink and the oil collection pipe is within a reasonable range, resulting in a low radiator welding pass rate. This necessitates a significant investment of manpower for rework, increasing production costs and reducing production efficiency. Based on this, please refer to Figure 1 A smart welding device for radiators includes a welding assembly 4, a frame, a control module, a sensing module, a telescopic component 6, and a control panel. The welding assembly 4 utilizes an existing, mature welding mechanism used in radiators, which can be adaptively selected based on the welding material, requiring only one or two welding heads. The top of the frame is equipped with a common adjustable clamping mechanism 1 for fixing the first oil collection pipe 2 after welding several heat sink fins 3. The clamping mechanism can flexibly adjust the clamping force according to the diameter of the first oil collection pipe 2, ensuring the stability of the first oil collection pipe 2 and the heat sink fins 3 during welding, preventing displacement due to welding vibration or external forces, thus ensuring welding accuracy and preventing secondary deviations in the gap. The telescopic component 6 can adopt a ball screw drive structure, which only needs to meet the accurate requirements of fine adjustment of welding gap. Its telescopic end is fixedly installed with the second oil collection pipe 5 through a common adjustable clamping mechanism, which facilitates the disassembly and replacement of the second oil collection pipe 5, and is also compatible with the production of radiators of different specifications. The telescopic component 6 is electrically connected to the control module through a cable. Under the control of the electrical signal output by the control module, it can smoothly drive the second oil collection pipe 5 to move linearly in the direction of approaching or moving away from the heat sink 3. The moving speed can be flexibly adjusted according to the gap adjustment requirements, thereby realizing the compensation of the gap between the heat sink 3 and the second oil collection pipe 5 and avoiding the error caused by manual adjustment. The sensing module uses a high-precision laser rangefinder sensor, which can identify the gap between each heat sink 3 and the second oil collection pipe 5. The sensing module is electrically connected to the control module. Its built-in data acquisition module can collect the gap Ai data between each heat sink 3 and the second oil collection pipe 5 in real time, and convert the collected analog signal into a digital signal and transmit it to the control module in real time, providing accurate and reliable data support for the gap analysis of the control module and the output of subsequent control commands. The control module uses an industrial-grade PLC controller, capable of stably processing the large amount of gap data transmitted by the sensor module, and accurately controlling the coordinated operation of the telescopic component 6 and the welding assembly 4. The control module has a built-in memory with preset variance threshold b and standard welding gap A0. The standard welding gap A0 can be flexibly set according to the specifications of the heat sink, the thickness of the heat sink 3, and welding process parameters (such as solder type, welding current, and welding speed), ensuring that the solder fully fills the gap and effectively avoiding defects such as incomplete soldering or penetration caused by excessive gaps. Similarly, the value of the variance threshold b can be determined based on the thickness of the heat sink 3. The requirements for workmanship accuracy, material properties, and welding process are usually set and calibrated in combination with the gap deviation range commonly found in production practice. Both of these parameters can be obtained through a limited number of experiments, so we will not go into too much detail here. After the control module receives all the gap Ai data transmitted by the sensor module, it first calculates the variance a of all Ai through the built-in calculation program. The variance a is used to quantitatively reflect the overall uniformity of the gaps between all heat sinks 3 and the second oil collection pipe 5. The smaller the variance value, the smaller the dispersion of each gap and the better the overall uniformity of the gaps. Conversely, the larger the variance value, the greater the difference between each gap and the poorer the uniformity.

