Wire break butt welding device

Abstract

This invention discloses a wire-breaking butt welding device, relating to the field of butt welding technology. The device includes: a workbench; a resistance butt welding machine, mounted on the workbench, used to resistively heat the ends of two wires to be welded and complete the butt welding; a clamping mechanism, comprising two sets, left and right, respectively used to clamp the two wires, with the two sets of clamping mechanisms staggered front and rear to allow the ends of the two wires to be welded to overlap axially; and a solidification mechanism, located between the left and right clamping mechanisms, including front and rear solidification cavities. The solidification cavities and corresponding clamping mechanisms can move synchronously and rapidly towards each other from the front and rear sides when the wire ends are in a molten state, applying radial constraint force to the welding area to plastically densify and standardize the weld point instantly upon completion of welding.

Description

Technical Field

[0001] This invention relates to the field of butt welding technology, specifically to a butt welding device for broken wires. Background Technology

[0002] A broken wire butt welding device is a device used to repair broken metal wires (such as copper wire, aluminum wire, steel wire, etc.) by joining and welding the ends together. It is mainly based on the principle of resistance butt welding, which uses high current heating to melt the metal ends and fuse them under pressure to form a strong joint. It is widely used in industries such as wire and cable, metal wire mesh and steel wire products, and has the advantages of reducing material waste and improving production continuity.

[0003] However, the following problems still exist in the current process of butt welding metal wires: When forging force is applied in the molten state, the ends of the wire are prone to relative misalignment, displacement, or even bending deformation due to uneven force or lack of constraint, resulting in misalignment, incomplete connection, or excessively large and irregular weld beads. At the same time, the lack of radial constraint and forming control in the welding area during the high-temperature plastic stage makes the molten metal prone to disorderly overflow, which not only affects the uniformity of the weld appearance but also easily produces defects such as internal porosity and looseness. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a wire-breaking welding device, which solves the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a wire butt welding device, comprising: a workbench; a resistance butt welding machine, wherein the resistance butt welding machine is disposed on the workbench and is used to resistively heat the ends of two wires to be welded and complete the butt welding; a clamping mechanism, wherein the clamping mechanism is provided with two sets, left and right, respectively for clamping two wires, and the two sets of clamping mechanisms are staggered front and rear, so that the ends of the two wires to be welded overlap axially; a solidification mechanism, wherein the solidification mechanism is disposed between the left and right clamping mechanisms and includes two sets of solidification cavities, front and rear; wherein, when the ends of the wires are in a molten state, the solidification cavities and the corresponding clamping mechanisms can move synchronously and rapidly towards each other from the front and rear sides, applying radial constraint force to the welding area, so as to plastically densify and regularize the shape of the weld point at the instant the welding is completed.

[0006] Furthermore, the clamping mechanism includes an annular cylinder disposed above the worktable. The annular cylinder is divided into an upper cylinder and a lower cylinder along the axial direction. The annular cylinder is provided with circumferentially evenly distributed limiting rods inside. Two threaded columns arranged symmetrically on the left and right are rotatably connected to the outer side of the limiting rods. The threaded columns are threadedly engaged with the cylinder wall of the annular cylinder.

[0007] Furthermore, the upper cylinder has matching rods installed on the front and rear lower end faces on both sides, and the lower cylinder has matching holes corresponding to the matching rods on the front and rear upper end faces on both sides; U-shaped frames are fixedly installed on the adjacent ends of the upper cylinder on both sides, and a stop bar is installed in the middle of the horizontal section of the U-shaped frame.

[0008] Furthermore, the solid cavity is a semi-annular structure with an inner wall profile that is a composite curved surface with tapered ends and a cylindrical middle section. This surface is used to guide metal flow and constrain the shape of the weld point when the welding area is under pressure. The solid cavity can also rotate circumferentially around its axis.

[0009] Furthermore, the solid cavity is rotatably mounted on the inner wall of the arc plate, and a half gear that is rotatably connected to the arc plate is fixedly mounted on its exterior. The half gears corresponding to the front and rear solid cavities are interlocked and engaged in the docking state to form a complete rotating gear. A drive gear is meshed on the outer side of one half gear. The drive gear is connected to the output shaft of the drive motor. The drive motor and the drive gear can move synchronously with the corresponding arc plate.

[0010] Furthermore, a limiting hole is provided on the half gear located on the rear side, and an elastic telescopic rod is fixedly installed on the outer side of the arc plate, with the telescopic end of the elastic telescopic rod cooperating with the limiting hole.

