A welding device for power transformer production

Abstract

The application discloses a welding device for power transformer production and belongs to the technical field of transformer welding, which comprises an equipment body, the equipment body comprises a platform arranged at the middle part and a cross beam arranged at the top part, the lower surfaces of the cross beam are uniformly and fixedly provided with pressing mechanisms, a welding mechanism is assembled on the cross beam, the upper surface of the platform is symmetrically and fixedly provided with moving mechanisms, a rectangular cavity is formed in the upper surface of the platform, and a variable heat conduction mechanism is assembled in the rectangular cavity, the variable heat conduction mechanism is arranged, the mechanism can quickly and reversibly change the heat conductivity of a local area according to the real-time requirements of a welding process, the active and intelligent control of a welding heat cycle process is realized, the fine management of a workpiece temperature field is realized, the structural deformation caused by welding is reduced to the minimum, the radiator assembly after welding has excellent flatness, the cooling fins are in close contact with the bottom plate, and the overall heat dissipation efficiency and structural stability are remarkably improved.

Description

Technical Field

[0001] This invention belongs to the field of transformer welding technology, and specifically provides a welding device for the production of power transformers. Background Technology

[0002] Power transformers are core equipment in power grid systems, and their long-term stable operation depends on efficient heat dissipation. The radiator, as a critical component, typically consists of a metal base plate and multiple parallel heat dissipation fins welded to it. Currently, the connection between the heat dissipation fins and the base plate generally employs welding processes, especially automated multi-head welding. However, this process still faces a series of technical challenges in actual production: Firstly, during the welding process of power transformer radiators, due to the thinness of the base plate and the dense arrangement of multiple heat sinks on it, the concentrated input of welding heat sources can easily create a severe temperature gradient in local areas of the base plate. This non-uniform temperature field will cause differential thermal expansion and contraction, resulting in complex wavy warping or angular deformation of the base plate. The slight deformation of the radiator base plate will directly affect the root fit of the multiple heat sinks, forming local gaps, worsening the heat conduction path, and significantly reducing heat dissipation efficiency. Secondly, existing welding equipment has shortcomings in the positioning and clamping of heat sinks. Heat sinks need to be perpendicular to the base plate and evenly spaced, but common rigid clamps are difficult to accommodate the minute dimensional tolerances of all heat sinks, easily leading to individual heat sinks being misaligned or uneven clamping force. Insufficient clamping force can cause heat sink displacement during welding, resulting in incomplete welds; excessive clamping force may damage the heat sink or exacerbate base plate deformation. Furthermore, there is a lack of proactive control methods for the welding thermal process. Existing technologies mainly control deformation by optimizing welding parameters or using passive heat dissipation methods such as backing with copper plates, lacking the ability to precisely control the local heat flow of the base plate in real time, dynamically, and programmably, making it difficult to achieve differentiated thermal management for different welding areas.

[0003] Therefore, there is an urgent need for a dedicated welding device for power transformer heat sinks that is highly integrated, can actively suppress thermal deformation, and ensure welding quality and efficiency. Summary of the Invention

[0004] To address the above problems, the present invention provides a welding apparatus for the production of power transformers.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: a welding device for power transformer production, comprising a device body, the device body comprising a platform disposed in the middle and a crossbeam disposed at the top, a clamping mechanism uniformly fixedly installed on the lower surface of the crossbeam, and the heat sink of the transformer heat sink plate disposed at the clamping mechanism, a welding mechanism assembled on the crossbeam, a moving mechanism symmetrically fixedly installed on the upper surface of the platform, and the bottom plate of the transformer heat sink plate disposed on the platform and the moving mechanism, a rectangular cavity opened on the upper surface of the platform, and a variable thermal conductivity mechanism assembled inside the rectangular cavity; The variable thermal conductivity mechanism has a cylindrical cavity uniformly formed on its upper surface. A substrate is fixedly installed at the bottom of the inner cavity of the cylindrical cavity, and a through hole is formed in the middle of the substrate. A cover plate is fixedly installed at the top of the inner cavity of the cylindrical cavity. A dielectric elastomer substrate is provided on the upper surface of the substrate. An insulating diaphragm is provided on the upper surface of the dielectric elastomer substrate. An installation ring is clamped between the cover plate and the insulating diaphragm. Liquid metal is provided on the upper surface of the insulating diaphragm. By controlling the voltage applied to the dielectric elastomer substrate, the dielectric elastomer substrate is driven to deform, thereby changing the spreading state of the liquid metal and forming different thermal conductivity states. A cold air channel is provided on the inner side of the bottom of the variable thermal conductivity mechanism, and the cold air channel is connected to the through hole of the substrate.

