A bridge plate assembly terminal welding machine

Abstract

This invention discloses a bridge board assembly terminal welding machine for assembling and welding bridge boards on motor covers with pre-installed P-side or Q-side terminals. The machine includes a frame with a turntable mechanism, and assembly, welding, solder joint push-pull testing, and continuity testing mechanisms arranged sequentially along the rotation direction of the turntable mechanism. The assembly mechanism assembles conductive terminals and the bridge board to the motor cover; the welding mechanism welds the first solder joint between the conductive terminals and the bridge board, and the second solder joint between the P / Q-side terminals and the bridge board; the solder joint push-pull testing mechanism includes two push-pull components with perpendicular directions of movement for testing solder joint firmness; the continuity testing mechanism forms a continuity detection circuit using dual probes. This invention automates the entire assembly, welding, and testing process, improving production efficiency and product qualification rate, solving the problems of low automation and inaccurate testing in existing technologies, and is suitable for mass production needs.

Description

Technical Field

[0001] This invention relates to the field of motor manufacturing, and more particularly to a bridge board assembly terminal welding machine. Background Technology

[0002] Brushed motors are widely used actuating drive components in the automotive industry, primarily used to drive the movements of vehicle body mechanisms such as windows, wipers, door locks, fuel pumps, and throttle valves. Their core components include the housing and the motor cover at the end. The motor cover, as a key component carrying conductive terminals and enabling electrical connections, also provides insulation protection. It typically has two types of mirror-symmetrical conductive terminals: the P-side terminal and the Q-side terminal. These two terminals respectively form the power supply path and circuit of the motor, forming the core foundation for ensuring the normal operation of the motor.

[0003] During the production and processing of the motor cover, after assembling the P-side terminals and Q-side terminals, a bridging plate needs to be installed on the motor cover. The bridging plate is used to bridge the P-side terminals, Q-side terminals and corresponding conductive terminals to construct a complete electrical circuit inside the motor. Its installation accuracy and welding firmness directly determine the electrical performance and operational reliability of the motor.

[0004] However, existing technologies still have several technical shortcomings regarding the assembly and welding processes of bridging plates, which urgently need to be addressed. Specifically: First, bridging plates have a delicate structure and precise dimensions, requiring extremely high positioning accuracy during installation and welding. Existing technologies often employ a semi-manual operation mode with simple tooling, resulting in low production efficiency and an inability to seamlessly integrate with automated assembly lines for PQ side terminals, creating a serious capacity bottleneck. Second, manual operation suffers from poor stability, easily leading to problems such as misaligned bridging plate insertion, incomplete welding, and weld explosions, resulting in a high product defect rate and difficulty in ensuring batch consistency in motor electrical conductivity. Third, existing equipment lacks a fully automated closed-loop inspection system, failing to comprehensively inspect the bridging plate assembly, weld strength, electrical conductivity, and post-weld terminal dimensional accuracy. Defective products are prone to flowing into downstream processes, posing a quality risk of complete motor failure.

[0005] Therefore, the aforementioned problems in the existing technology still need to be improved. Summary of the Invention

[0006] The main objective of this invention is to provide a bridge board assembly terminal welding machine. By setting up an integrated production line machine including a welding mechanism, a solder joint push-pull testing mechanism, and a continuity testing mechanism, an automated production line integrating installation, welding, and testing is formed, solving the problem of inconvenient installation and testing of bridge boards in the prior art.

[0007] This invention provides a bridge board assembly terminal welding machine for assembling and welding bridge boards on motor covers that have already been fitted with P-side terminals or Q-side terminals. The machine is characterized by comprising a frame, on which a turntable mechanism is mounted, and an assembly mechanism, a welding mechanism, a solder joint push-pull testing mechanism, and a continuity testing mechanism arranged sequentially along the rotation direction of the turntable mechanism. The assembly mechanism is used to sequentially assemble conductive terminals and the bridge board to corresponding mounting positions on the motor cover. The welding mechanism is used to weld and solidify a first solder joint between the conductive terminal and the bridge board, and a second solder joint between the P-side terminal or Q-side terminal and the bridge board. The solder joint push-pull testing mechanism includes a first push-pull assembly and a second push-pull assembly. Both the first and second push-pull assemblies include a push-pull driving cylinder and a push block. The push blocks of the first and second push-pull assemblies are respectively used to apply a pushing force to the bridging plate at the first solder joint and the second solder joint under the drive of the corresponding push-pull driving cylinder. The push-pull movement directions of the first and second push-pull assemblies are perpendicular to each other. The continuity testing mechanism includes a first probe and a second probe. The first probe and the second probe are respectively used to abut against the first solder joint and the second solder joint to form a continuity detection circuit.