[0011] Furthermore, a support plate is fixedly installed at the lower end of the lower half of the cylinder. Two strip-shaped grooves are provided on the worktable corresponding to the position of the support plate. A strip-shaped rod that slides with the support plate is installed inside the strip-shaped groove. A connecting spring is sleeved on the outer front end of the strip-shaped rod corresponding to the left clamping mechanism and the outer rear end of the strip-shaped rod corresponding to the right clamping mechanism. The connecting spring is located between the support plate and the groove wall of the strip-shaped groove.

[0012] Furthermore, a pusher frame is installed on the front side of the lower half-cylinder on the left and the rear side of the lower half-cylinder on the right, and the upper end of the pusher frame is provided with an inclined surface; a wedge-shaped platform is installed on the side of the two arc-shaped plates that are far apart from each other, and an installation groove is opened on the worktable corresponding to the position of the wedge-shaped platform to slide with the wedge-shaped platform, and a spring rod is connected between the wedge-shaped platform and the groove wall of the installation groove.

[0013] Furthermore, a pressure block is provided at the upper end of the inclined surface of the push frame, and the lower end surface of the pressure block is inclined to match the inclined surface of the push frame; a wedge block is provided at the upper end of the inclined surface of the wedge platform, and the lower end surface of the wedge block is inclined and slides in cooperation with the inclined surface of the wedge platform; the pressure block and the wedge block are installed together at the lower end of the rectangular frame.

[0014] Furthermore, a movable plate is fixedly installed on the upper end of the upper cylinder. The movable plate is slidably connected to the lower end of the horizontal plate. The horizontal plate is located below the rectangular frame and slides vertically with the corresponding pressure block. Columns are installed on the upper end of the worktable at the four corners of the rectangular frame. The columns slide vertically with the rectangular frame and the horizontal plate. A control spring sleeved on the outside of the column connects the horizontal plate and the rectangular frame. The upper end of the rectangular frame is connected to the telescopic end of the cylinder.

[0015] The present invention has the following beneficial effects: (1) The broken wire welding device arranges the left and right clamping mechanisms in a staggered manner to make the ends of the two wires to be welded axially overlap. When the wires are in a molten state, the left clamping mechanism drives the wire to move backward and the right clamping mechanism drives the wire to move forward, so that the two wires can move towards each other and fully fit together in the molten state. This staggered overlap, combined with the subsequent opposite movement, not only increases the welding contact area and facilitates current concentration and uniform heating, but also effectively prevents end face misalignment or incomplete connection in the subsequent extrusion process, and improves the centering and bonding strength of the joint.

[0016] (2) The wire break welding device, by setting a solidification mechanism between the left and right clamping mechanisms, includes two sets of solidification cavities, which can move synchronously and rapidly towards each other at the moment when the wire end is in a molten state and the welding is about to be completed, and apply controllable radial constraint force from both sides of the weld point. This constraint effectively inhibits the disorderly flow of molten metal, prevents the weld bead from being too large or the flash from being generated, and achieves plastic densification in the early stage of weld point solidification, eliminates internal porosity and loose defects, and forces the weld point contour to fit the preset surface of the inner wall of the solidification cavity, thereby improving the weld point shape regularity, dimensional consistency and mechanical properties, and ensuring stable and reliable welding quality.

[0017] (3) The solid cavity of the wire break welding device adopts a semi-circular structure. Its inner wall is designed as a composite curved surface with tapered transitions at both ends and a cylindrical section in the middle. The tapered section can guide the orderly backflow of molten metal and reduce the accumulation or flash at the weld edge. The cylindrical section in the middle is precisely matched with the outer diameter of the wire, effectively limiting the diameter of the weld point and ensuring that the shape is regular and the size is consistent. At the same time, the solid cavity can rotate around its own axis in a circumferential manner. It can not only further compact the weld point and improve the density through micro-movement during the solidification process, but also achieve dynamic separation from the surface of the weld point after the forming is completed, reducing the risk of metal adhesion or residue and facilitating smooth demolding.

[0018] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0019] Figure 1 This is an overall structural diagram of the present invention; Figure 2This is a schematic diagram of the resistance welding machine, clamping mechanism and fixing mechanism in this invention; Figure 3 This is a schematic diagram of the rectangular frame, horizontal plate, and vertical column in this invention; Figure 4 This is a schematic diagram of the structure of the horizontal plate, the movable plate, and the clamping mechanism in this invention; Figure 5 This is a schematic diagram of the left and right clamping mechanisms in this invention; Figure 6 This is a partial cross-sectional view of the annular cylinder in this invention; Figure 7 For the present invention Figure 6 Enlarged view of region A in the middle; Figure 8 This is a cross-sectional plan view of the annular cylinder in this invention; Figure 9 This is a schematic diagram of the structure of the U-shaped frame and the stop bar in this invention; Figure 10 This is a schematic diagram of the structure of the wedge-shaped platform, wedge block, and solidification mechanism in this invention; Figure 11 This is a schematic diagram of the arc-shaped plate, the half gear, and the drive gear in this invention; Figure 12 This is a schematic diagram of the structure of the arc-shaped plate and the solid cavity in this invention.