[0006] Furthermore, the dielectric elastomer substrate is a pre-stretched PDMS dielectric elastomer film.

[0007] Furthermore, the clamping mechanism includes a slide rail, which is fixedly installed on the lower surface of the crossbeam. A first telescopic rod and a second telescopic rod are movably mounted inside the slide rail, with the second telescopic rod located outside the first telescopic rod. A limit frame is fixedly installed at the lower end of the first telescopic rod, and the heat sink of the transformer heat sink is placed inside the limit frame. An installation plate is fixedly installed on the side surface of the limit frame. A rectangular groove is formed on the inner surface of the installation plate. Elongated holes are symmetrically formed on the outer surface of the installation plate and the side surface of the limit frame. An adsorption pipe is movably mounted inside the elongated hole. An end cap is fixedly installed at the outer end of the adsorption pipe and is fixedly installed on the outer surface of the installation plate. The end cap is provided with a connection port for connecting to an external vacuum device. A pressure sensor is fixedly installed on the upper surface of the inner cavity of the rectangular groove. A connecting block is fixedly installed between the adsorption pipes. An elastic structure in contact with the pressure sensor is fixedly installed on the upper surface of the connecting block.

[0008] Furthermore, a limiting plate is fixedly installed at the lower end of the second telescopic rod, and the lower side of the inner wall of the limiting plate is provided with an involute slope.

[0009] Furthermore, the welding mechanism includes a hydraulic cylinder and an adjusting rod, with the hydraulic cylinder fixedly installed on the upper surface of the crossbeam. A moving groove is provided on the lower surface of the crossbeam, and the adjusting rod is vertically moved and assembled in the moving groove. The adjusting rod is fixedly installed at the output end of the hydraulic cylinder, and an adjusting motor is uniformly fixedly installed on the lower surface of the adjusting rod. A welding torch is fixedly installed on the output shaft of the adjusting motor, and the welding torch is installed at an angle.

[0010] Furthermore, the welding mechanism also includes a rotating motor, which is fixedly installed on the lower surface of the crossbeam. A rotating shaft is fixedly installed at the output end of the rotating motor, and a cleaning brush is fixedly installed at the lower end of the rotating shaft.

[0011] Furthermore, the welding mechanism also includes a transmission plate, which is sleeved on the output shaft and rotating shaft of the regulating motor. The rotating shaft is hollow inside, and the outer wall of the rotating shaft has an air vent. A sealing cylinder is fixedly installed on the lower surface of the transmission plate, and the air vent is located inside the sealing cylinder. An air outlet head is assembled on the outer wall of the sealing cylinder.

[0012] Furthermore, a limit ring is fixedly installed on the output shaft of the regulating motor, and the limit ring is located on the lower side of the transmission plate.

[0013] Furthermore, the upper surface of the platform is symmetrically provided with mounting slots, and the moving mechanism is fixedly installed in the mounting slots. The moving mechanism is equipped with a drive motor, and the output end of the drive motor is provided with a transmission belt. The outer surface of the transmission belt is fixedly installed with push blocks, and the bottom plate of the transformer heat sink is located between the two push blocks.

[0014] The beneficial effects of using this invention are: This invention incorporates a variable thermal conductivity mechanism that can rapidly and reversibly change the thermal conductivity of a local area according to the real-time requirements of the welding process. Through proactive and intelligent control of the welding thermal cycle, it achieves refined management of the workpiece temperature field, minimizes structural deformation caused by welding, ensures that the heat sink assembly has excellent flatness after welding, and ensures close contact between the heat sink and the base plate, significantly improving the overall heat dissipation efficiency and structural stability.

[0015] This invention features a clamping mechanism that integrates vacuum adsorption and force feedback control. Vacuum adsorption securely and without damage fixes each heat sink, while a component equipped with a pressure sensor applies clamping force. This allows for real-time monitoring and automatic adjustment, ensuring that all heat sinks are subjected to uniform and appropriate clamping force during welding. This mechanism can accommodate the dimensional tolerances of the heat sinks themselves, completely avoiding problems such as heat sink displacement, incomplete welding, or workpiece surface damage caused by uneven or insufficient clamping force. This ensures the uniformity and reliability of the welded joint from the source.