[0008] Preferably, the welding mechanism includes a fixed electrode and a follower electrode. The fixed electrode is used to abut against the first side of the first weld point or the second weld point, and the follower electrode is used to abut against the second side of the first weld point or the second weld point. The end of the follower electrode is connected to a first preload spring, and the follower electrode is pressed against the surface of the first weld point or the second weld point by the elastic force of the first preload spring.

[0009] Preferably, the fixed electrode and / or the follower electrode are provided with clearance notches, which are used to avoid non-welded structures on the motor cover.

[0010] Preferably, the front surfaces of the fixed electrode and the follower electrode are welding contact surfaces for contacting the first weld point or the second weld point; the clearance notch is formed on the back surface of the fixed electrode, and / or, the back surface of the follower electrode is a rounded chamfered structure.

[0011] Preferably, the push-pull testing mechanism for weld joints further includes a lifting drive assembly and a thrust adjustment spring. The output end of the lifting drive assembly is fixedly connected to the push-pull drive cylinder, and is used to drive the push-pull drive cylinder and the push block to move up and down in the vertical direction. The output end of the push-pull drive cylinder is connected to the push block through the thrust adjustment spring, and the thrust adjustment spring is used to output a preset thrust to the push block. The push block has an L-shaped structure. The horizontal section of the push block is connected to the thrust adjustment spring, and the vertical section of the push block is used to extend into the bridge plate mounting position of the motor cover and abut against the corresponding position of the weld joint of the bridge plate.

[0012] Preferably, the solder joint push-pull testing mechanism further includes a displacement sensor, the detection end of which is linked with the push block to detect the displacement of the push block during the push-pull process.

[0013] Preferably, the solder joint push-pull testing mechanism further includes a first vision detection component, the lens imaging area of ​​which corresponds to the positions of the first solder joint and the second solder joint, and is used to detect whether there are crack defects in the solder joint after push-pull.

[0014] Preferably, the continuity testing mechanism further includes a continuity tester, a downward driving component, and an upward driving component. The output end of the downward driving component is connected to the first probe, and the first probe is mounted on the lower end of the downward driving component via a second preload spring. The output end of the upward driving component is connected to the second probe, and the second probe is mounted on the upper end of the upward driving component via a third preload spring. Both the first probe and the second probe are connected to the continuity tester via signal.

[0015] Preferably, the frame is further provided with a second vision inspection component, which is arranged downstream of the continuity testing mechanism along the rotation direction of the turntable mechanism. The lens of the second vision inspection component is facing the terminal welding area of ​​the motor cover, and is used to detect whether the installation height and pin spacing of the welded end are in line with the preset accuracy requirements.

[0016] Preferably, the frame is further provided with a feeding mechanism, which includes a defective product discharge component. The defective product discharge component is connected to the solder joint push-pull test mechanism, the continuity test mechanism and the second vision inspection component for signal connection, and is used to discharge products that are determined to be unqualified by the solder joint push-pull test mechanism, the continuity test mechanism or the second vision inspection mechanism.