[0023] Therefore, after the control module receives all the gap Ai data transmitted by the sensing module and calculates the variance a, it compares the variance a with the preset variance threshold b in real time and selects the reference heat sink 3 based on the relationship between the two. The purpose of selecting the reference heat sink 3 is to determine the reference benchmark for gap adjustment, ensuring that subsequent gap adjustments can take into account the reasonableness of the gaps of all heat sinks 3, and avoiding the gaps of some heat sinks 3 exceeding the reasonable range due to improper selection of a single benchmark. After the reference heat sink 3 is determined, the control module sends an accurate control signal to the telescopic component 6, driving the telescopic component 6 to move smoothly along the preset trajectory, thereby causing the second oil collection pipe 5 to move closer to or further away from the heat sink 3 synchronously, until the gap between the reference heat sink 3 and the second oil collection pipe 5 is accurately adjusted to the preset standard welding gap A0. At this time, the gaps between the remaining heat sinks 3 and the second oil collection pipe 5 are also synchronously within the reasonable adaptation range. After the gap adjustment is completed, the control module sends a start signal to the welding assembly 4 through the preset control logic, and controls the welding assembly 4 to complete the welding and fixing of the second oil pipe 5 and the other end of all heat sinks 3 in sequence according to the preset welding parameters (such as welding current, welding speed, and solder supply). This ensures the stability and consistency of the welding quality and avoids problems such as incomplete welding or incomplete penetration caused by excessive gap.

[0024] In one embodiment, the control module selects the baseline heat sink 3 according to the relationship between variance 'a' and a preset threshold 'b', and the specific selection logic is as follows: After completing the acquisition of all gap Ai data and the calculation of variance a, the control module uses a preset variance threshold b as the criterion. Considering the overall uniformity difference in the gaps between all heat sinks 3 and the second oil pipe 5, it adopts a scenario-adaptive selection of the reference heat sink 3. This aims to adapt to different gap conditions, focus on controlling welding defects, and ensure that subsequent gap adjustments take into account the reasonableness of the gaps of all heat sinks 3. The specific selection is as follows: The first step involves the control module using the initial gap Ai data between each heat sink 3 and the second oil collection pipe 5 transmitted by the sensor module to obtain the average value T1 of all gaps Ai. The average value T1 can objectively and comprehensively reflect the overall distribution level of the gaps between all heat sinks 3 and the second oil collection pipe 5. In the second step, when the control module determines that a≤b, it indicates that the gap dispersion between all heat sinks 3 and the second oil collection pipe 5 is small and the overall uniformity is good. At this time, there is no need to prioritize the gap control of a particular heat sink 3; the reasonableness of the gaps of all heat sinks 3 can be taken into account. Based on this, the control module will automatically start the gap comparison program, calculate the absolute difference between the gap Ai corresponding to each heat sink 3 and the mean T1, and accurately lock the heat sink 3 with the smallest difference, that is, the gap value closest to the mean T1, as the reference heat sink 3. Subsequent gap adjustments based on this heat sink 3 can make the gaps of all heat sinks 3 evenly distributed around the preset standard welding gap A0, thereby effectively avoiding defects such as incomplete soldering and incomplete penetration caused by excessive gaps.

[0025] Thirdly, when a>b, it indicates that the gaps between all heat sinks 3 and the second oil collection pipe 5 are highly dispersed, resulting in poor overall uniformity. If the overall average value T1 is still used as the reference for selecting the benchmark heat sink 3, it is easy to cause excessive deviations in some gaps, especially for heat sinks 3 with gaps exceeding the average value. Due to the large gaps, the solder cannot be fully filled, which can easily lead to fatal welding defects such as cold solder joints and incomplete penetration. Therefore, it is necessary to adopt a "key control and graded judgment" approach for selecting the benchmark heat sink 3. First, the control module will automatically filter all gap Ai data and separate all J gap values ​​that are greater than the average value T1. Since these gaps exceed the overall average level, they are the key targets for welding defect prevention and control. Prioritizing the control of these gaps can reduce the incidence of cold solder joints and incomplete penetration, and ensure the structural strength and heat dissipation performance of the heat sink. Subsequently, the control module performs variance calculation on these J gap values ​​again to obtain variance c. By comparing variance c with the preset threshold b, the uniformity of the key control gaps is further determined: if c≤b, it means that the uniformity of the gaps greater than the mean T1 is good. At this time, the control module calculates the mean T2 of the J gap values. The mean T2 is used as the average reference for the key gaps in this part. The heat sink 3 with the gap value closest to the mean T2 is locked as the reference heat sink 3 to ensure that the gaps in this part that are prone to excessive problems can accurately adapt to the standard welding gap A0, while taking into account the rationality of the gaps of other heat sinks 3, so as to achieve accurate adaptation of gap adjustment. If c>b, it means that the uniformity of the gaps greater than the average value T1 is also poor, which is a condition of extremely uneven gap distribution. At this time, the control module directly locks the heat sink 3 corresponding to the maximum value among all Ai as the reference heat sink 3. Adopting the principle of "defect priority prevention and control", it ensures that the heat sink 3 with the largest gap can reach the standard welding gap, thereby avoiding fatal defects such as poor soldering and incomplete soldering due to excessive gap of the heat sink 3.