[0016] This invention incorporates a welding mechanism. After the welding torch completes welding, a moving cleaning component immediately removes spatter and slag around the weld. Simultaneously, an integrated cooling air path provides real-time, directional cooling to the weld. This integrates multiple post-processing steps that were previously separate into the welding process, significantly reducing the processing time for individual workpieces, minimizing equipment footprint and inter-process transfers, and creating a cleaner, more controllable working environment. This, in turn, improves the overall intelligence and efficiency of production. Attached Figure Description

[0017] Figure 1 This is one of the three-dimensional schematic diagrams of the present invention.

[0018] Figure 2 This is a second three-dimensional schematic diagram of the present invention.

[0019] Figure 3 This is the front view of the present invention.

[0020] Figure 4 This is a three-dimensional schematic diagram of the clamping mechanism of the present invention.

[0021] Figure 5 This is a partial exploded view of the clamping mechanism of the present invention.

[0022] Figure 6 This is a partial three-dimensional schematic diagram of the welding mechanism of the present invention.

[0023] Figure 7 This is a schematic diagram of the four functional areas of the present invention.

[0024] Figure 8 This is a partial cross-sectional view of the variable thermal conductivity mechanism of the present invention in a high thermal conductivity conduction state.

[0025] Figure 9 This is a partial cross-sectional view of the variable thermal conductivity mechanism of the present invention in the low thermal conductivity cutoff state.

[0026] The attached reference numerals include: 1. Equipment body; 11. Platform; 12. Crossbeam; 2. Clamping mechanism; 21. Slide rail; 22. First telescopic rod; 23. Limiting frame; 24. Second telescopic rod; 25. Limiting plate; 26. Mounting plate; 261. Pressure sensor; 27. Adsorption pipeline; 271. End cap; 28. Connecting block; 281. Elastic structure; 3. Welding mechanism; 31. Hydraulic cylinder; 32. Adjusting motor; 33. Welding torch; 34. 35. Rotating motor, 36. Cleaning brush, 37. Sealing cylinder, 38. Air outlet, 4. Transmission plate, 41. Moving mechanism, 42. Transmission belt, 53. Push block, 54. Variable thermal conductivity mechanism, 55. Cylindrical cavity, 56. Substrate, 57. Cover plate, 58. Dielectric elastomer substrate, 59. Insulating diaphragm, 50. Mounting ring, 51. Liquid metal, 52. Cold air passage, 6. Waiting area for welding, 7. Welding area, 8. Residual heat area, 9. Cooled area. Detailed Implementation

[0027] 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.

[0028] Reference Figures 1 to 9 A welding device for power transformer production includes a device body 1. The device body includes a platform 11 located in the middle and a crossbeam 12 located at the top. A clamping mechanism 2 is uniformly fixedly installed on the lower surface of the crossbeam 12, and the heat sink of the transformer heat sink plate is located at the clamping mechanism 2. A welding mechanism 3 is assembled on the crossbeam 12. A moving mechanism 4 is symmetrically fixedly installed on the upper surface of the platform 11, and the bottom plate of the transformer heat sink plate is located on the platform 11 and the moving mechanism 4. A rectangular cavity is opened on the upper surface of the platform 11, and a variable thermal conductivity mechanism 5 is assembled in the rectangular cavity.

[0029] This welding device is used for welding heat sinks in power transformer production, mainly for welding heat sinks to the base plate. The base plate is placed on the platform 11 and the moving mechanism 4, and the heat sink is placed in the clamping mechanism 2. The clamping mechanism 2 ensures that the heat sink is accurately and tightly placed on the base plate. The operation of the moving mechanism 4 and the clamping mechanism 2 can synchronously drive the base plate and the heat sink to move. The welding mechanism 3 is fixed in position on the crossbeam 12 and can move vertically. The welding gun 33 of the welding mechanism 3 can be adjusted to align with the welding point. During welding, the base plate and the heat sink move synchronously, and multiple heat sinks are welded at the same time, improving work efficiency.

