An intelligent spot welding device based on an EGR cooler production and a welding method thereof

Abstract

This application discloses an intelligent spot welding device and welding method based on an EGR cooler, relating to the field of welding technology. The device includes: a welding table; a first clamping part disposed along a first direction, corresponding to the clamping position of the cooler end cap; and a second clamping part disposed along a second direction, corresponding to the clamping position of the cooler side. The first clamping part is connected to the welding table and is rotatable relative to it. The second clamping part is connected to the first clamping part and is slidable along the first direction, so that the effective clamping area of ​​the second clamping part covers the cooler side. This device constructs a sensor-driven closed-loop rigid / elastic switchable clamping system through the coordinated control of end cap flexible cavity clamping, snap-on magnetic buffering, side segment deformation fitting, and cable tightening.

Description

Technical Field

[0001] This application relates to the field of welding technology, specifically to an intelligent spot welding device and welding method based on an EGR cooler. Background Technology

[0002] EGR coolers are heat exchangers used in exhaust gas recirculation systems to cool high-temperature exhaust gases. Spot welding on EGR coolers is mainly used for lap joint fixing of thin-walled shells and end caps, local reinforcement of shell supports and mounting ears, and spot fixing of external flanges / sensor mounts.

[0003] Announcement No. CN115781079A discloses a spot welding device for an EGR cooler, comprising a main frame and a welding apparatus. The main frame has multiple clamping stations corresponding to the parts to be welded. A base is mounted on the main frame, and a horizontal rotation mechanism and a rotation limiting mechanism are mounted on the base. The horizontal rotation mechanism includes a rotation shaft and a turntable. The rotation limiting mechanism includes limiting components installed around the rotation shaft. A vertical rotation mechanism, a vertical limiting mechanism, and a clamping mechanism are mounted above the turntable. The vertical rotation mechanism includes a rotation shaft and a handle connected to one end of the rotation shaft, and a clamping plate is mounted on the rotation shaft. The vertical limiting mechanism limits the rotation angle of the rotation shaft. The welding apparatus performs spot welding on the parts to be welded at the clamping stations. This device enables centralized spot welding of the various parts that make up the EGR cooler, simplifying workpiece transfer. Centralized spot welding significantly improves dimensional control accuracy, reduces workpiece turnaround time, and increases processing efficiency.

[0004] Among them, the positions of the end cap and shell joint, the lugs, the brackets, the reinforcing ribs, and the flange lugs are deviated due to the change in the cooler specifications. When spot welding is performed after changing the cooler specifications, the cooler fixtures need to be adjusted or replaced to ensure the stability and welding accuracy of the end cap, lugs, brackets, reinforcing ribs, flange lugs, and other structures during welding.

[0005] In the prior art, when spot welding coolers of different specifications, it is necessary to replace the corresponding fixtures or adjust the fixtures to ensure the clamping stability of the components. Moreover, the clamping stability is affected when performing multi-sided flip welding. Summary of the Invention

[0006] In view of this, the embodiments of this application aim to provide an intelligent spot welding equipment and welding method based on EGR cooler production, which has an adaptive clamping structure and can adaptively clamp when spot welding coolers of different specifications.

[0007] To achieve the above objectives, the first aspect of this application provides: an intelligent spot welding device based on an EGR cooler, comprising:

[0008] A welding table that forms a working surface, wherein a welding assembly is provided on the upper part of the welding table and the welding assembly faces the working surface;

[0009] A first clamping part is provided along the first direction, and the first clamping part corresponds to the clamping position of the cooler end cover;

[0010] The second clamping part is provided along the second direction and is correspondingly clamped to the side of the cooler;

[0011] The first clamping part is connected to the welding table and can rotate relative to the welding table. The second clamping part is connected to the first clamping part and can slide along the first direction so that the effective clamping area of ​​the second clamping part covers the side of the cooler.

[0012] In some embodiments, the first clamping part includes a clamping seat, a locking block, a pressure plate, a clamping groove, and a chamber. The clamping seat is connected to the welding table and is rotatable relative to the welding table. The locking block and the pressure plate are both disposed at the end of the clamping seat facing the cooler.