[0026] After selecting the reference heat sink 3 and adjusting the initial position of the second oil manifold 5, the control module sorts all the gap Ai values ​​between the heat sink 3 and the second oil manifold 5 transmitted in real time by the sensing module in descending order of gap value. During the sorting process, the heat sink 3 identifier (such as the heat sink 3 number) corresponding to each gap value is recorded simultaneously to ensure that each gap value corresponds to a unique heat sink 3, thereby binding the gap data with the heat sink 3. Based on the sorting result, the control module generates a mapping table that corresponds one-to-one between gap values ​​and heat sink 3. This mapping table records the specific gap size and corresponding number of each heat sink 3, and also marks the actual installation position coordinates of each heat sink 3 on the radiator. Subsequently, the control module generates a welding table based on this mapping table to directly guide the welding operation. The welding table specifies the welding sequence, welding time, welding current, and other welding parameters for each heat sink 3 and the second oil manifold 5 of the welding component 4. The planning of the welding sequence is combined with the distribution of gap value sizes. After receiving the welding instruction from the control module, the welding assembly 4 will follow the parameters and sequence specified in the welding table to complete the welding operation of each heat sink 3 and the second oil pipe 5.

[0027] Specifically, if the distance between any two adjacent heat sinks 3 in the welding table is less than the safety threshold, the welding assembly 4 will perform welding operations according to the order of the heat sinks 3 in the welding table, which can achieve uniform welding and reduce thermal deformation. The safety threshold is a quantitative parameter used to judge the uniformity of the gap distribution of the heat sinks 3. Its value is not fixed but needs to be reasonably set according to the actual size (such as length and width), material properties (such as thermal conductivity and coefficient of thermal expansion) and welding process parameters (such as welding temperature and welding speed) of the heat sinks 3, and can distinguish gap distribution scenarios. When the distance between any two adjacent heat sinks 3 in the welding table is less than the safety threshold, the judgment result indicates that the gaps between all heat sinks 3 from one end to the other are distributed from large to small or from small to large, with a relatively uniform distribution. There are no abrupt changes in the gap between two adjacent heat sinks 3, or abnormally large or small local gaps. In this case, the welding sequence in the welding table will tend to weld continuously from one end of the heat sink to the other, rather than using a skip welding sequence. Continuous welding allows the heat generated during the welding process to diffuse slowly and evenly along the length of the second oil pipe 5, avoiding the random distribution of heat in different areas caused by skip welding. This prevents excessive local thermal deformation and uncontrollable deformation of the heat sink 3, which can lead to residual stress disorder after welding. Simultaneously, continuous welding reduces the frequent movement of the welding component 4 between different heat sinks 3, reducing mechanical wear and positioning errors during movement. This ensures the stability and continuity of the welding process, improving welding efficiency and further optimizing welding quality. It also guarantees that the gap at each weld meets standard welding requirements, preventing defects such as incomplete welds or insufficient penetration.