[0020] In the diagram: 1. Workbench; 2. Resistance welding machine; 3. Clamping mechanism; 31. Annular cylinder; 311. Limiting rod; 312. Threaded column; 313. Matching rod; 314. U-shaped frame; 315. Stop bar; 32. Support plate; 321. Strip groove; 322. Connecting spring; 33. Push frame; 331. Pressure block; 34. Moving plate; 4. Solidification mechanism; 41. Solidification cavity; 411. Arc plate; 412. Half gear; 413. Drive gear; 414. Support; 415. Drive motor; 416. Elastic telescopic rod; 42. Wedge platform; 421. Spring rod; 422. Wedge block; 43. Rectangular frame; 431. Horizontal plate; 432. Control spring; 44. Column; 45. Cylinder. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] In the description of this invention, it should be understood that the terms "opening", "upper", "lower", "thickness", "top", "middle", "length", "inner", "around", etc., which indicate orientation or positional relationship, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting this invention.

[0023] The following is based on Figures 1-12 This invention describes a wire-breaking butt welding device provided in an embodiment of the present invention.

[0024] Please refer to Figure 1 and Figure 2 The broken wire welding device includes a workbench 1, on which a resistance welding machine 2 is installed. The resistance welding machine 2 adopts the existing mature electrode pressure and electric heating method to pass a large current to the ends of two metal wires to be welded. The Joule heat generated by the contact resistance causes the end face to melt locally, thereby achieving a firm connection. Its matching power system can adjust the current and energizing time according to the wire material and diameter to ensure sufficient heating without burning. This makes the welding process efficient and stable, and the joint strength is close to that of the base material. It is suitable for continuous broken wire repair operations of metal wires such as steel wire and copper wire.

[0025] Please refer to Figure 2 To ensure the stability of the wires during the welding process, two sets of clamping mechanisms 3 are set on the workbench 1, one on the left and one on the right, to clamp the two wires respectively. The two sets of clamping mechanisms 3 are staggered, so that the ends of the two wires to be welded overlap axially. This staggered overlap method not only ensures that the welding area has sufficient contact area, but also effectively reduces end face misalignment or incomplete connection in the subsequent extrusion forging process, improves the alignment and bonding strength of the welded joint, and thus ensures the reliability of the welding quality.

[0026] Specifically, please refer to Figures 3-6 and Figure 8 The clamping mechanism 3 includes an annular cylinder 31 disposed above the worktable 1. The annular cylinder 31 is divided into an upper cylinder and a lower cylinder along the axial direction. The annular cylinder 31 is provided with circumferentially evenly distributed limiting rods 311 inside. The side of each limiting rod 311 facing the center of the cylinder is a smooth arc surface, which can effectively fit the outer wall of the wire and reduce surface damage during clamping. Before welding, the wire to be welded can be placed between the upper ends of the corresponding limiting rods 311 in the lower cylinder to achieve stable support. Then the upper cylinder can be moved down, driving its corresponding limiting rods 311 to move down synchronously, so that the upper and lower limiting rods 311 clamp the wire together to complete positioning and locking.

[0027] Please refer to Figure 5 , Figure 6 and Figure 8To accommodate wires of different diameters, two symmetrically arranged threaded posts 312 are rotatably connected to the outside of the limiting rod 311. The threaded posts 312 are threaded into the cylinder wall of the annular cylinder 31. When changing to different diameter batches of wires, the threaded posts 312 only need to be rotated before operation to drive the limiting rod 311 to be adjusted radially to the appropriate position, thereby matching the outer diameter of the wire.

[0028] Please refer to Figure 6 and Figure 7 Matching rods 313 are installed on the front and rear lower end faces of the left and right sides of the upper cylinder. Matching holes that match the matching rods 313 are opened on the front and rear upper end faces of the left and right sides of the lower cylinder. When the upper cylinder closes down to the lower cylinder, each matching rod 313 is inserted into the corresponding matching hole to form a multi-point positioning structure. This not only effectively prevents the upper and lower cylinders from shifting, twisting or misaligning during the clamping process, but also ensures that the upper and lower limit rods 311 are radially aligned and closed, so that the wire is evenly and stably clamped in the center position, thereby improving the axial alignment accuracy and clamping reliability of the wire end during the welding process.