[0013] The chamber is located inside the clamping seat and is filled with a medium. The pressure plate is flexibly configured. When the pressure of the medium inside the chamber increases, the pressure plate bulges outward. The clamping groove is formed on the side of the pressure plate facing the cooler. The locking block extends into the chamber and slides when the pressure inside the chamber changes.

[0014] In some embodiments, the clamping seat has a diaphragm on its inner side, the diaphragm is embedded in the clamping seat, and the deformation of the diaphragm changes the chamber pressure. A magnetic plate is embedded on the side of the diaphragm away from the chamber. A cover plate is installed on the outer side of the clamping seat, and an electromagnetic ring is provided on the inner side of the cover plate. The electromagnetic ring corresponds to the magnetic plate, so that the diaphragm changes the chamber pressure under the magnetic force of the electromagnetic ring and the magnetic plate.

[0015] In some embodiments, the first clamping part further includes a clamping member, the clamping member including a sliding plate, a buckle plate, a torsion spring, a buffer pad, a first magnetic control group and a second magnetic control group, the outer side of the clamping seat has a sliding groove, the sliding plate engages with the sliding groove and can slide relative to the sliding groove, the buckle plate is hinged to the sliding plate and connected to the torsion spring to support the buckle plate, and the buffer pad is embedded in the side of the buckle plate that contacts the cooler.

[0016] The buckle plate has an arc groove on one side that contacts the torsion spring. The two ends of the arc groove are concave. The first magnetic control group and the second magnetic control group are arranged on both sides of the sliding groove and connected to the buckle plate, so that the buckle plate changes the position of the torsion spring in the arc groove under the control of the first magnetic control group or the second magnetic control group.

[0017] In some embodiments, the first magnetic control group and the second magnetic control group each include an active magnet and a passive magnet, the active magnet being fixed to the outside of the clamping base, and the passive magnet being fixed to both sides of the buckle plate;

[0018] When the first magnetic control group or the second magnetic control group pushes the buckle to swing relative to the slide plate, one end of the torsion spring connected to the buckle slides in the arc groove.

[0019] In some embodiments, the second clamping part includes a deformable part, the deformable part including a plurality of mounting brackets, a connector, a clamping plate, a spring, a rubber pad and a cavity, the plurality of mounting brackets being connected to each other through the connector and adjacent mounting brackets being inclined, the clamping plate being hinged to the mounting bracket and being able to swing relative to the mounting bracket, and the spring being embedded between the clamping plate and the mounting bracket and supporting the clamping plate outward;

[0020] The rubber pad is embedded on the outside of the card plate, and the cavity is located inside the rubber pad, causing the rubber pad to bulge.

[0021] In some embodiments, a guide groove is provided at the connection position between the mounting bracket and the connector so that adjacent mounting brackets can swing along the length direction, and when the swing angle of adjacent mounting brackets is within the range of ±0-5°, the mounting bracket can be lifted along the height direction;

[0022] The mounting brackets are raised in the following order: from both sides toward the middle, and the mounting brackets are arranged symmetrically from left to right.

[0023] In some embodiments, the second clamping part further includes a tightening member connected to the mounting frame. The tightening member includes a cable, a drive unit, a limiting plate, a guide rod, a support rod, and a roller. The cable passes through the mounting frame and is connected to the mounting frame. The limiting plate is fixed to the outside of the cable and is connected to the mounting frame. The drive unit is connected to the cable and pulls the mounting frame to slide through the cable.

[0024] The support rod is telescopically mounted inside the clamping seat, the roller is embedded inside the support rod and can rotate relative to the support rod, and the guide rod is mounted on one end of the support rod located inside the clamping seat and pushes the support rod to extend and retract.

[0025] In some embodiments, the support rod is equipped with a pressure sensor that detects the pressure when the support rod extends outward, the extension of the support rod controlling the mounting bracket to lift along the height.

[0026] A second aspect of this application provides a spot welding method for an EGR cooler, characterized by comprising the following steps:

[0027] Place the EGR cooler to be welded on the welding table working surface;

[0028] Control the first clamping part to rotate relative to the welding table to the end cap alignment angle, confirm the end cap position and fine-tune it to the predetermined alignment position to provide pre-pressure;

[0029] The second clamping part is driven to slide along the first direction to the initial position on the side, so that the mounting bracket covers the target side component area, ready for deformation fitting;

[0030] After completing the segmented tightening and confirming uniform force, control the first clamping part to achieve rigid positioning, and prepare for welding after confirming the rigid positioning state.