[0030] The upper surface of the variable thermal conductivity mechanism 5 is uniformly provided with cylindrical cavities 51. A substrate 52 is fixedly installed at the bottom of the inner cavity of the cylindrical cavity 51, and a through hole is provided in the middle of the substrate 52. A cover plate 53 is fixedly installed at the top of the inner cavity of the cylindrical cavity 51. A dielectric elastomer substrate 54 is provided on the upper surface of the substrate 52. An insulating diaphragm 55 is provided on the upper surface of the dielectric elastomer substrate 54. An installation ring 56 is clamped between the cover plate 53 and the insulating diaphragm 55. Liquid metal 57 is provided on the upper surface of the insulating diaphragm 55. By controlling the voltage applied to the dielectric elastomer substrate 54, the dielectric elastomer substrate 54 is driven to deform, thereby changing the spreading state of the liquid metal 57 and forming different thermal conductivity states. A cold air channel 58 is provided on the inner side of the bottom of the variable thermal conductivity mechanism 5.

[0031] The main body of the variable thermal conductivity mechanism 5 is a flat plate with cylindrical cavities 51 evenly distributed on its surface, which can correspond to various positions of the heat sink base plate.

[0032] The cover plate 53 is made of a high thermal conductivity insulating material, specifically aluminum nitride ceramic, which has high thermal conductivity, good insulation, and is easy to process. Its upper surface, which serves as the contact surface with the heat sink base plate, is precision polished to ensure low contact thermal resistance. Its lower surface is etched with an array of micro-pits or grooves to increase the contact area with the liquid metal 57. A micro-thin film thermocouple or resistance temperature detector is embedded in the cover plate 53 to monitor the temperature at the corresponding location in real time.

[0033] The substrate 52 is made of low-temperature co-fired ceramic, which can provide mechanical support and can also integrate wiring. The through hole in the middle is a channel that connects to the cold air channel 58.

[0034] The dielectric elastomer substrate 54 is made of pre-stretched PDMS dielectric elastomer film, which has extremely high elongation and elastic recovery capability. Before assembly, it is stretched to three times its original size, and then installed by extrusion through cover plate 53, mounting ring 56 and substrate 52. The installation method can also be achieved by setting a corresponding frame structure. The pre-stretching stress is the basis for subsequent deformation. When voltage is applied, the planar expansion trend of the PDMS dielectric elastomer film is constrained by the boundary and transformed into an upward bulge in the middle, which extrudes the upper cavity. A layer of carbon nanotube flexible electrode is printed on the upper and lower surfaces of the PDMS dielectric elastomer film. The electrode is made into a mesh structure, which can ensure the uniformity of the electric field and stretch synchronously with the film, without the problem of breakage or detachment.

[0035] The insulating diaphragm 55 is made of PDMS film, which is the same material as the dielectric elastomer substrate 54. The deformation characteristics are matched. When the dielectric elastomer is energized and bulges upward, the diaphragm can undergo tensile deformation synchronously without stress mismatch or breakage. After the voltage is removed, the diaphragm will also completely return to its original position along with the dielectric elastomer without residual deformation. The PDMS material has extremely high resistivity and excellent compatibility with liquid metal 57 and dielectric elastomer, without any reaction or penetration problems.

[0036] The liquid metal 57 is made of gallium indium tin alloy, which is liquid at room temperature and has a thermal conductivity of 16.5 W / mK. It is non-toxic and non-volatile. The inner walls of the cover plate 53 and the mounting ring 56 are hydrophobically treated to reduce the adhesion of the liquid metal 57. The other spaces in the microcavity formed between the cover plate 53, the mounting ring 56, and the insulating diaphragm 55 are filled with dry nitrogen gas with a thermal conductivity of 0.026 W / mK to ensure high thermal resistance in the cut-off state. At the same time, the inert gas can prevent the liquid metal 57 from oxidizing.

[0037] The cold air channel 58 is used to transport cold air. A valve can be installed between the cold air channel 58 and the through hole of the substrate 52 to control the heat exchange of the cold air. In conjunction with the temperature monitoring on the cover plate 53, the cooling effect can be adjusted in real time. The cold air channel 58 can also be set between the lower surface of the variable thermal conductivity mechanism 5 and the surface of the platform 11, which is more convenient for processing.

[0038] Depending on the voltage applied to the dielectric elastomer substrate 54, a high thermal conductivity conduction state and a low thermal conductivity cutoff state are formed, which are applied to different areas of the welding operation.