[0029] Please refer to Figure 9 A U-shaped frame 314 is fixedly installed at the close end of the upper half of the left and right sides of the cylinder. A stop bar 315 is installed in the middle of the horizontal section of the U-shaped frame 314, and the stop bar 315 is arranged directly opposite the axis of the corresponding annular cylinder 31. When the upper half of the cylinder has not yet moved down to approach the lower half of the cylinder, the U-shaped frame 314 and the stop bar 315 are in the initial position slightly above the upper half of the cylinder. At this time, the stop bar 315 is exactly in front of the axial end of the wire to be welded, which can axially position the wire placed on the limiting rod 311 of the lower half of the cylinder - that is, the end of the wire abuts against the stop bar 315, achieving reliable limiting. When the upper half of the cylinder closes downward, the U-shaped frame 314 and the stop bar 315 move down synchronously, thereby avoiding the welding area and avoiding interference with the welding process of the ends of the two wires.

[0030] Furthermore, the stop bars 315 on the left and right sides are staggered in the front-to-back direction and have a certain overlap in the left-to-right direction, so that the two wires to be welded can be stably placed on the corresponding limit bars 311 in a way that the ends are in contact with each other. This not only achieves rapid and accurate centering and contact of the ends of the wires before welding, but also effectively reduces welding deviations caused by axial movement or misalignment, and improves the stability of the subsequent clamping and moving process.

[0031] It should be noted that the workbench 1 is provided with clearance grooves for the movement of the U-shaped frame 314 and the stop bar 315, providing necessary space for the U-shaped frame 314 and the connected stop bar 315 during movement, and reducing interference between them and the workbench 1 body.

[0032] Please refer to Figure 3 and Figure 4 To enable the left and right clamping mechanisms 3 to move backward and forward respectively when the wire is molten, a support plate 32 is fixedly installed at the lower end of the lower cylinder. Two strip grooves 321 are provided on the worktable 1 corresponding to the position of the support plate 32. A strip rod that slides with the support plate 32 is installed inside the strip groove 321, so that the lower cylinder can slide smoothly in the horizontal direction. A connecting spring 322 is sleeved on the outer front end of the strip rod corresponding to the left clamping mechanism 3 and the outer rear end of the strip rod corresponding to the right clamping mechanism 3. The connecting spring 322 is connected between the groove wall of the strip groove 321 and the support plate 32.

[0033] In the initial state, the connecting spring 322 pulls the left and right clamping mechanisms 3 to staggered positions (left side forward, right side backward) through preload, thereby stabilizing the initial posture of the lower cylinder. When one side of the clamping mechanism 3 is displaced during welding, the spring is stretched, which allows the necessary relative movement to adapt to wire melting and necking or butt joint adjustment, and provides a reliable reset force after the action is completed, ensuring the repeatability of positioning accuracy and structural stability of the equipment during cyclic operation.

[0034] To enable the clamping mechanism 3 to be finely adjusted in the front-back direction to meet the precise welding requirements of wires of different diameters, the connecting spring 322 with different elasticity can be replaced. By replacing the spring, its preload and extension stroke can be changed, thereby adjusting the relative front-back position of the left and right clamping mechanisms 3 in the initial state, which in turn causes the support plate 32 and the lower cylinder to undergo a slight displacement.

[0035] Please refer to Figure 6 and Figure 7 Because the upper and lower cylinders are provided with a guide and positioning structure consisting of a mating rod 313 and a mating hole, even if there is a slight deviation between the two in the front-to-back direction due to spring replacement or manufacturing tolerance, the mating rod 313 can automatically guide the cylinder into the mating hole during the mold closing process to achieve self-centering and reliable docking. If necessary, the position of the upper cylinder can also be finely adjusted to further compensate for the deviation and ensure that the upper and lower cylinders are tightly and completely closed.

[0036] Please refer to Figure 2 and Figure 10 In order to effectively reduce the problem of excessive weld bead size and irregular shape, a solidification mechanism 4 is provided between the left and right clamping mechanisms 3. The solidification mechanism 4 includes two sets of solidification cavities 41, one in front and one in back. The solidification cavities 41 and the corresponding clamping mechanisms 3 can move synchronously. When the wire end is in a molten state and the welding is about to be completed, the two sets of solidification cavities 41 can move synchronously and quickly towards each other, applying controllable radial constraint force from the front and back sides of the welding area.

[0037] This radial constraint not only reduces the disorderly flow of molten metal and prevents it from overflowing excessively and forming large weld beads, but also plastically densifies the weld joint in the early stage of solidification, eliminating internal porosity or looseness defects. At the same time, it forces the weld joint contour to fit the inner surface of the solid cavity 41, achieving regularization of shape and consistency of size.