[0028] If the distance between adjacent heat sinks 3 in the welding table is greater than the safety threshold, it indicates that the distribution of gaps between heat sinks 3 from large to small is uneven, with abrupt gap changes, abnormally large or small local gaps. In this case, if the order of heat sinks 3 in the welding table is still used for welding, obvious skip welding problems will occur (for example, if the sequence number of heat sink 3 is 1-20, then there will be skip welding according to 1, 5, 15, 8, 20....; while when the distance between adjacent heat sinks 3 is less than the safety threshold, the welding sequence will tend to be 1, 2, 3, 4, 5....). This will lead to uneven distribution of welding heat, which in turn will cause excessive local thermal deformation of heat sink 3, residual stress disorder, and other problems, seriously affecting the welding quality. In this case, in one embodiment of the present invention, the welding component 4 needs to first determine whether the heat sink 3 with the gap value closest to the average value T1 is located in the central safety area E to select the appropriate welding sequence. Among them, the heat sink 3 with the gap value closest to the average value T1 best represents the average gap level of all heat sinks 3. Using this heat sink 3 as the judgment benchmark ensures that the selection of the welding sequence is more scientific and reasonable. The central safety area E is a key range preset by the control module to define the central area of ​​the heat sink 3. Its function is to provide a judgment basis for the selection of the welding sequence and avoid errors in the selection of the welding sequence due to unclear judgment benchmarks, which would affect the welding quality. When the welding component 4 receives the judgment command from the control module, it will identify the actual position of the heat sink 3 with the gap value closest to the average value T1 and compare it with the range of the central safety area E. Based on the comparison result, it will select the optimal solution from two welding methods: "expanding from the center to both ends" and "symmetrically converging from both ends to the center". This ensures uniform heat conduction during the welding process, reduces thermal deformation, and guarantees the quality of the weld joint. In addition, the welding component 4 uses two welding heads in this process, which can effectively improve welding efficiency while avoiding problems such as excessive local thermal deformation and residual stress disorder. Specifically, when the heat sink 3 with the gap value closest to the average value T1 is located within the central safe area E, the welding assembly 4 adopts a welding method that extends outward from the heat sink 3 as the center. This welding method, with the heat sink 3 representing the average gap level as the center, gradually extends the welding towards both ends, allowing the welding heat to diffuse slowly and evenly from the central area to both ends, avoiding local heat concentration. It also effectively counteracts the mutual influence of thermal deformation generated during the welding of heat sinks 3 with different gaps, ensuring uniform overall deformation of the heat sink 3 and reducing the generation of residual stress after welding. Specifically, the welding assembly 4 first completes the welding of the central reference heat sink 3 to the second oil collection pipe 5. After the welding temperature at this location has initially cooled and the deformation has stabilized, it then sequentially welds the adjacent heat sinks 3 on both sides of the center, progressing step by step from the center to both ends until all heat sinks 3 are welded. This method ensures a stable temperature environment during the welding of each heat sink 3, thereby guaranteeing that the welding gap remains within a reasonable range. Conversely, when the heat sink 3 closest to the average value T1 is not located within the central safe area E, it indicates that the reference heat sink 3 is biased towards one end of the heat sink. In this case, if a welding method extending from the center to both ends is adopted, it will lead to heat asymmetry at the two ends far from the reference heat sink 3, resulting in excessive thermal deformation. Therefore, the welding assembly 4 adopts a welding method that converges symmetrically from both ends to the center. This method, by simultaneously welding symmetrically from both ends of the heat sink towards the center, allows the heat at both ends to be conducted and cooled synchronously, effectively balancing the thermal deformation of the heat sink 3 at both ends and avoiding excessive deformation at one end that would affect the overall welding accuracy. During the welding process, the two welding heads in the welding assembly 4 work synchronously, gradually moving closer to the central reference heat sink 3, and finally completing the finishing welding at the center. This ensures the stability of the welding process and effectively solves the welding defects caused by uneven gap distribution, ensuring that the welding quality meets the standards.