[0017] In summary, the bridging board assembly terminal welding machine provided by this invention is used to assemble and weld bridging boards on motor covers with pre-installed P-side or Q-side terminals. It includes a frame with a turntable mechanism on the frame, and an assembly mechanism, a welding mechanism, a solder joint push-pull testing mechanism, and a continuity testing mechanism arranged sequentially along the rotation direction of the turntable mechanism. The assembly mechanism assembles the conductive terminals and the bridging board to the motor cover; the welding mechanism welds the first solder joint between the conductive terminals and the bridging board, and the second solder joint between the P / Q side terminals and the bridging board; the solder joint push-pull testing mechanism includes two push-pull components with mutually perpendicular movement directions, used to detect the solder joint firmness; the continuity testing mechanism forms a continuity detection circuit through dual probes. This invention achieves full automation of the assembly, welding, and testing process, improving production efficiency and product qualification rate, solving the problems of low automation and inaccurate testing in existing technologies, and is suitable for mass production needs. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 A schematic diagram of the finished motor cover processed by the bridge board assembly terminal welding machine provided by the present invention;

[0020] Figure 2 This is a three-dimensional schematic diagram of the bridge board assembly terminal welding machine provided by the present invention;

[0021] Figure 3 This is a top view of the bridge board assembly terminal welding machine provided by the present invention;

[0022] Figure 4 This is a schematic diagram of the turntable assembly in the bridge board assembly terminal welding machine provided by the present invention;

[0023] Figure 5 This is a schematic diagram of the 180-degree rotating exchange mechanism in the bridge board assembly terminal welding machine provided by the present invention;

[0024] Figure 6 This is a schematic diagram of the terminal assembly mechanism in the bridge plate assembly terminal welding machine provided by the present invention;

[0025] Figure 7 This is a schematic diagram of the bridge board assembly mechanism in the bridge board assembly terminal welding machine provided by the present invention;

[0026] Figure 8 This is a schematic diagram of the bridge board inspection mechanism in the bridge board assembly terminal welding machine provided by the present invention;

[0027] Figure 9a This is a schematic diagram of the welding mechanism in the bridge board assembly terminal welding machine provided by the present invention;

[0028] Figure 9b This is a schematic diagram of the follower electrode side of the welding mechanism in the bridge board assembly terminal welding machine provided by the present invention;

[0029] Figure 9c This is a schematic diagram of the fixed electrode side of the welding mechanism in the bridge board assembly terminal welding machine provided by the present invention;

[0030] Figure 10a This is a schematic diagram of the solder joint push-pull testing mechanism in the bridge board assembly terminal welding machine provided by the present invention;

[0031] Figure 10bThis is a schematic diagram of the first vision inspection component in the bridge board assembly terminal welding machine provided by the present invention;

[0032] Figure 11 This is a schematic diagram of the continuity testing mechanism in the bridge board assembly terminal welding machine provided by the present invention;

[0033] Figure 12 This is a schematic diagram of the second vision inspection component of the bridge board assembly terminal welding machine provided by the present invention. Detailed Implementation

[0034] 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, not all, of the embodiments of the present invention. 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.

[0035] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0036] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0037] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0038] Brushed motors are widely used actuation and drive components in the automotive industry, mainly used to drive the movement of body mechanisms such as windows, wipers, door locks, oil pumps, and throttle valves. Their core components include the housing and the motor cover 10 at the end. The motor cover 10 is a key component that carries conductive terminals and enables electrical connections, while also providing insulation protection. It is typically equipped with two types of mirror-symmetrical conductive terminals: the P-side terminal and the Q-side terminal 11. These two terminals respectively constitute the power supply path and circuit of the motor, forming the core foundation for ensuring the normal operation of the motor.

[0039] like Figure 1As shown, during the production and processing of the motor cover 10, after the assembly of the P-side terminal or Q-side terminal 11 is completed, a bridging plate 12 needs to be installed on the motor cover 10. The bridging plate 12 is used to bridge the P-side terminal or Q-side terminal 11 with the corresponding conductive terminal 13 to construct a complete electrical circuit inside the motor. Its installation accuracy and welding firmness directly determine the electrical performance and operational reliability of the motor.

