A welding device and welding method for aviation electrical connectors

Abstract

The application discloses a kind of special welding device and welding method of aviation electric connector, which is composed of base, support column, crab clamp assembly and welding tool clamping assembly. The top of the support column is provided with a U-shaped connector, which can realize the height adjustment and 360° horizontal rotation positioning of the crab clamp assembly by cooperating with the star-shaped adjusting knob, connecting screw and gear. The articulated crab clamp is opened and closed by the knob screw, and the clamping surface is additionally provided with a non-slip wear-resistant layer, so that the workpiece is clamped stably and protected. The welding tool clamping assembly adopts a ring-type curved surface clamping structure, which can clamp the tool and adjust the angle slightly. The device is flexible, easy to operate, and has high positioning accuracy, effectively improving the defects of traditional equipment, such as angle limitation, inaccurate positioning and easy to produce virtual welding. The matching welding method is practical, can meet the welding needs of different specifications of aviation electric connectors, significantly improves the welding quality and efficiency, and is suitable for batch welding of aviation electric connectors.

Description

Technical Field

[0001] This invention belongs to the field of aviation electronic connector manufacturing equipment technology. Background Technology

[0002] In the field of electronic equipment manufacturing, electrical connectors are key components for signal and power transmission, and their soldering quality directly affects the performance and reliability of the equipment. Due to the special nature of the aerospace environment, the requirements for soldering precision and quality of electrical connectors are extremely high.

[0003] Limitations of traditional welding equipment: 1. Fixed angle: The welding head usually only supports single or limited angle operation, making it difficult to adapt to the multi-directional welding needs of complex connectors; 2. Low efficiency: It is time-consuming and laborious for workers to adjust the workpiece angle, and it is difficult to guarantee the repeatability of positioning accuracy; 3. Quality risks: Non-perpendicular welding is prone to problems such as poor solder joints and spatter, which affect the conductivity and durability of connectors.

[0004] While some simple welding auxiliary devices have been put into use, they generally suffer from limited structural functionality. For example, traditional clamps can only achieve basic clamping and lack the ability to precisely adjust electrical connectors in multiple dimensions, making them unsuitable for welding different connector specifications. The adjustment mechanisms are cumbersome to operate, making it difficult to quickly and stably adjust to the ideal welding position, and they are prone to loosening during welding, affecting the stability of welding quality. Therefore, in the high-end manufacturing field of aerospace technology, electrical connectors need to meet 360-degree spatial layout requirements. Traditional fixed welding processes cannot meet the production requirements of high precision, high efficiency, and high stability; that is, there is a lack of a welding device that also offers "omnidirectional rotational flexibility."

[0005] Therefore, it is of great significance to develop a dedicated welding device for aviation electrical connectors with precise positioning, flexible adjustment, and stable clamping functions to improve the welding quality of electrical connectors and enhance the conductivity of aircraft-specific cable electrical connectors. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a welding device specifically for aviation electrical connectors.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A welding device for aviation electrical connectors, characterized in that it includes a base, a support column, a hinged crab claw clamp assembly, and a welding tool clamping assembly. The support column is fixedly installed on the base, the crab claw clamp assembly is connected to the support column through a connecting screw, and the welding tool clamping assembly is fixedly installed on the base and arranged opposite to the crab claw clamp assembly. A U-shaped connector is fixed to the top of the support column, and through-holes are provided on both sides of the U-shaped connector. A cylinder and a star-shaped adjusting knob are also provided. A threaded hole is machined in the center of the cylinder. One end of the connecting screw is fixed perpendicularly to the side wall of the cylinder, and the cylinder is fitted into the inner cavity of the U-shaped connector. The central threaded rod of the star-shaped adjusting knob passes through the holes on both sides of the U-shaped connector and is threadedly engaged with the threaded hole of the cylinder for locking. A gear meshes at the other end of the connecting screw, and this end of the connecting screw is fixedly connected to the crab claw clamp assembly by a fixing bolt. Rotating the star-shaped adjustment knob can cause the cylinder to rotate circumferentially within the U-shaped connector, thereby causing the connecting screw to swing in the vertical plane with the cylinder as the center of rotation, thus realizing the height adjustment of the crab claw clamp assembly; Rotating the crab claw clamp assembly allows it to rotate 360° around the connecting screw, and the gears work together to lock the position, thus fixing the crab claw clamp assembly at any angle. The welding tool clamping assembly adopts a ring-shaped structure to clamp the welding tool and can finely adjust the angle of the welding tool. Together with the crab claw clamping assembly, it can achieve precise positioning of the spatial height and horizontal angle of the aviation electrical connector.