[0031] The welding assembly is triggered to perform spot welding according to a preset weld point sequence, and the welding electrical parameters are monitored in real time.

[0032] After welding is completed, the first clamping part is switched to the elastic buffer state to relieve thermal stress, and then the material is ready to be unloaded.

[0033] This equipment constructs a sensor-driven, closed-loop rigid / elastic switchable clamping system through flexible cavity clamping of end caps, magnetic buffering of buckles, coordinated control of side segment deformation bonding and cable tightening. Under the process rhythm of feeding—flexible bonding—segmented tightening—rigid positioning—spot welding—elastic release, it can achieve high adaptability and uniform force on complex geometric parts, provide stable rigid positioning during the welding stage, and release thermal stress after welding.

[0034] The linkage of the cavity, diaphragm, and electromagnetic ring enables the pressure plate to seamlessly switch between elasticity and rigidity. The sliding of the clamping block compensates for dimensional tolerances, providing uniform surface pressure and micro-displacement compensation when the end cap is attached. This reduces local stress concentration and clamping deformation, protects the end cap surface, and improves contact stability during welding, thereby reducing defects caused by welding displacement and improving the consistency of the end cap welds.

[0035] The segmented swing of the mounting frame, combined with the gradual tightening from both sides towards the center, along with the cable pull and support rod pressure feedback, achieves gradual fit and balanced force on the side components. This avoids stress concentration and deformation caused by a single large tightening, and can adapt to complex curved surfaces and various component positions. It ensures complete coverage of the side weld points and structural integrity, and reduces the risk of cracking or warping caused by thermal stress.

[0036] Other features and advantages of this application will be set forth in the following description, and in part will be apparent from the description, or may be learned by practicing the application. The objectives and other advantages of this application may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings. Attached Figure Description

[0037] Figure 1 This is a perspective view of the present application;

[0038] Figure 2 This is a schematic diagram of the first clamping part and the second clamping part of this application;

[0039] Figure 3 This is a schematic diagram of the first clamping part of this application;

[0040] Figure 4 This is a schematic diagram of the internal structure of the first clamping part of this application;

[0041] Figure 5 This is a schematic diagram of the chamber structure of this application;

[0042] Figure 6 This is a schematic diagram of the card plate and pressure plate structure of this application;

[0043] Figure 7 This is a schematic diagram of the clamping component structure of this application;

[0044] Figure 8 This is a schematic diagram of the second clamping part of this application;

[0045] Figure 9 This is a schematic diagram of the deformable and tightening parts of this application;

[0046] Figure 10 This is a schematic diagram of the guide rod structure of this application;

[0047] Figure 11 This is a schematic diagram of the deformable part structure of this application;

[0048] Figure 12 This is an exploded view of the deformable part structure of this application;

[0049] Figure 13 This is a schematic diagram of the spring structure of this application;

[0050] Figure 14 This is a schematic diagram of the connector and guide groove structure of this application.

[0051] In the diagram: 100 welding station, 200 first clamping part, 300 second clamping part;

[0052] 21 Clamping seat, 22 Clamping block, 23 Pressure plate, 24 Clamping groove, 25 Chamber, 26 Diaphragm, 27 Cover plate, 28 Magnetic plate, 29 Electromagnetic ring;

[0053] 220 Clamping component, 221 Slide plate, 222 Buckle plate, 223 Torsion spring, 224 Buffer pad, 225 First magnetic control group, 226 Second magnetic control group, 227 Slide groove, 228 Arc groove;

[0054] 51. Active magnet; 52. Passive magnet;

[0055] 310 Deformation part, 311 Mounting bracket, 312 Connector, 313 Clamping plate, 314 Spring, 315 Rubber pad, 316 Cavity, 317 Guide groove;

[0056] 320 Tightening component, 321 Cable, 322 Drive unit, 323 Guide rod, 324 Support rod, 325 Roller, 326 Pressure sensor. Detailed Implementation

[0057] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0058] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of this application. The terms “comprising” and “having”, and any variations thereof, are intended to cover non-exclusive inclusion.