[0038] Specifically, please refer to Figure 11 and Figure 12 The solid cavity 41 adopts a semi-annular structure, and its inner wall contour is designed as a composite curved surface: the two ends are conical transition sections, and the middle is a cylindrical section that matches the outer diameter of the wire. It is made of a non-adhesive material with high hardness, high temperature resistance and low surface energy (such as special ceramics or alloy steel with titanium nitride coating), which has excellent anti-molten metal adhesion performance. At the moment of completion of welding, when the two sets of solid cavities 41 move towards each other synchronously and apply radial constraints to the weld point, the composite curved surface can effectively guide the molten metal to flow back in an orderly manner along the conical section, reducing the formation of local accumulation or flash at the weld edge. At the same time, the diameter of the weld point is precisely limited by the middle cylindrical section to ensure that the weld bead shape is regular and the size is consistent.

[0039] In addition, the composite curved surface has reserved a suitable volume space in the central cylindrical section for the overlapping area of ​​the two wires, which is conducive to promoting atomic diffusion and metallurgical bonding under pressure and temperature, and improving the joint strength. At the same time, the solid cavity 41 can rotate around its own axis to dynamically shape the weld point in the molten state, improve the density and contour consistency, and can also achieve dynamic detachment from the weld point surface through slight rotation, reducing the risk of metal residue or adhesion.

[0040] Please refer to Figure 3 and Figures 10-12 To achieve circumferential reciprocating rotation of the solid cavity 41, the solid cavity 41 is rotatably mounted on the inner wall of the arc plate 411. The two sets of arc plates 411 can drive the solid cavities 41 they support to move synchronously in the front-back direction. Half gears 412 that are rotatably connected to the arc plates 411 are fixedly mounted on the outside of the solid cavity 41. When the two arc plates 411 move towards each other to the welding position, the two half gears 412 they carry are precisely connected and interlocked to form a complete, continuous, full-circle rotating gear. A drive gear 413 meshes with the outer side of one half gear 412. The drive gear 413 is rotatably mounted on the support 414 and is directly driven by the output shaft of the drive motor 415 fixed on the support 414.

[0041] Please refer to Figure 10The support 414 slides back and forth with the worktable 1 and can move back and forth synchronously with the corresponding arc plate 411. When the arc plate 411 drives the solid cavity 41 and the half gear 412 to move towards the center of the wire, the support 414 drives the drive motor 415 and the drive gear 413 to move together, always maintaining the correct meshing state between the drive gear 413 and the corresponding half gear 412, reducing disengagement or interference caused by relative displacement. After the two half gears 412 are connected to form a complete gear, the drive motor 415 is started, and its output shaft drives the drive gear 413 to reciprocate at a set angle. This rotational motion is transmitted to the connected complete gear through the gear pair, thereby driving the front and rear half gears 412 to reciprocate synchronously in a circumferential direction, and finally driving their respective solid cavities 41 to achieve synchronous circumferential reciprocating rotation.

[0042] Please refer to Figure 12 To ensure that the rear half gear 412 maintains its initial position when not driven (i.e., the solid surface of the solid cavity 41 always faces the front), a limiting hole is provided on the half gear 412, and an elastic telescopic rod 416 is fixedly installed on the outside of the arc plate 411. The telescopic end of the elastic telescopic rod 416 cooperates with the limiting hole. In the non-working state, the telescopic end of the elastic telescopic rod 416 is inserted into the limiting hole to circumferentially limit the half gear 412 and prevent it from deflecting due to gravity, vibration or assembly gap. This ensures that the posture of the solid cavity 41 is consistent each time the mold is closed. When the drive gear 413 drives the complete gear after docking to rotate, the driving torque transmitted to the rear half gear 412 is sufficient to overcome the preload of the elastic telescopic rod 416, causing its telescopic end to automatically retract.

[0043] Please refer to Figure 3 and Figure 10 A protective shell covering the half gear 412 and the rotating gear is provided on the arc plate 411 and the support 414. The protective shell can prevent dust, prevent metal splashes and isolate the high temperature radiation of welding, thereby improving the reliability and safety of the transmission system.

[0044] Please refer to Figure 3 , Figure 4 and Figure 10 To enable the left clamping mechanism 3 to move backward and the right clamping mechanism 3 to move forward, push frames 33 are installed on the front side of the lower half of the cylinder on the left and the rear side of the lower half of the cylinder on the right. The upper end of the push frame 33 is provided with an inclined surface, and a pressure block 331 is provided at the upper end of the inclined surface of the push frame 33. The lower end surface of the pressure block 331 is inclined to match the inclined surface of the push frame 33. When the pressure block 331 moves vertically downward, its lower inclined surface contacts the upper inclined surface of the push frame 33 and produces an inclined sliding fit, converting the vertical movement into a horizontal thrust.