[0008] Furthermore, the crab claw clamp assembly includes an upper part and a lower part, which are hinged together by locking rivets a and b to form an openable clamping structure; a first T-shaped knob screw is provided through the crab claw clamp assembly, which is threaded with the upper part to adjust the clamping opening degree between the upper part and the lower part.

[0009] Furthermore, the crab claw clamp assembly has a through-hole, through which the connecting screw passes and is locked and fixed to the crab claw clamp assembly by a fixing bolt.

[0010] Furthermore, the clamping contact surfaces of the upper and lower components that cooperate with each other are provided with an anti-slip and wear-resistant layer.

[0011] Furthermore, the diameter of the circular holes on both sides of the U-shaped connector is larger than the outer diameter of the central threaded rod of the star-shaped adjustment knob, allowing the central threaded rod of the star-shaped adjustment knob to rotate freely within the circular holes; a rotational clearance is left between the cylinder and the inner cavity of the U-shaped connector to ensure that the cylinder can rotate smoothly in the circumferential direction.

[0012] Furthermore, the welding tool clamping assembly includes a C-shaped clamp fixed on the base, an arc-shaped base fixed on the upper inner side of the C-shaped clamp, and a movable clamping head matched above the arc-shaped base; a second T-shaped knob screw is threaded through the C-shaped clamp, the second T-shaped knob screw is threaded with the C-shaped clamp, and its end abuts against the movable clamping head, the movable clamping head and the arc-shaped base cooperate with each other to form a ring-shaped clamping structure.

[0013] Furthermore, the movable clamping head and the arc-shaped base adopt a curved surface fitting structure.

[0014] A special welding method for aviation electrical connectors, using the aforementioned special welding equipment for aviation electrical connectors, includes the following steps: S1 Assembly and Fixing: Place the base on the workbench, assemble the support column, crab claw clamp assembly and welding tool clamp assembly in sequence, and complete the overall machine debugging; S2 Workpiece clamping: Rotate the first T-shaped knob screw to open the crab claw clamping assembly, place the aviation electrical connector in the clamping position, and then tighten the first T-shaped knob screw in the opposite direction to complete the clamping. Then, use the fixing bolts to initially position the crab claw clamping assembly. S3 Multi-dimensional Adjustment: Rotate the star-shaped adjustment knob to drive the cylinder and connecting screw to rotate synchronously, adjusting the crab claw clamp assembly to the target height; rotate the crab claw clamp assembly to the required horizontal angle, and then lock it in place by the gear to put the aviation electrical connector in the preset welding position; S4 Tool clamping: Place the welding tool on the arc-shaped base inside the C-shaped clamp, rotate the second T-shaped knob screw to push the movable clamping head, which cooperates with the arc-shaped base to hold the welding tool tightly, and finely adjust the angle of the welding tool so that the welding head is aligned with the welding part; S5 Welding Operation: Welding operations are carried out according to the predetermined process parameters. During the welding process, the position of the workpiece and welding tools is finely adjusted in real time through various knobs. S6 Workpiece Removal and Maintenance: Loosen the crab claw clamp assembly to remove the processed workpiece, clean the device, and periodically inspect the device and the weld points and electrical performance of the welded products.