[0059] In the description of the embodiments of this application, the technical terms "first," "second," "third," etc., are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0060] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0061] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0062] Spot welding on EGR coolers is mainly used for the overlapping and fixing of thin-walled shells and end caps, the local reinforcement of shell supports and mounting ears, and the spot fixing of external flanges / sensor seats.

[0063] The positions of the end cap and shell joint, lugs, brackets, reinforcing ribs, and flange lugs may deviate due to changes in the cooler specifications. When spot welding is performed after changing the cooler specifications, the cooler fixtures need to be adjusted or replaced to ensure the stability and welding accuracy of the end cap, lugs, brackets, reinforcing ribs, flange lugs, and other structures during welding.

[0064] When adjusting the position of components such as lugs, brackets, reinforcing ribs, and flanges, or when changing the specifications of the cooler, it is necessary to replace the clamps or manually clamp the components before welding. When multi-sided welding requires flipping, the stability of the clamping is easily affected.

[0065] To address the aforementioned issues, this application provides an intelligent spot welding device based on an EGR cooler. (See attached document.) Figure 1-7 As shown. It includes a welding table 100, a first clamping part 200 and a second clamping part 300. The welding table 100 integrates welding components and defines the working surface of the cooler. The welding components are set facing the working surface. When welding the cooler, each component of the cooler is clamped by the first clamping part 200 and the second clamping part 300 and then spot welded by the welding components.

[0066] The first clamping part 200 is arranged along the first direction and corresponds to the end cap position of the cooler. The second clamping part 300 is arranged along the second direction and corresponds to the support lugs, brackets, reinforcing ribs, flanges and other components on the side of the cooler.

[0067] To meet the multi-sided welding requirements of the cooler, the first clamping part 200 is movably connected to the welding table 100 and can rotate relative to the welding table 100. The second clamping part 300 is connected to the first clamping part 200, and rotates accordingly when the first clamping part 200 rotates. The second clamping part 300 can slide along a first direction so that the effective clamping area of ​​the second clamping part 300 covers the side of the cooler.

[0068] The first clamping part 200 and the second clamping part 300 are respectively configured to clamp the end cover and the side of the cooler, and the effective clamping area of ​​the second clamping part 300 covers the entire side of the cooler, which can stably clamp components at different positions.

[0069] In some embodiments, the first clamping part 200 includes a clamping seat 21, a locking block 22, a pressure plate 23, a clamping groove 24, and a chamber 25. The chamber 25 is located inside the clamping seat 21, and the locking block 22 and the pressure plate 23 both extend into the chamber 25 or form the wall of the chamber 25. The pressure plate 23 is flexibly configured to expand or contract, and the clamping groove 24 is provided on the surface of the pressure plate 23.

[0070] When the pressure plate 23 expands, the clamping groove 24 is stretched and deformed. When it fits the end cap, the pressure plate 23 contracts and the deformation of the clamping groove 24 is used to hold the edge of the end cap and keep the end cap stable.

[0071] When the clamping block 22 is in a retracted state, it moves toward the middle of the clamping seat 21. The displacement of the clamping block 22 is within the size range of the cooler, which stably clamps the end cover. Combined with the deformation of the pressure plate 23, it provides flexible compression to the end cover, thereby improving the stability of the end cover and the clamping seat 21.

[0072] Furthermore, a cover plate 27 is provided on the side of the clamping seat 21 opposite to the clamping end cap position. The cover plate 27 is threaded or snapped into the clamping seat 21 to maintain the stability of the cover plate 27 and the clamping seat 21 during the welding process. Secondly, the chamber 25 is provided with at least one diaphragm 26. Similarly, the diaphragm 26 can also bulge or contract. A magnetic plate 28 is embedded in the side of the diaphragm 26 facing the end cap. An electromagnetic ring 29 is installed inside the cover plate 27. The electromagnetic ring 29 cooperates with the magnetic plate 28 to change the state of the diaphragm 26, causing the diaphragm 26 to bulge or contract. This changes the pressure in the chamber 25, causing the pressure plate 23 and the clamping block 22 to change.

[0073] The cooperation between the electromagnetic ring 29 and the magnetic plate 28 causes the diaphragm 26 to deform. Since the amount of medium inside the chamber 25 is constant, after the diaphragm 26 deforms, the corresponding locking block 22 and pressure plate 23 will also deform.