[0039] When no voltage is applied to the dielectric elastomer substrate 54, the dielectric elastomer substrate 54 remains unchanged, the microcavity has the largest volume, the liquid metal 57 is spherical under the action of surface tension, and does not contact or is not in contact with the cover plate 53, so that the effective thermal conductivity of this structure is close to the thermal conductivity of nitrogen, which is a low thermal conductivity cutoff state. When a voltage is applied to the dielectric elastomer substrate 54, the dielectric elastomer substrate 54 deforms and bulges in the middle, reducing the volume of the microcavity. This flattens the liquid metal 57 and spreads it inside the microcavity, making large-area contact with the cover plate 53 and forming a continuous liquid metal bridge. At this time, the effective thermal conductivity of this structure is close to that of the liquid metal 57 itself, and it is in a high thermal conductivity conducting state.

[0040] By adjusting the voltage applied to the dielectric elastomer substrate 54, the degree of deformation of the dielectric elastomer substrate 54 can be adjusted, thereby adjusting the contact area between the liquid metal 57 and the cover plate 53, and thus adjusting the thermal conductivity.

[0041] Specifically, the clamping mechanism 2 includes a slide rail 21, which is fixedly installed on the lower surface of the crossbeam 12. A first telescopic rod 22 and a second telescopic rod 24 are movably mounted inside the slide rail 21, with the second telescopic rod 24 located outside the first telescopic rod 22. A limit frame 23 is fixedly installed at the lower end of the first telescopic rod 22, and the heat sink of the transformer heat sink is placed inside the limit frame 23. A mounting plate 26 is fixedly installed on the side surface of the limit frame 23. A rectangular groove is formed on the inner surface of the mounting plate 26, and the outer surface of the mounting plate 26 is flush with the limit frame. The side surfaces of 23 are symmetrically provided with elongated holes. Adsorption tubes 27 are movably assembled in the elongated holes. An end cap 271 is fixedly installed at the outer end of the adsorption tube 27 and is fixedly installed on the outer surface of the mounting plate 26. The end cap 271 is provided with a connection port for connecting to an external vacuum device. A pressure sensor 261 is fixedly installed on the upper surface of the inner cavity of the rectangular groove. A connecting block 28 is fixedly installed between the adsorption tubes 27. An elastic structure 281 that contacts the pressure sensor 261 is fixedly installed on the upper surface of the connecting block 28.

[0042] A lead screw assembly is installed inside the slide rail 21 to drive the first telescopic rod 22 and the second telescopic rod 24 to move, thereby driving the heat sink to move.

[0043] The elastic structure 281 can be made of rubber blocks, or it can be made of elastic parts such as springs and disc springs.

[0044] Specifically, a limiting plate 25 is fixedly installed at the lower end of the second telescopic rod 24, and the lower side of the inner wall of the limiting plate 25 is provided with an involute slope.

[0045] When placing the heat sink, insert the heat sink into the frame of the limiting frame 23, so that both ends of the heat sink are located in the limiting frames 23 on both sides. Then, control the limiting plate 25 to move down by the second telescopic rod 24, so that the heat sink can be pushed to the set position. The limiting frame 23 and the limiting plate 25 cooperate to position the heat sink.

[0046] Before pressing, a vacuum device is used to create negative pressure or even a vacuum in the space between the adsorption pipe 27 and the heat sink. The pressure difference is used to fix the heat sink in the limiting frame 23. Then, the first telescopic rod 22 controls the limiting frame 23 to move down to complete the pressing of the heat sink on the base plate. The pressure is detected by the pressure sensor 261, and after feedback control, it is ensured that all heat sinks are subjected to the same pressure and within the set range.

[0047] During the welding process, the base plate is moved by the moving mechanism 4, and the heat sink is moved synchronously by the slide rail 21, thus completing the welding.

[0048] Specifically, the welding mechanism 3 includes a hydraulic cylinder 31 and an adjusting rod. The hydraulic cylinder 31 is fixedly installed on the upper surface of the crossbeam 12. A moving groove is provided on the lower surface of the crossbeam 12. The adjusting rod is vertically moved and assembled in the moving groove. The adjusting rod is fixedly installed at the output end of the hydraulic cylinder 31. An adjusting motor 32 is uniformly fixedly installed on the lower surface of the adjusting rod. A welding torch 33 is fixedly installed on the output shaft of the adjusting motor 32. The welding torch 33 is installed at an angle.

[0049] The welding torch 33 is tilted so that it can be aligned with the welding area. The orientation of the welding torch 33 can be adjusted by running the adjustment motor 32 to complete the welding work on both sides.