[0015] The beneficial effects of this invention are as follows: The electrical connector welding device provided by this invention achieves multi-dimensional precise adjustment of the electrical connector through the coordinated action of the crab clamp assembly and the adjustment transmission assembly. It also works with the welding tool clamping assembly to adjust the tool's posture, ensuring precise alignment of the welding area. The ring-shaped clamping structure and the knob fastening action ensure stable clamping of the electrical connector and the welding tool. The knob design makes operation simple, requiring no professional skills, shortening preparation time, improving welding efficiency, and reducing labor intensity. Furthermore, it can be adjusted to adapt to different specifications of workpieces and tools, reducing equipment investment, meeting diverse production needs, effectively improving welding quality and production efficiency, and solving the pain points of existing electrical connector welding technology. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall device of the present invention; Figure 2 This is a schematic diagram of the structural components of the present invention disassembled; Among them, 1-upper part, 2-lower part, 3-locking rivet a, 4-locking rivet b, 5-fixing bolt, 6-first T-shaped knob screw, 7-connecting screw, 8-support column, 9-gear, 10-star-shaped adjustment knob, 11-base, 12-C-shaped clamp, 13-second T-shaped knob screw, 14-movable clamping head, 15-arc-shaped base, 16-cylinder, 17-U-shaped connector. Detailed Implementation

[0017] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0018] To achieve the above objectives, the present invention provides the following specific embodiments: Example 1: See Figure 1-2 This embodiment provides a special welding device for aviation electrical connectors. The device mainly consists of a base 11, a support column 8, a hinged crab claw clamp assembly, and a welding tool clamping assembly. The support column 8 is fixedly installed on the base 11. The crab claw clamp assembly is connected to the support column 8 through the connecting screw 7. The welding tool clamp assembly is fixed on the base 11 and arranged opposite to the crab claw clamp assembly.

[0019] A U-shaped connector 17 is fixed to the top of the supporting column 8. Both sides of the U-shaped connector 17 have through-holes. A threaded hole is located in the center of a cylinder 16. One end of the connecting screw 7 is vertically fixed to the side wall of the cylinder 16, and the cylinder 16 is loosely fitted inside the cavity of the U-shaped connector 17. The central threaded rod of the star-shaped adjusting knob 10 passes through the holes on both sides of the U-shaped connector 17 and is threaded into the threaded hole of the cylinder 16 for locking. The other end of the connecting screw 7 meshes with the gear 9, and this end is also secured by a fixing bolt 5 and a crab claw clamp assembly.

[0020] Manually rotating the star-shaped adjustment knob 10 causes the cylinder 16 to rotate circumferentially inside the U-shaped connector 17, which in turn drives the connecting screw 7 to swing in the vertical plane around the cylinder 16 as the center of rotation, thereby adjusting the height of the crab claw clamp assembly. Manually rotating the crab claw clamp assembly allows it to rotate 360° around the connecting screw 7. After rotating to the target angle, the gear 9 locks it in place, fixing the crab claw clamp assembly at any angle.

[0021] The crab claw clamp assembly consists of an upper part 1 and a lower part 2. The upper part 1 and the lower part 2 are hinged together by locking rivets a3 and b4 to form an openable clamping structure.

[0022] The first T-shaped knob screw 6 passes through the upper component 1 and is threaded into it. Rotating the first T-shaped knob screw 6 can change the opening and closing distance between the upper component 1 and the lower component 2, thereby realizing the clamping and releasing of the workpiece.

[0023] A pre-drilled hole is made on the crab claw clamp assembly. After the connecting screw 7 passes through the pre-drilled hole, it is fitted with the fixing bolt 5 to complete the overall assembly.

[0024] The clamping contact surfaces of the upper component 1 and the lower component 2 are provided with an anti-slip and wear-resistant layer, which can not only prevent scratches on the aviation electrical connector housing during clamping, but also improve clamping stability.

[0025] The diameter of the round holes on both sides of the U-shaped connector 17 is larger than the outer diameter of the central threaded rod of the star-shaped adjustment knob 10, ensuring that the threaded rod rotates without jamming; a rotation gap is reserved between the cylinder 16 and the inner cavity of the U-shaped connector 17 to ensure that the cylinder 16 rotates smoothly.

[0026] The welding tool clamping assembly includes a C-shaped clamp 12 fixed to a base 11. An arc-shaped base 15 is mounted on the upper inner side of the C-shaped clamp 12, and a movable clamping head 14 is correspondingly positioned above the arc-shaped base 15. A second T-shaped knob screw 13 passes through the C-shaped clamp 12 and forms a threaded engagement. The end of the second T-shaped knob screw 13 abuts against the movable clamping head 14. The movable clamping head 14 and the arc-shaped base 15 have a curved surface fitting structure, and the two together form a ring-shaped clamping structure, which can not only firmly clamp the welding tool, but also allow for small-scale adjustment of the angle of the welding tool.