[0074] This application does not limit the medium inside chamber 25. Exemplarily, in an embodiment of this application, the medium is air.

[0075] In some embodiments, the first clamping part 200 further includes a clamping member 220 to clamp the cooler housing, so that the housing and the end cover are kept in a stable state. The clamping member 220 includes a sliding plate 221, a buckle plate 222 and a buffer pad 224. A sliding groove 227 is provided on the outer side of the clamping seat 21. The sliding plate 221 is engaged with the inner side of the sliding groove 227 and can slide along the sliding groove 227. The buckle plate 222 is hinged to the sliding plate 221. After the sliding plate 221 slides, the clamping position of the buckle plate 222 on the housing changes. The buffer pad 224 is embedded in the end of the buckle plate 222 that contacts the housing, reducing the impact between the buckle plate 222 and the housing.

[0076] The buffer pad 224 increases the friction generated after the buckle plate 222 comes into contact with the housing. A torsion spring 223 is provided between the buckle plate 222 and the slide plate 221. The torsion spring 223 supports the buckle plate 222, allowing the buckle plate 222 to apply pressure toward the housing.

[0077] It should be noted that an arc groove 228 is formed at the position where the buckle plate 222 contacts the torsion spring 223. The two ends of the arc groove 228 are concave, so that the depth of the two ends of the arc groove 228 is greater than the depth of the middle part of the arc groove 228. When the torsion spring 223 is located at the concave ends of the arc groove 228, the connection between the torsion spring 223 and the buckle plate 222 is stronger. When the position of the torsion spring 223 at the two ends of the arc groove 228 changes, the support state of the buckle plate 222 also changes accordingly. When the torsion spring 223 is at one end of the arc groove 228, the buckle plate 222 clamps the shell. When the torsion spring 223 moves to the other end of the arc groove 228, the buckle plate 222 is lifted and does not contact the shell.

[0078] The first magnetic control group 225 and the second magnetic control group 226 are respectively provided at both ends of the slide groove 227. The first magnetic control group 225 and the second magnetic control group 226 are both connected to the buckle plate 222 and the buckle plate 222 is swung by magnetic force. Under the magnetic control of the first magnetic control group 225 or the second magnetic control group 226, the buckle plate 222 will change the position of the torsion spring 223 in the arc groove 228.

[0079] The first magnetic control group 225 and the second magnetic control group 226 both include an active magnet 51 and a passive magnet 52. The active magnet 51 is fixed outside the clamping seats 21 on both sides of the slide groove 227, and the passive magnet 52 is fixed on both sides of the buckle plate 222. The active magnet 51 is electrically driven, and the cooperation between the active magnet 51 and the passive magnet 52 changes the buckle plate 222.

[0080] Optionally, the slide plate 221 and the slide groove 227 are interference fit to increase the force required for the slide plate 221 to slide; alternatively, the bottom of the slide plate 221 has several balls, and the slide groove 227 forms multiple recesses, with the balls and recesses working together to position the slide plate 221.

[0081] In some embodiments, see Figure 8-14 As shown. The second clamping part 300 includes a deformation part 310, which can be formed to fit and clamp the component located on the side of the cooler. The deformation part 310 includes a plurality of mounting brackets 311 arranged along the second direction. The mounting brackets 311 are connected by connectors 312. A guide groove 317 is opened at the connection position between the mounting bracket 311 and the connector 312. The opening of the guide groove 317 allows the adjacent mounting brackets 311 to tilt, swing or lift.

[0082] It should be noted that the mounting bracket 311 is provided at each of the two end caps and can slide along the first direction. Due to the swingable nature of the mounting bracket 311, it can conform to the component and deform when it slides to the side of the cooler.

[0083] The mounting bracket 311, constrained by the guide groove 317 and the connector 312, can swing along its length and can be lifted along its height when the swing angle of the adjacent mounting bracket 311 is within the range of ±0-5°.

[0084] The mounting bracket 311 is lifted sequentially from both sides towards the center. At the component clamping position, since the swing angle of the mounting bracket 311 exceeds the lifting angle range of the connector 312, the mounting bracket 311 at the clamping position cannot be lifted, so as to reduce the interference of non-component clamping positions on the welding process.