[0050] Specifically, the welding mechanism 3 also includes a rotating motor 34, which is fixedly installed on the lower surface of the crossbeam 12. A rotating shaft is fixedly installed at the output end of the rotating motor 34, and a cleaning brush 35 is fixedly installed at the lower end of the rotating shaft.

[0051] The cleaning brush 35 can be used to clean the welded area; the rotating motor 34 is a double-ended output shaft motor.

[0052] Specifically, the welding mechanism 3 also includes a transmission plate 38, which is sleeved on the output shaft and rotating shaft of the regulating motor 32. The rotating shaft is hollow inside and has an air vent on its outer wall. A sealing cylinder 36 is fixedly installed on the lower surface of the transmission plate 38, and the air vent is located inside the sealing cylinder 36. An air vent head 37 is assembled on the outer wall of the sealing cylinder 36.

[0053] The upper end of the rotating shaft is connected to an external ventilation device, while the lower end is sealed. After the cold air is introduced, it flows out from the air outlet into the sealed cylinder 36 and finally flows out from the air outlet 37. The air outlet 37 can be set as an electric nozzle or other structure, which can open or close according to feedback and control the flow rate of cold air.

[0054] The exhaust head 37 is angled and faces the weld between the heat sink and the base plate.

[0055] Specifically, a limit ring is fixedly installed on the output shaft of the regulating motor 32, and the limit ring is located on the lower side of the transmission plate 38.

[0056] The position of the transmission plate 38 is limited by the limiting ring, thereby ensuring the height position of the air outlet 37 and ensuring that the air outlet 37 faces the welding point between the heat sink and the base plate.

[0057] Specifically, the upper surface of the platform 11 is symmetrically provided with mounting slots, and the moving mechanism 4 is fixedly installed in the mounting slots. The moving mechanism 4 is equipped with a drive motor, and the output end of the drive motor is provided with a transmission belt 41. The outer surface of the transmission belt 41 is fixedly installed with push blocks 42, and the bottom plate of the transformer heat sink is located between the two push blocks 42.

[0058] When the moving mechanism 4 is running, it will drive the transmission belt 41 to move, which in turn will drive the base plate of the heat sink to move through the push block 42.

[0059] like Figure 7 As shown, the variable thermal conductivity mechanism 5 can be divided into four regions: the area to be soldered 6, the soldering area 7, the residual heat area 8, and the cooled area 9, wherein: The welding area 6 is located in front of the welding torch 33 and corresponds to the unwelded room temperature workpiece. The corresponding variable thermal conductivity mechanism 5 area is in a low thermal conductivity cutoff state, and the control valve prevents the cold air in the cold air channel 58 from flowing to the cylindrical cavity 51. This area isolates the cold air below to prevent the welding position from being cooled in advance and ensures the normal formation of the molten pool during welding. Welding zone 7 is located directly below welding torch 33, corresponding to the weld that is being heated by welding torch 33. The corresponding variable thermal conductivity mechanism 5 area is in a high thermal conductivity conduction state, and the control valve causes the cold air in the cold air passage 58 to flow into the cylindrical cavity 51; opening the heat passage can remove the heat input from welding and limit heat diffusion. The residual heat zone 8 is located in the near zone behind the welding torch 33, corresponding to the weld that has just been welded and still has residual heat. The corresponding variable heat conduction mechanism 5 area is in a high heat conduction state. The valve is opened to allow the cold air in the cold air channel 58 to flow into the cylindrical cavity 51. At the same time, the cooling intensity is dynamically adjusted according to the temperature feedback. The residual heat is continuously discharged, allowing the weld temperature to drop quickly to room temperature and eliminating the deformation caused by residual heat. The cooled zone 9 is located in the far zone behind the welding torch 33. It corresponds to the welded area where the temperature has returned to normal. The corresponding variable thermal conductivity mechanism 5 area is in a low thermal conductivity cutoff state, and the control valve prevents the cold air in the cold air channel 58 from flowing to the cylindrical cavity 51; thus saving cooling energy and avoiding the cold air from affecting subsequent workpieces.

[0060] Because a miniature thin-film thermocouple or resistance temperature detector is installed on the cover plate 53 to monitor the temperature at the corresponding location in real time, the range of each area can be adjusted according to the temperature feedback during actual operation, or the deformation of the dielectric elastomer substrate 54 can be adjusted to achieve the adjustment of thermal conductivity.