[0027] Example 2: This example provides a special welding method for aviation electrical connectors, using the special welding device for aviation electrical connectors described in Example 1. The specific operation steps are as follows: S1 Assembly and Fixing: Place the base 11 on the workbench, and assemble the support column 8, crab claw clamp assembly, and welding tool clamping assembly in sequence. Check the flexibility of each rotating and clamping structure, and complete the overall machine debugging.

[0028] S2 Workpiece clamping: Turn the first T-shaped knob screw 6 in the forward direction to open the upper part 1 and lower part 2 of the crab claw clamping assembly, place the aviation electrical connector to be processed in the clamping area, turn the first T-shaped knob screw 6 in the reverse direction to clamp the workpiece, and then tighten the fixing bolt 5 to initially position the crab claw clamping assembly.

[0029] S3 Multi-dimensional Adjustment: Manually rotate the star-shaped adjustment knob 10 to drive the cylinder 16 and connecting screw 7 to rotate synchronously, adjusting the crab claw clamp assembly and aviation electrical connector to the required operating height; manually rotate the crab claw clamp assembly to rotate it around the connecting screw 7 to the set horizontal angle, and adjust the gear 9 to complete the position locking, so that the aviation electrical connector is accurately in the welding position.

[0030] S4 Tool clamping: Place the welding tool on the arc-shaped base 15 inside the C-shaped clamp 12, rotate the second T-shaped knob screw 13 to push the movable clamping head 14 toward the arc-shaped base 15 and clamp the welding tool; use the curved surface of the movable clamping head 14 and the arc-shaped base 15 to finely adjust the angle of the welding tool so that the welding head is accurately aligned with the welding point of the connector.

[0031] S5 Welding Operation: Welding operations are carried out according to the established welding process parameters for aviation electrical connectors. During the operation, the position of the workpiece and welding tools can be finely adjusted in real time by rotating the star-shaped adjustment knob 10, the first T-shaped knob screw 6, and the second T-shaped knob screw 13, depending on the actual situation. S6 Workpiece Removal and Maintenance: After welding is completed, loosen the second T-type knob screw 13 and the first T-type knob screw 6 in sequence to remove the processed aviation electrical connector; clean the surface of the device of welding slag, dust and other debris, regularly inspect and lubricate the moving parts of the device, and randomly check the quality of the finished weld points and electrical conductivity.

[0032] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A welding device specifically for aviation electrical connectors, characterized in that, Includes a base (11), a support column (8), a hinged crab claw clamp assembly for holding electrical connectors, and a welding tool clamping assembly; The support column (8) is fixedly installed on the base (11). The crab claw clamp assembly is connected to the support column (8) through the connecting screw (7). The welding tool clamp assembly is fixedly installed on the base (11) and arranged opposite to the crab claw clamp assembly. A U-shaped connector (17) is fixed to the top of the support column (8). A through round hole is provided on both sides of the U-shaped connector (17). A cylinder (16) and a star-shaped adjustment knob (10) are also provided. A threaded hole is machined in the center of the cylinder (16). One end of the connecting screw (7) is fixed perpendicularly to the side wall of the cylinder (16). The cylinder (16) is fitted into the inner cavity of the U-shaped connector (17). The central threaded rod of the star-shaped adjustment knob (10) passes through the round holes on both sides of the U-shaped connector (17) and is threadedly engaged with the threaded hole of the cylinder (16) and locked. A gear (9) is engaged at the other end of the connecting screw (7) and is fixedly connected to the crab claw clamp assembly by a fixing bolt (5). Rotating the star-shaped adjustment knob (10) can drive the cylinder (16) to rotate circumferentially within the U-shaped connector (17), thereby driving the connecting screw (7) to swing in the vertical plane with the cylinder (16) as the center of rotation, thus realizing the height adjustment of the crab claw clamp assembly; Rotating the crab claw clamp assembly allows it to rotate 360° around the connecting screw (7), and in conjunction with the gear (9) completes the position locking, thus achieving the fixation of the crab claw clamp assembly at any angle; The welding tool clamping assembly adopts a ring-shaped structure to clamp the welding tool and can finely adjust the angle of the welding tool. Together with the crab claw clamping assembly, it can achieve precise positioning of the spatial height and horizontal angle of the aviation electrical connector.