[0085] In some embodiments, the deformable part 310 further includes a retaining plate 313, a spring piece 314, a rubber pad 315, and a cavity 316. The retaining plate 313 is hinged to the mounting frame 311 by a pin, so that the retaining plate 313 can swing relative to the mounting frame 311. The spring piece 314 is disposed between the mounting frame 311 and the retaining plate 313 and supports the retaining plate 313 outward. The rubber pad 315 is embedded or bonded to the side of the retaining plate 313 near the frame. The cavity 316 is formed on the side of the rubber pad 315 where the retaining plate 313 is hinged to the mounting frame 311. As the retaining plate 313 contracts, the compressive force of the cavity 316 on the component gradually increases.

[0086] When the mounting bracket 311 clamps the component, one side of the clamping plate 313 supported by the spring 314 will first adhere to the component. As the mounting bracket 311 slides, the clamping plate 313 is squeezed and contracted, and the cavity 316 side of the rubber pad 315 is pushed out, increasing the compressive force on the component and maintaining the stability of the component.

[0087] In some embodiments, the second clamping part 300 further includes a tightening member 320, which is connected to the mounting frame 311 and drives the mounting frame 311 to slide. The tightening member 320 includes a cable 321, a drive unit 322, and a limiting piece. The cable 321 passes through the mounting frame 311 and is connected to one of the symmetrically arranged mounting frames 311. The limiting piece is fixed to the outside of the cable 321 and is connected to the mounting frame 311. Under the action of the limiting piece, each cable 321 can drive at least one mounting frame 311 to slide independently.

[0088] The drive unit 322 enables the winding of the cable 321, and the control of the cable 321 drives the sliding of the mounting frame 311.

[0089] In addition, after clamping the component, part of the mounting frame 311 needs to be lifted. A guide rod 323, a support rod 324, a roller 325, and a pressure sensor 326 are set at the end. The telescopic end of the guide rod 323 is connected to the support rod 324. The roller 325 is set at the outward extension end of the support rod 324. The cable 321 passes around the roller 325. When the cable 321 is pulled, the roller 325 rotates.

[0090] Pressure sensor 326 is installed at the connection position between roller 325 and support rod 324 or at the connection position between support rod 324 and guide rod 323 to detect the pressure of support rod 324 when the mounting frame 311 is lifted by cable 321. Based on the change in pressure, the clamping position of mounting frame 311 on the component is determined.

[0091] This application embodiment also provides a spot welding method for an EGR cooler, including the following steps:

[0092] Place the EGR cooler to be welded on the welding table 100 working surface. The operator confirms that the workpiece model matches the work order and triggers the next action.

[0093] Control the first clamping part 200 to rotate relative to the welding table 100 to the end cap alignment angle, confirm the end cap position and fine-tune it to the predetermined alignment position.

[0094] The control of the first clamping part 200 chamber 25 is activated, causing the pressure plate 23 to bulge slightly and fit against the edge of the end cap through the clamping groove 24. The clamping block 22 slides under the pressure of the cavity 316 to compensate for the dimensional tolerance of the end cap, forming a flexible initial clamping state and recording the pressure of the cavity 316 and the position of the clamping block 22.

[0095] The sliding plate 221 slides to make the buckle plate 222 contact the housing, the torsion spring 223 provides preload, and the buffer pad 224 absorbs the contact impact; the buckle plate 222 is selectively controlled to swing by the first magnetic control group 225 or the second magnetic control group 226 to complete the stable clamping of the housing and the end cover.

[0096] The second clamping part 300 is driven to slide along the first direction to the initial position on the side, so that the mounting bracket 311 covers the target side component area, ready for deformation bonding.

[0097] Utilizing the degrees of freedom of the connector 312 and the guide groove 317, the adjacent mounting bracket 311 swings along the length direction, and the clamping plate 313 supported by the spring piece 314 contacts the component first, completing the initial contact and trigger position confirmation.

[0098] The rubber pad 315 is inflated by the cavity 316 or mechanical drive, and the rubber pad 315 on the outside of the clamping plate 313 forms a flexible fit with the side components, which alleviates local unevenness and fixes the position of the components.