[0061] The area division of the unwelded zone 6, the welding zone 7, the residual heat zone 8, and the cooled zone 9 can be adjusted for different welding tasks.

[0062] In addition, other monitoring devices, such as cameras and infrared detectors, can be installed on platform 11 or crossbeam 12 to help detect the shape and temperature of the welded joint. Feedback can prompt the device to make corresponding adjustments to further improve the quality of the heat sink.

[0063] The operating procedures for using the welding equipment in the production of this power transformer are as follows: Step 1: Pre-welding preparation and workpiece clamping: Place the base plate of the heat sink horizontally on the platform 11 and insert its two sides between the two push blocks 42 on the moving mechanism 4. Each heat sink is inserted into the limiting frame 23 of the clamping mechanism 2 one by one, and then the limiting plate 25 is driven to descend. The position of the heat sink is adjusted by the inclined surface on its inner side so that it is neatly placed on the base plate. Start the vacuum equipment and use negative pressure to adsorb and fix the heat sinks to the same side within their respective limiting frames 23; The drive limit frame 23 moves down to press the heat sink onto the base plate, and the pressure sensor 261 provides feedback to ensure that the pressing force is appropriate and uniform. Drive the moving mechanism 4 and the pressing mechanism 2 to move the base plate and heat sink backward synchronously until the welding start position; The hydraulic cylinder of the welding mechanism drives the welding torch to descend to a suitable working height. At the same time, according to the welding path planning, the unit of the corresponding area to be welded on the variable thermal conductivity mechanism 5 on platform 11 is set to a low thermal conductivity cutoff state in advance to prepare for welding.

[0064] Step 2, Sequential welding on both sides and dynamic thermal management: When welding begins, the base plate and heat sink move from back to front at a constant speed under the drive of the moving mechanism 4 and the clamping mechanism 2, and the welding torch 33 continuously welds the joints between all the heat sinks and the base plate on the side it faces. After the welding process is completed, the hydraulic cylinder 31 moves the welding torch 33 upward and controls the welding torch 33 to rotate 180° by adjusting the motor 32. At the same time, the moving mechanism 4 and the clamping mechanism 2 drive the base plate and heat sink back to the welding start position. Repeat step 201 to complete the continuous welding of all the heat sinks and the base plate on the other side.

[0065] During the welding process, the variable thermal conductivity mechanism 5 forms areas that perform different working modes as welding progresses: the waiting area 6, the welding area 7, the residual heat area 8, and the cooled area 9.

[0066] During the welding process, the cleaning brush 35 rotates under the drive of the rotating motor 34 to remove spatter and slag around the weld. At the same time, with the temperature feedback provided by the variable thermal conductivity mechanism 5, the opening and closing status and degree of the air outlet 37 are controlled to facilitate directional cooling of the weld.

[0067] The welding work on the outer weld seams of the heat sinks on both sides can be done manually or by adding a welding mechanism 3.

[0068] Step 3, Welding completed and repositioned: After the welding work is completed, the moving mechanism 4 stops moving and sends the workpiece to the unloading position; The clamping mechanism 2 releases the vacuum adsorption, and the first telescopic rod 22 and the second telescopic rod 24 rise, loosening the fixation on the heat sink; The hydraulic cylinder 31 of the welding mechanism 3 lifts the welding torch 33, cleaning brush 35 and other components to a safe height; The operator moves the welded heat sink out of the work area, resets all mechanisms of the equipment, and prepares for the next workpiece welding cycle.

[0069] The above content is only a preferred embodiment of the present invention. For those skilled in the art, many changes can be made in the specific implementation and application scope based on the concept of the present invention. As long as these changes do not depart from the concept of the present invention, they all fall within the protection scope of the present invention.