2. The welding device for aviation electrical connectors as described in claim 1, characterized in that, The crab claw clamp assembly includes an upper part (1) and a lower part (2). The upper part (1) and the lower part (2) are hinged together by locking rivets a (3) and b (4) to form an openable clamping structure. A first T-shaped knob screw (6) is provided through the crab claw clamp assembly. The first T-shaped knob screw (6) is threaded with the upper part (1) and is used to adjust the clamping opening degree between the upper part (1) and the lower part (2).

3. A welding device for aviation electrical connectors as described in claim 1 or 2, characterized in that, The crab claw clamp assembly has a through-hole, and the connecting screw (7) passes through the hole and is locked and fixed to the crab claw clamp assembly by the fixing bolt (5).

4. The welding device for aviation electrical connectors according to claim 2, characterized in that, The clamping contact surfaces of the upper component (1) and the lower component (2) are both provided with anti-slip and wear-resistant layers.

5. The special welding device for aviation electrical connectors according to claim 1, characterized in that, The The diameter of the round holes on both sides of the U-shaped connector (17) is slightly larger than the outer diameter of the central thread rod of the star-shaped adjustment knob (10). The central thread rod of the star-shaped adjustment knob (10) can rotate freely in the round hole. There is a rotation gap between the cylinder (16) and the inner cavity of the U-shaped connector (17) to ensure that the cylinder (16) can rotate smoothly in the circumferential direction.

6. The welding device for aviation electrical connectors as described in claim 1, characterized in that, The welding tool clamping assembly includes a C-shaped clamp (12) fixed on a base (11), an arc-shaped base (15) fixed on the upper inner side of the C-shaped clamp (12), and a movable clamping head (14) matched above the arc-shaped base (15); a second T-shaped knob screw (13) is mounted through the C-shaped clamp (12), the second T-shaped knob screw (13) is threadedly engaged with the C-shaped clamp (12), and its rod end abuts against the movable clamping head (14). The movable clamping head (14) and the arc-shaped base (15) cooperate with each other to form a ring-shaped clamping structure.

7. The welding device for aviation electrical connectors according to claim 6, characterized in that, Place The movable clamping head (14) and the arc-shaped base (15) adopt a curved surface fitting structure.

8. A special soldering method for aviation electrical connectors, characterized in that, A method for welding using the welding apparatus according to any one of claims 1 to 7, comprising the following steps: S1 Assembly and Fixing: Place the base (11) on the workbench, assemble the support column (8), crab claw clamp assembly and welding tool clamp assembly in sequence, and complete the whole machine debugging; S2 workpiece clamping: Rotate the first T-shaped knob screw (6) to open the crab claw clamping assembly, place the aviation electrical connector in the clamping position, and then tighten the first T-shaped knob screw (6) in the opposite direction to complete the clamping. Then use the fixing bolt (5) to perform preliminary positioning of the crab claw clamping assembly. S3 Multi-dimensional Adjustment: Rotate the star-shaped adjustment knob (10) to drive the cylinder (16) and connecting screw (7) to rotate synchronously, and adjust the crab claw clamp assembly to the target height; rotate the crab claw clamp assembly to the required horizontal angle, and then lock and fix it through the gear (9) so that the aviation electrical connector is in the preset welding position; S4 Tool clamping: Place the welding tool on the arc base (15) inside the C-shaped clamp (12), rotate the second T-shaped knob screw (13) to push the movable clamping head (14), which cooperates with the arc base (15) to hold the welding tool tightly, and finely adjust the angle of the welding tool so that the welding head is aligned with the welding part; S5 Welding Operation: Welding operations are carried out according to the predetermined process parameters. During the welding process, the position of the workpiece and welding tools is finely adjusted in real time using various knobs. S6 Workpiece Removal and Maintenance: Loosen the crab claw clamp assembly to remove the processed workpiece, clean the device, and periodically inspect the device and the weld points and electrical performance of the welded products.

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