[0045] Specifically, when the left pressure block 331 is pressed down, the inclined plane pushes the left pusher 33 to slide backward, thereby causing the left clamping mechanism 3 and the lower cylinder to move backward synchronously. Similarly, when the right pressure block 331 is pressed down, it pushes the right pusher 33 to slide forward, causing the right clamping mechanism 3 to move forward. In addition, with the aforementioned resetting of the connecting spring 322, the pressure block 331 can automatically return to its initial position after the return stroke, preparing for the next welding cycle.

[0046] Please refer to Figure 3 , Figure 10 and Figure 11 To enable the front and rear solid cavities 41 to move towards each other, wedge-shaped platforms 42 are installed on the opposite sides of the two arc-shaped plates 411. The worktable 1 has a mounting groove corresponding to the position of the wedge-shaped platform 42, which slides and engages with the wedge-shaped platform 42. A spring rod 421 is connected between the wedge-shaped platform 42 and the groove wall of the mounting groove. The spring rod 421 provides preload under normal conditions to ensure that the wedge-shaped platform 42 is in the initial reset position. When pushed by an external force, it is allowed to move and automatically springs back to reset after the external force is removed.

[0047] In addition, the spring rod 421 can be replaced according to the clamping force or stroke range required for the docking of wires of different specifications. Spring rods 421 with different elastic coefficients or free lengths can be selected to adjust the initial preload and maximum displacement of the wedge stage 42, thereby adapting to the requirements of different diameter wires on the closing speed, closing force and centering accuracy of the solid cavity 41.

[0048] Please refer to Figure 3 and Figure 10 A wedge block 422 is provided at the upper end of the inclined surface of the wedge platform 42. The lower end surface of the wedge block 422 is an inclined surface and slides in cooperation with the inclined surface of the wedge platform 42. When the wedge block 422 moves vertically downward, its lower end inclined surface slides in contact with the inclined surface of the wedge platform 42. The vertical motion is converted into horizontal thrust by using the inclined plane transmission principle: the front wedge block 422 presses down and pushes the front wedge platform 42 to move backward (i.e. towards the central axis), and the rear wedge block 422 presses down and pushes the rear wedge platform 42 to move forward, thereby driving the front and rear arc plates 411 and the solid cavity 41 they support to move towards each other synchronously, so as to achieve precise wrapping and forming constraint of the end of the molten wire.

[0049] Please refer to Figure 10 and Figure 11 The support 414 is fixedly connected to the wedge-shaped platform 42 located on the front side, so that the drive motor 415 and drive gear 413 installed on the support 414 can move synchronously with the front arc plate 411 and the solid cavity 41.

[0050] Please refer to Figures 2-4 and Figure 10To enable the clamping mechanism 3 and the solid cavity 41 to achieve coordinated and synchronous movements, the pressure block 331 and the wedge block 422 are installed together at the lower end of the rectangular frame 43. When the rectangular frame 43 moves down as a whole, the pressure block 331 and the wedge block 422 can move vertically downwards in sync, thereby acting on the corresponding push frame 33 and wedge platform 42 respectively, realizing the linkage control between the clamping mechanism 3 and the solid cavity 41.

[0051] Please refer to Figures 2-4 To achieve the downward movement of the upper cylinder to clamp the wire, a movable plate 34 is fixedly installed at the upper end of the upper cylinder. The movable plate 34 is slidably connected to the lower end of the horizontal plate 431, so that the position of the upper cylinder can be slightly adjusted in the horizontal direction to adapt to different specifications of wire or centering deviation. The horizontal plate 431 is located below the rectangular frame 43 and slides up and down with the corresponding pressure block 331. By adjusting the front and rear position of the movable plate 34 along the horizontal plate 431, the horizontal alignment state of the upper cylinder relative to the lower cylinder can be changed, thereby improving the clamping accuracy.

[0052] Furthermore, during the subsequent forward and backward movement of the clamping mechanism 3, the moving plate 34 can slide freely along the horizontal plate 431 in the forward and backward direction, which not only does not restrict the overall displacement of the clamping mechanism 3, but also maintains the relative positional relationship between the upper half cylinder and the lower half cylinder, ensuring that the clamping force continues to act effectively on the end of the wire.

[0053] Please refer to Figures 2-4 and Figure 10 The upper end of the workbench 1 is equipped with columns 44 at the four corners of the rectangular frame 43. The columns 44 slide vertically with the rectangular frame 43 and the horizontal plate 431, providing stable vertical guidance and support for both. In order to realize the controllable movement of the rectangular frame 43 along the columns 44, a control spring 432 is provided between the horizontal plate 431 and the rectangular frame 43, which is sleeved on the outer periphery of each column 44. The control spring 432 has a large elastic coefficient and can effectively transmit the downward pressure of the rectangular frame 43 to the horizontal plate 431 in the initial stage without significant compression deformation.