[0029] In one embodiment, the control module presets a standard width M0 for the central safety area E. This standard width M0 is a reference value determined through multiple experiments based on the structural parameters of the standard specification radiator, the distribution characteristics of the heat sink 3, and the welding process requirements. Its core function is to provide a basic reference for adjusting the actual width of the central safety area E, ensuring the rationality of subsequent width adjustments. Due to differences in radiator specifications during actual production, the actual equidistant dimensions, total number, and thickness of the heat sink 3 may differ from the standard parameters. If a fixed standard width M0 is always used, the range of the central safety area E will not match the actual distribution of the heat sink 3, thus affecting the accuracy of judging the position of the reference heat sink 3, ultimately leading to errors in the selection of the welding sequence and affecting the welding quality. Based on this, the control module dynamically adjusts the actual width M1 of the central safety zone E according to the actual production conditions, where M1 = e*M0*(k1*d / d0+k2*Z / Z0+k3*t0 / t), ensuring that the central safety zone E can accommodate heat sinks of different specifications, providing a reliable basis for the correct selection of the welding sequence. It should be noted that changes in the parameters in the formula will affect the value of the actual width M1, thus affecting the definition of the central safety zone E, and ultimately having a chain reaction on the determination of the position of the reference heat sink 3 and the welding quality. The specific effects of parameter changes are detailed below: M1 represents the actual width of the central safety area E, which is the target of the formula calculation and a key parameter used by the control module to define the scope of the central safety area. Its value determines the size of the central safety area, affects the accuracy of the position judgment of the reference heat sink 3, and thus affects the selection of the welding sequence and the welding quality. The adjustment coefficient e, which typically ranges from 0.8 to 1.2, is a preset adjustable parameter. Its function is to compensate for external environmental interference (such as temperature fluctuations, humidity changes, and dust interference in the welding area) and equipment errors (such as measurement errors of the sensor module, positioning errors of the telescopic component 6, and calculation errors of the control module), ensuring the accuracy of the M1 calculation and avoiding deviations in the definition of the central safety area caused by various errors. M0 represents the standard width of the central safety area E, which is a fixed preset reference value that does not change with actual production conditions. It is the basic reference for the M1 calculation, and its value has been verified through multiple tests to ensure that the central safety area can accurately cover the heat sink 3 at the center position under standard specification heat sink conditions. d: The actual equidistant dimension of the heat sink 3, that is, the distance between the centers of two adjacent heat sinks 3 in actual production. It is obtained by the sensor module or manually input through the control panel. Its influence is on the heat conduction and distribution during the welding process. The larger the actual equidistant dimension d of the heat sink 3, the larger the distance between adjacent heat sinks 3. The less likely the heat generated during welding will accumulate in local areas, the more evenly the heat can be diffused between the heat sinks 3, the higher the heat dissipation efficiency, the more balanced the heat distribution, and the lower the risk of thermal deformation. Conversely, the smaller d is, the smaller the distance between adjacent heat sinks 3. The welding heat is more likely to concentrate between adjacent heat sinks 3, resulting in excessively high local temperature, uneven heat distribution, and thus thermal deformation. d0 is the standard dimension that matches M0. The quasi-equidistant dimension is a fixed preset value, which is the center distance between adjacent heat sinks 3 in a standard specification radiator. Its setting is based on the optimal spacing parameter under standard working conditions, which allows heat to be evenly diffused during the welding of heat sinks 3, making it less prone to local concentration and excessive thermal deformation. d0 is used to compare with the actual parameter d to calculate the deviation between the actual heat sink 3 spacing and the standard spacing, thereby judging the uniformity of heat distribution during the actual welding of heat sinks 3, and providing a basis for the spacing-related deviation for adjusting M1. When d is greater than d0, heat is less likely to concentrate and is more evenly distributed, and M1 can be increased by adjusting the formula. When d is less than d0, heat is prone to local concentration and uneven distribution, and M1 needs to be appropriately reduced to ensure that the central safe area is adapted to the heat distribution conditions.

[0030] Z: The total number of actual heat sinks 3, i.e., the total number of heat sinks 3 installed on the heat sink to be welded. It is determined according to the production order requirements and can be manually entered through the control panel. It affects the total length of the heat sink and the adjustable range of the central safety area. That is, the larger the total number of actual heat sinks 3 Z, the larger the total length of the heat sink, and the wider the adjustable range of the central safety area E. Conversely, the smaller Z is, the smaller the total length of the heat sink, and the narrower the adjustable space of the central safety area. The size of Z determines the adjustment requirements of the width of the central safety area. Its function is to expand the range of the central safety area by adapting to the total length of the heat sink, so as to avoid the problem of excessive thermal deformation caused by the heat asymmetry at both ends far from the reference heat sink 3 due to the total length of the heat sink being too small and the central area being too large. Z0 represents the total number of standard heat sinks (3) that are matched with M0. This is a fixed preset value used to compare with the actual parameter Z, calculate the deviation between the actual total number of heat sinks (3) and the standard total number, and thus determine the difference between the actual total length of the heat sink and the standard total length. This provides a basis for adjusting M1 based on the total length-related deviation. When Z is greater than Z0, the total length of the heat sink increases, and the adjustable range of the central safety area widens. M1 can be increased by adjusting the formula. When Z is less than Z0, the total length of the heat sink decreases, and the adjustable space of the central safety area narrows. M1 needs to be appropriately reduced to avoid thermal deformation problems at the ends far from the reference.