[0099] The drive unit 322 pulls the cable 321 to tighten the mounting frame 311 section by section from both sides to the middle. The support rod 324 extends and supports the mounting frame 311 to lift through the roller 325. The pressure sensor 326 monitors the support force in real time and adjusts the pulling force and the extension of the support rod 324 according to the feedback to ensure uniform force distribution.

[0100] After completing the segmented tightening and confirming uniform force, the electromagnetic ring 29 of the first clamping part 200 is controlled to move, causing the diaphragm 26 to return to its original position, the pressure in the cavity 316 to decrease, and the pressure plate 23 to retract to achieve rigid positioning. After confirming the rigid positioning state, welding is prepared.

[0101] The welding assembly is triggered to perform spot welding according to the preset welding point sequence. The welding electrical parameters, the displacement of the clamp 22, the pressure of the support rod 324 and the pressure of the cavity 316 are monitored in real time. If any abnormality occurs, it is handled according to the graded response strategy. If necessary, it is briefly switched to the elastic state to relieve thermal stress.

[0102] After welding is completed, the first clamping part 200 is switched to the elastic buffer state to relieve thermal stress. The cable 321 is loosened in reverse order and the mounting frame 311 is returned to its original position segment by segment. The support rod 324 is retracted, the buckle plate 222 and the slide plate 221 are reset, and the pressure plate 23 and the locking block 22 are retracted to prepare for material unloading.

[0103] The above embodiments are merely illustrative of the technical solutions of this application and are not intended to limit it. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application, and all should be covered within the scope of this application. In particular, as long as there is no structural conflict, the various technical features mentioned in the embodiments can be combined in any way. This application is not limited to the specific embodiments disclosed herein.

Claims

1. An intelligent spot welding device based on an EGR cooler, characterized in that, include: A welding table (100) forms a working surface, and the upper part of the welding table (100) has a welding assembly facing the working surface; A first clamping part (200) is provided along a first direction, and the first clamping part (200) corresponds to the clamping position of the cooler end cover; The second clamping part (300) is provided along the second direction and the second clamping part (300) clamps the side of the cooler accordingly; The first clamping part (200) is connected to the welding table (100) and can rotate relative to the welding table (100). The second clamping part (300) is connected to the first clamping part (200) and can slide along a first direction so that the effective clamping area of ​​the second clamping part (300) covers the side of the cooler. The first clamping part (200) includes a clamping seat (21), a locking block (22), a pressure plate (23), a clamping groove (24), and a chamber (25). The clamping seat (21) is connected to the welding table (100), and the clamping seat (21) can rotate relative to the welding table (100). The locking block (22) and the pressure plate (23) are both located at the end of the clamping seat (21) facing the cooler. The chamber (25) is located inside the clamping seat (21), and the chamber (25) is filled with a medium. The pressure plate (23) is flexibly arranged. When the pressure of the medium inside the chamber (25) increases, the pressure plate (23) bulges outward. The clamping groove (24) is formed on the side of the pressure plate (23) facing the cooler. The locking block (22) extends into the chamber (25). When the pressure inside the chamber (25) changes, the locking block (22) slides. The clamping seat (21) has a diaphragm (26) on its inner side. The diaphragm (26) is embedded in the clamping seat (21), and the deformation of the diaphragm (26) changes the pressure of the chamber (25). A magnetic plate (28) is embedded on the side of the diaphragm (26) away from the chamber (25). A cover plate (27) is installed on the outer side of the clamping seat (21). An electromagnetic ring (29) is provided on the inner side of the cover plate (27). The electromagnetic ring (29) corresponds to the magnetic plate (28) so that the diaphragm (26) changes the pressure of the chamber (25) under the magnetic force cooperation of the electromagnetic ring (29) and the magnetic plate (28). The second clamping part (300) includes a deformable part (310), which includes a plurality of mounting brackets (311), a connector (312), a clamping plate (313), a spring (314), a rubber pad (315), and a cavity (316). The plurality of mounting brackets (311) are connected to each other through the connector (312), and adjacent mounting brackets (311) are inclined to each other. The clamping plate (313) is hinged to the mounting bracket (311) and can swing relative to the mounting bracket (311). The spring (314) is embedded between the clamping plate (313) and the mounting bracket (311) and supports the clamping plate (313) outward. The rubber pad (315) is embedded on the outside of the card plate (313), and the cavity (316) is located inside the rubber pad (315) to make the rubber pad (315) bulge.