[0054] Please refer to Figure 2 The upper end of the rectangular frame 43 is connected to the telescopic end of the cylinder 45, and the cylinder 45 is fixedly installed on the bracket at the upper end of the worktable 1.

[0055] During operation, the cylinders 45 on both sides start synchronously, pushing the rectangular frame 43 to move smoothly down along the column 44. Since the control spring 432 has a large stiffness, it is hardly compressed in this initial stage. Therefore, the rectangular frame 43 transmits the downward pressure directly to the horizontal plate 431 through the control spring 432, causing the horizontal plate 431 and the moving plate 34 connected to its lower end to move down synchronously. This causes the upper cylinder and its internal limiting rod 311 to press down together, achieving the initial clamping and positioning of the wire end. At this time, the pressure block 331 and the wedge block 422 have not yet contacted the corresponding push frame 33 and wedge platform 42, and the clamping action is completed independently.

[0056] After the wire pressing is completed, the cylinder 45 continues to apply thrust, causing the rectangular frame 43 to overcome the elastic force of the control spring 432 and further compress the control spring 432 downward along the column 44. At this time, the rectangular frame 43 generates relative displacement with respect to the horizontal plate 431, and drives the pressure block 331 and wedge block 422 installed at its lower end to move down quickly, so that its inclined surface contacts and slides with the inclined surface on the left / right push frame 33 and the front / rear wedge platform 42 respectively. As a result, the pressure block 331 pushes the left and right push frames 33 to move back and forth in opposite directions, thereby driving the clamping mechanism 3 to move synchronously. The wedge block 422 pushes the front and rear wedge platforms 42 to move back and forth in opposite directions, driving the arc plate 411 and the solid cavity 41 to move closer together synchronously, completing the encapsulation and forming of the welding area.

[0057] In actual operation (use), firstly, the two metal wires to be welded are placed on the limiting rods 311 of the clamping mechanisms 3 on the left and right sides, respectively. The limiting rods 311 provide support, and the stop rods 315 achieve axial positioning. Then, the cylinder 45 is activated to push the rectangular frame 43 downward along the column 44. The rectangular frame 43 drives the horizontal plate 431 to move downward synchronously through the control spring 432 with high rigidity. The horizontal plate 431 then drives the upper half of the cylinder and its limiting rods 311 to move downward through the moving plate 34, closing with the lower half of the cylinder and completing the initial clamping and fixing of the wires. Next, the resistance welding machine 2 is energized to heat the joint ends of the two wires to a molten state. After that, the cylinder 45 continues to press down, compressing the control spring 432, causing the rectangular frame 43 to move further downward relative to the horizontal plate 431, driving the pressure block 331 at its lower end. As the wedge block 422 moves rapidly downward, the pressure block 331 and the push frame 33, and the wedge block 422 and the wedge platform 42 cooperate through inclined surfaces to convert vertical motion into horizontal thrust, thereby driving the left clamping mechanism 3 to move backward with the wire and the right clamping mechanism 3 to move forward with the wire. At the same time, the front and rear solid cavities 41 close towards each other, quickly covering and shaping the molten joint. During this process, the drive motor 415 drives the drive gear 413 and half gear 412 to rotate back and forth, achieving uniform forging or shaping of the welding area. After the forming is completed, the cylinder 45 resets, controls the spring 432 to rebound, and drives the rectangular frame 43, the horizontal plate 431, the pressure block 331, the wedge block 422 and all linkage components to return to the initial position synchronously. The clamping mechanism 3 and the solid cavity 41 then release, and the wire that has been welded can be taken out.

[0058] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0059] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A wire-breaking welding device, characterized in that, include: Workbench (1); Resistance welding machine (2), the resistance welding machine (2) is set on the workbench (1) and is used to resistively heat the ends of two wires to be welded and complete the welding; The clamping mechanism (3) is provided with two sets of left and right clamping mechanisms, which are used to clamp two wires respectively. The two sets of clamping mechanisms (3) are staggered front and back so that the ends of the two wires to be welded overlap axially. Solidification mechanism (4), which is located between the left and right clamping mechanisms (3) and includes two sets of solidification cavities (41) in the front and rear. Among them, the solid cavity (41) and the corresponding clamping mechanism (3) can move synchronously and rapidly towards each other from the front and rear sides when the wire end is in a molten state, and apply radial constraint force to the welding area so as to plastically densify and regularize the weld point at the moment the welding is completed.