[0031] t: The actual thickness of heat sink 3; the larger t is, the more heat is absorbed during welding. Since the heat conduction speed inside the thick heat sink 3 is slow, it is easier for local heat accumulation and uneven heat distribution to occur, which in turn leads to increased thermal deformation at the weld. Conversely, the smaller t is, the less heat is absorbed by heat sink 3, the more uniform the heat conduction is, and the lower the risk of thermal deformation. t0 is the standard thickness of heat sink 3 that matches M0. It is a fixed preset value used to compare with the actual parameter t and calculate the deviation between the actual thickness of heat sink 3 and the standard thickness. When t is greater than t0, the risk of heat accumulation and uneven distribution increases, and M1 needs to be adjusted and reduced using the formula. When t is less than t0, the heat distribution is more uniform, and M1 can be appropriately increased to ensure that the central safe area is adapted to the heat distribution conditions.

[0032] Furthermore, for the weighting coefficients k1, k2, and k3, the condition k1 + k2 + k3 = 1 is met to avoid abnormal summation values ​​due to unbalanced weighting, which could lead to deviations in the adjustment of the central safety zone width. Their values ​​are not randomly set, but rather reasonably allocated based on the influence of each parameter (d, Z, t) on the central safety zone width M1 in actual production, following the principle of "the greater the influence, the higher the weighting coefficient," ensuring that the adjustment of M1 primarily adapts to the most significantly affected parameters and meets the needs of actual production conditions. Specifically, the setting of the weighting coefficients needs to consider the production specifications of the radiator, welding process requirements, and actual operating conditions. For example, if the fluctuation frequency of the equidistant dimension d of the heat sink 3 is the highest during production, and its impact on the uniformity of heat distribution and the definition of the central area is the most significant—meaning that even a small change in d would require a significant adjustment to M1—then k1 = 0.5, k2 = 0.25, and k3 = 0.25 can be set. By increasing the weight of k1, the influence of d on the adjustment of M1 can be strengthened. If the variation frequency of the actual total number Z of heat sink 3 is high, the weighting coefficients can be adjusted accordingly. For complex heat sinks, the fluctuation in the total length of the heat sink has the most significant impact on the central safety area. It is necessary to focus on adapting to the changes in Z to avoid thermal deformation problems far from the reference end. In this case, k1=0.25, k2=0.5, and k3=0.25 can be set, and the weight of k2 can be increased. If the thickness t of the heat sink 3 has various specifications, and the thickness variation has the greatest impact on heat accumulation and thermal deformation, it is necessary to focus on adjusting M1 by changing the t to avoid the risk of thermal deformation. In this case, k1=0.25, k2=0.25, and k3=0.5 can be set, and the weight of k3 can be increased.

[0033] Therefore, the role of the weighting coefficient is to accurately allocate the influence weight of the actual parameters (d, Z, t) on M1, so that the dynamic adjustment of M1 can be adapted to the change range and influence of each parameter, avoid the influence of a certain key parameter being weakened or over-amplified, ensure the accuracy and rationality of M1 adjustment, and thus ensure that the central safety area E can always adapt to the distribution state and heat distribution conditions of the actual heat sink 3, providing reliable support for the accurate judgment of the reference heat sink 3 and the scientific selection of the welding sequence.

[0034] In addition, this device also includes a control panel electrically connected to the control module, which allows operators to flexibly adjust various preset parameters according to actual production conditions. Specifically, the control panel is used for manual input of various key preset parameters, including the variance threshold b, standard welding gap A0, standard width M0 of the central safety area E, standard equidistant dimension d0 of heat sink 3, total number of standard heat sink 3 Z0, thickness t0 of standard heat sink 3, adjustment coefficient e, and weighting coefficients k1, k2, and k3.