Claims

1. A welding device for power transformer production, characterized by: The device includes a main body, which includes a platform in the middle and a crossbeam at the top. A clamping mechanism is uniformly fixedly installed on the lower surface of the crossbeam, and the heat sink of the transformer heat sink is located at the clamping mechanism. A welding mechanism is assembled on the crossbeam. A moving mechanism is symmetrically fixedly installed on the upper surface of the platform, and the bottom plate of the transformer heat sink is located on the platform and the moving mechanism. A rectangular cavity is opened on the upper surface of the platform, and a variable thermal conductivity mechanism is assembled inside the rectangular cavity. The variable thermal conductivity mechanism has a cylindrical cavity uniformly formed on its upper surface. A substrate is fixedly installed at the bottom of the inner cavity of the cylindrical cavity, and a through hole is formed in the middle of the substrate. A cover plate is fixedly installed at the top of the inner cavity of the cylindrical cavity. A dielectric elastomer substrate is provided on the upper surface of the substrate. Flexible electrodes are printed on both the upper and lower surfaces of the dielectric elastomer substrate. An insulating diaphragm is provided on the upper surface of the dielectric elastomer substrate. An installation ring is clamped between the cover plate and the insulating diaphragm. Liquid metal is provided on the upper surface of the insulating diaphragm. By controlling the voltage applied to the dielectric elastomer substrate, the dielectric elastomer substrate is driven to deform, thereby changing the spreading state of the liquid metal and forming different thermal conductivity states. A cold air channel is provided on the inner side of the bottom of the variable thermal conductivity mechanism, and the cold air channel is connected to the through hole of the substrate.

2. The welding device for power transformer production as claimed in claim 1, characterized in that: The dielectric elastomer substrate is a pre-stretched PDMS dielectric elastomer film.

3. The welding apparatus for power transformer production according to claim 1, characterized in that: The clamping mechanism includes a slide rail, which is fixedly installed on the lower surface of the crossbeam. A first telescopic rod and a second telescopic rod are movably mounted inside the slide rail, with the second telescopic rod located outside the first telescopic rod. A limit frame is fixedly installed at the lower end of the first telescopic rod, and the heat sink of the transformer heat sink is placed inside the limit frame. An mounting plate is fixedly installed on the side surface of the limit frame. A rectangular groove is formed on the inner surface of the mounting plate. Elongated holes are symmetrically formed on the outer surface of the mounting plate and the side surface of the limit frame. An adsorption pipe is movably mounted inside the elongated hole. An end cap is fixedly installed at the outer end of the adsorption pipe and is fixedly installed on the outer surface of the mounting plate. The end cap is provided with a connection port for connecting to an external vacuum device. A pressure sensor is fixedly installed on the upper surface of the inner cavity of the rectangular groove. A connecting block is fixedly installed between the adsorption pipes. An elastic structure in contact with the pressure sensor is fixedly installed on the upper surface of the connecting block.

4. The welding apparatus for power transformer production according to claim 3, characterized in that: A limiting plate is fixedly installed at the lower end of the second telescopic rod, and the lower side of the inner wall of the limiting plate is provided with an involute slope.

5. The welding apparatus for power transformer production according to claim 1, characterized in that: The welding mechanism includes a hydraulic cylinder and an adjusting rod. The hydraulic cylinder is fixedly installed on the upper surface of the crossbeam. A moving groove is provided on the lower surface of the crossbeam. The adjusting rod is vertically moved and assembled in the moving groove. The adjusting rod is fixedly installed at the output end of the hydraulic cylinder. An adjusting motor is uniformly fixedly installed on the lower surface of the adjusting rod. A welding torch is fixedly installed on the output shaft of the adjusting motor. The welding torch is installed at an angle.

6. The welding apparatus for producing power transformers according to claim 5, characterized in that: The welding mechanism also includes a rotating motor, which is fixedly installed on the lower surface of the crossbeam. A rotating shaft is fixedly installed at the output end of the rotating motor, and a cleaning brush is fixedly installed at the lower end of the rotating shaft.

7. The welding apparatus for power transformer production according to claim 6, characterized in that: The welding mechanism also includes a transmission plate, which is sleeved on the output shaft and rotating shaft of the regulating motor. The rotating shaft is hollow inside, and the outer wall of the rotating shaft has an air vent. A sealing cylinder is fixedly installed on the lower surface of the transmission plate, and the air vent is located inside the sealing cylinder. An air outlet head is assembled on the outer wall of the sealing cylinder.

8. The welding apparatus for producing power transformers according to claim 7, characterized in that: A limit ring is fixedly installed on the output shaft of the regulating motor, and the limit ring is located on the lower side of the transmission plate.

9. A welding apparatus for producing power transformers according to claim 1, characterized in that: The platform has symmetrical mounting slots on its upper surface, and the moving mechanism is fixedly installed in the mounting slots. The moving mechanism is equipped with a drive motor, and the output end of the drive motor is provided with a transmission belt. The outer surface of the transmission belt is fixedly installed with push blocks, and the bottom plate of the transformer heat sink is located between the two push blocks.

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