2. The wire-breaking welding device according to claim 1, characterized in that, The clamping mechanism (3) includes an annular cylinder (31) disposed above the workbench (1). The annular cylinder (31) is divided into an upper cylinder and a lower cylinder along the axial direction. The annular cylinder (31) is provided with circumferentially evenly distributed limiting rods (311). Two threaded columns (312) are rotatably connected to the outside of the limiting rods (311). The threaded columns (312) are threadedly engaged with the cylinder wall of the annular cylinder (31).

3. The wire-breaking welding device according to claim 2, characterized in that, The upper cylinder is equipped with a mating rod (313) on the front and rear lower end faces on both sides of the left and right sides, and the lower cylinder is provided with mating holes that mate with the mating rod (313) on the front and rear upper end faces on both sides of the left and right sides. A U-shaped frame (314) is fixedly installed at the end of the upper half of the left and right sides that are close to each other, and a stop bar (315) is installed in the middle of the horizontal section of the U-shaped frame (314).

4. The wire-breaking welding device according to claim 1, characterized in that, The solid cavity (41) is a semi-annular structure with an inner wall profile that is a composite curved surface with tapered ends and cylindrical middle. It is used to guide the flow of metal and constrain the shape of the weld point when the welding area is under pressure. The solid cavity (41) can rotate circumferentially around its axis.

5. The wire-breaking welding device according to claim 4, characterized in that, The solid cavity (41) is rotatably mounted on the inner wall of the arc plate (411), and a half gear (412) rotatably connected to the arc plate (411) is fixedly mounted on its exterior. The half gears (412) corresponding to the front and rear solid cavities (41) are interlocked in the docking state to form a complete rotating gear. A drive gear (413) meshes with the outer side of one half gear (412). The drive gear (413) is connected to the output shaft of the drive motor (415). The drive motor (415) and the drive gear (413) can move synchronously with the corresponding arc plate (411).

6. The wire-breaking welding device according to claim 5, characterized in that, A limiting hole is provided on the rear half gear (412), and an elastic telescopic rod (416) is fixedly installed on the outer side of the arc plate (411). The telescopic end of the elastic telescopic rod (416) cooperates with the limiting hole.

7. The wire-breaking welding device according to claim 2, characterized in that, The lower end of the lower cylinder is fixedly installed with a support plate (32). Two strip grooves (321) are provided on the worktable (1) corresponding to the position of the support plate (32). A strip rod that slides with the support plate (32) is installed inside the strip groove (321). A connecting spring (322) is sleeved on the outer front end of the strip rod corresponding to the left clamping mechanism (3) and the outer rear end of the strip rod corresponding to the right clamping mechanism (3). The connecting spring (322) is located between the support plate (32) and the groove wall of the strip groove (321).

8. A wire-breaking welding device according to claim 5 or 7, characterized in that, Pushing frames (33) are installed on the front side of the lower half-cylinder on the left and the rear side of the lower half-cylinder on the right, respectively. The upper end of the pushing frame (33) is provided with an inclined surface. A wedge-shaped platform (42) is installed on the side of the two arc-shaped plates (411) that are far apart from each other. A mounting groove is provided on the worktable (1) at the position corresponding to the wedge-shaped platform (42) to slide with the wedge-shaped platform (42). A spring rod (421) is connected between the wedge-shaped platform (42) and the groove wall of the mounting groove.

9. The wire-breaking welding device according to claim 8, characterized in that, The upper end of the inclined surface of the push frame (33) is provided with a pressure block (331), and the lower end surface of the pressure block (331) is inclined to match the inclined surface of the push frame (33); The wedge block (422) is provided with a wedge block (422) at the upper end of the inclined surface of the wedge platform (42). The lower end surface of the wedge block (422) is an inclined surface and slides in cooperation with the inclined surface of the wedge platform (42). The pressure block (331) and the wedge block (422) are installed together at the lower end of the rectangular frame (43).

10. A wire-breaking welding device according to claim 9, characterized in that, A movable plate (34) is fixedly installed on the upper half of the cylinder. The movable plate (34) is slidably connected to the lower end of the horizontal plate (431). The horizontal plate (431) is located below the rectangular frame (43) and slides vertically with the corresponding pressure block (331). Columns (44) are installed on the upper end of the workbench (1) at the four corners of the rectangular frame (43). The columns (44) slide vertically with the rectangular frame (43) and the horizontal plate (431). A control spring (432) sleeved on the outside of the column (44) is connected between the horizontal plate (431) and the rectangular frame (43). The upper end of the rectangular frame (43) is connected to the telescopic end of the cylinder (45).

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