[0035] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "upper," "lower," "left," "right," "front," "back," and similar expressions used in this document are for illustrative purposes only.

[0036] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A smart welding device for radiators, comprising a welding assembly, a frame, and welding components, wherein the welding components include heat sink fins, a first oil collection pipe, and a second oil collection pipe; the welding assembly is used to weld the heat sink fins to the first and second oil collection pipes; and the frame is used to fix the first oil collection pipe after welding several heat sink fins; characterized in that, It also includes a control module, a sensing module electrically connected to the control module, and a telescopic component for mounting the second manifold at the telescopic end; The sensing module is used to identify the gap Ai between each heat sink and the second oil pipe, and transmit all gap Ai data to the control module. The control module calculates the variance a of several Ai based on all gap Ai data. The telescopic component is electrically connected to the control module and is used to drive the second oil collection pipe to move in a direction closer to or further away from the heat sink under the control of the control module, thereby adjusting the gap between the heat sink and the second oil collection pipe. The control module is preset with a variance threshold b and a standard welding gap A0; The control module selects the reference heat sink according to the preset variance threshold relationship, and controls the telescopic component to adjust the gap between the second oil pipe and the reference heat sink to the standard welding gap A0. Then, it controls the welding assembly to complete the welding and fixing of the second oil pipe and all heat sinks.

2. The intelligent radiator welding device according to claim 1, characterized in that: The control module is used to calculate the mean T1 of all Ai; When a≤b, the control module locks the heat sink whose gap value is closest to the average value T1 as the reference heat sink; When a>b, the control module calculates the variance c of the J gap values ​​that are greater than the mean. If c≤b, the control module calculates the mean T2 of the J gap values ​​and locks the heat sink with the gap value closest to the mean T2 among the J heat sinks as the reference heat sink.

3. The intelligent radiator welding device according to claim 2, characterized in that: When a>b and c>b, the control module will lock the heatsink corresponding to the maximum value among all Ai as the reference heatsink.

4. The intelligent radiator welding device according to claim 3, characterized in that: The control module sorts all Ai values ​​from largest to smallest and creates a mapping table between gap values ​​and heat sinks based on this sorting. The control module then creates a welding table based on the sorting of heat sinks in the mapping table, and the welding assembly welds the heat sinks and the second oil pipe according to the welding table.

5. The intelligent radiator welding device according to claim 4, characterized in that: If the distance between any two adjacent heat sinks in the welding table is less than the safety threshold, the welding assembly shall be welded according to the order of the heat sinks in the welding table.

6. The intelligent radiator welding device according to claim 4, characterized in that: If the distance between adjacent heat sinks in the welding table is greater than the safety threshold, the welding assembly will choose to weld in either the order of expanding from the center to both ends or symmetrically converging from both ends to the center after determining whether the heat sink with the gap value closest to the average value T1 is located in the central safety area E.

7. The intelligent radiator welding device according to claim 6, characterized in that: When the heat sink closest to the mean T1 is located within the central safe area E, the welding assembly adopts a welding method that expands outward from the heat sink as the center; otherwise, the welding assembly adopts a welding method that converges symmetrically from both ends to the center.

8. The intelligent radiator welding device according to claim 7, characterized in that: The control module has a preset standard width M0 for the central safety area E. The control module adjusts the actual width M1 of the central safety area E according to the actual equidistant size d between the equally spaced heat sinks, the actual total number of heat sinks Z, and the actual thickness t of the heat sinks. M1 = e * M0 * (k1 * d / d0 + k2 * Z / Z0 + k3 * t0 / t). Where d0, Z0, and t0 are the standard equidistant size, the standard total number of heat sinks, and the standard thickness of the heat sinks, respectively, when the width is the standard width M0. k1, k2, and k3 are weighting coefficients, and k1 + k2 + k3 = 1. e is the adjustment coefficient.

9. The intelligent radiator welding device according to claim 8, characterized in that: It also includes a control panel for entering the values ​​of b, A0, M0, d0, Z0, t0, e, k1, k2, and k3.

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