2. The intelligent spot welding equipment based on an EGR cooler according to claim 1, characterized in that, The first clamping part (200) further includes a clamping member (220), which includes a sliding plate (221), a buckle plate (222), a torsion spring (223), a buffer pad (224), a first magnetic control group (225), and a second magnetic control group (226). The clamping base (21) has a sliding groove (227) on its outer side. The sliding plate (221) engages with the sliding groove (227) and can slide relative to the sliding groove (227). The buckle plate (222) is hinged to the sliding plate (221) and connected to the torsion spring (223) to support the buckle plate (222). The buffer pad (224) is embedded in the side of the buckle plate (222) that contacts the cooler. The buckle plate (222) has an arc groove (228) on one side that contacts the torsion spring (223). The two ends of the arc groove (228) are concave. The first magnetic control group (225) and the second magnetic control group (226) are disposed on both sides of the slide groove (227) and connected to the buckle plate (222) so that the buckle plate (222) changes the position of the torsion spring (223) in the arc groove (228) under the control of the first magnetic control group (225) or the second magnetic control group (226).

3. The intelligent spot welding equipment based on an EGR cooler according to claim 2, characterized in that, The first magnetic control group (225) and the second magnetic control group (226) both include an active magnet (51) and a passive magnet (52). The active magnet (51) is fixed to the outside of the clamping base (21), and the passive magnet (52) is fixed to both sides of the buckle plate (222). When the first magnetic control group (225) or the second magnetic control group (226) pushes the buckle plate (222) to swing relative to the slide plate (221), the torsion spring (223) connects one end of the buckle plate (222) to slide in the arc groove (228).

4. The intelligent spot welding equipment based on an EGR cooler as described in claim 1, characterized in that, A guide groove (317) is provided at the connection position between the mounting bracket (311) and the connector (312) so that the adjacent mounting brackets (311) can swing along the length direction, and when the swing angle of the adjacent mounting brackets (311) is within the range of ±0-5°, the mounting bracket (311) can be lifted along the height direction. The mounting brackets (311) are raised in the following order: from both sides toward the middle, and the mounting brackets (311) are arranged symmetrically from left to right.

5. The intelligent spot welding equipment based on an EGR cooler according to claim 4, characterized in that, The second clamping part (300) further includes a tightening member (320), which is connected to the mounting frame (311). The tightening member (320) includes a cable (321), a drive unit (322), a limiting piece, a guide rod (323), a support rod (324), and a roller (325). The cable (321) passes through the mounting frame (311) and is connected to the mounting frame (311). The limiting piece is fixed to the outside of the cable (321) and is connected to the mounting frame (311). The drive unit (322) is connected to the cable (321) and pulls the mounting frame (311) to slide through the cable (321). The support rod (324) is telescopically mounted inside the clamping seat (21), the roller (325) is embedded inside the support rod (324) and can rotate relative to the support rod (324), and the guide rod (323) is mounted on one end of the support rod (324) located inside the clamping seat (21) and pushes the support rod (324) to extend and retract.

6. The intelligent spot welding equipment based on an EGR cooler according to claim 5, characterized in that, The support rod (324) is equipped with a pressure sensor (326), which detects the pressure when the support rod (324) extends outward, and the support rod (324) extends to control the mounting bracket (311) to be raised in height.

7. A spot welding method for an EGR cooler, characterized in that, The intelligent spot welding equipment based on an EGR cooler as described in any one of claims 1-6 includes the following steps: Place the EGR cooler to be welded on the working surface of the welding table (100); Control the first clamping part (200) to rotate relative to the welding table (100) to the end cap alignment angle, confirm the end cap position and fine-tune it to the predetermined alignment position to provide pre-pressure; Drive the second clamping part (300) along the first direction to slide to the initial position on the side, so that the mounting bracket (311) covers the target side component area, ready for deformation fitting; After completing the segmented tightening and confirming uniform force, control the first clamping part (200) to achieve rigid positioning, and prepare for welding after confirming the rigid positioning state; The welding assembly is triggered to perform spot welding according to a preset weld point sequence, and the welding electrical parameters are monitored in real time. After welding is completed, the first clamping part (200) is switched to the elastic buffer state to relieve thermal stress and prepare for unloading.

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