[0040] However, existing technologies still have many technical shortcomings regarding the assembly and welding processes of the bridging plate 12, which are as follows: First, the bridging plate 12 itself has a slender structure and precise dimensions, requiring extremely high positioning accuracy for installation and welding. Existing technologies mostly adopt a semi-manual operation mode with manual assistance and simple tooling, resulting in low production efficiency and an inability to seamlessly match with the automated assembly line of the front-end PQ side terminals, creating a serious capacity bottleneck. Second, manual operation has poor stability, easily leading to problems such as misaligned insertion of the bridging plate 12, incomplete welding, and weld explosions, resulting in a high product defect rate and making it difficult to guarantee batch consistency of the motor's electrical conductivity performance. Third, existing equipment lacks a fully automated closed-loop inspection system, making it impossible to conduct comprehensive inspections of the bridging plate 12 assembly, weld strength, electrical conductivity performance, and post-weld terminal dimensional accuracy. Defective products are prone to flow into downstream processes, posing a quality risk of complete motor failure.

[0041] To address the aforementioned issues, this application provides a bridge board assembly terminal welding machine. By setting up an integrated production line machine including a welding mechanism 400, a solder joint push-pull testing mechanism 500, and a continuity testing mechanism 600, an automated production line integrating installation, welding, and testing is formed, solving the problem of inconvenient installation and testing of the bridge board 12 in the prior art.

[0042] The detailed plan is as follows:

[0043] like Figure 2 , Figure 3 As shown, this embodiment provides a bridge board assembly terminal welding machine for assembling and welding bridge boards 12 on motor covers 10 that have P-side terminals or Q-side terminals 11 installed. It includes a frame 100, a turntable mechanism 200 on the frame 100, and an assembly mechanism 300, a welding mechanism 400, a solder joint push-pull test mechanism 500, and a continuity test mechanism 600 arranged sequentially along the rotation direction of the turntable mechanism 200.

[0044] like Figure 4As shown, the turntable mechanism 200 is circumferentially arranged with multiple sets of fixtures 210 for positioning and supporting the motor cover 10. The turntable mechanism 200 is driven by an intermittent cam divider and can rotate intermittently, driving the motor cover 10 on the fixture 210, which has completed the assembly of the P-side terminal or Q-side terminal 11, to flow to each station in sequence to complete the corresponding process operation, so as to realize the fully automated flow of the product.

[0045] The functions of each institution are as follows:

[0046] like Figure 3 As shown, the assembly mechanism 300 is used to sequentially assemble the conductive terminal 13 and the bridge plate 12 to the corresponding mounting positions of the motor cover 10.

[0047] In this embodiment, as Figure 3 As shown, the assembly mechanism 300 includes a terminal assembly mechanism 310 and a bridge plate assembly mechanism 320 arranged sequentially along the rotation direction of the turntable mechanism 200.

[0048] like Figure 3 and Figure 5 As shown, optionally, a 180-degree rotation exchange mechanism 700 is provided upstream of the assembly mechanism 300. The 180-degree rotation exchange mechanism includes a rotation drive component 710 and symmetrically arranged loading and unloading grippers 720. The rotation drive component 710 can drive the loading and unloading grippers 720 to perform a 180-degree rotational movement to complete the automated loading of the motor cover 10. At the same time, it rotates the incoming motor cover 10 from a pin-outward posture to a pin-inward posture to adapt to the operation requirements of subsequent welding processes.

[0049] like Figure 6 As shown, the terminal assembly mechanism 310 includes a vibratory feeder assembly 311, a flipping feeder assembly 312, a gripper mounting assembly 313, and a pressing drive assembly 314. It is used to automatically feed the linear conductive terminals 13 for welding and adopts a one-step pressing method, relying on air pressure to directly press the conductive terminals 13 onto the corresponding mounting positions of the motor cover 10, without the need for step-by-step pre-assembly and clamping.

[0050] like Figure 7 As shown, the bridging plate assembly mechanism 320 includes a vibratory feeder assembly 321, a material distribution mechanism 322, and a clamping and insertion assembly 323. Optionally, the material distribution mechanism 322 is equipped with an optical fiber sensing element. When the optical fiber senses that the bridging plate 12 is in place, the material distribution mechanism 322 is offset backward to block subsequent incoming materials, ensuring that only a single bridging plate 12 is picked up by the clamping and insertion assembly 323 each time, thus completing the alignment and insertion of the bridging plate 12.

[0051] Optionally, such as Figure 7 and Figure 8As shown, the bridging plate assembly mechanism 320 also includes a bridging plate detection mechanism 330. The bridging plate detection mechanism 330 includes a first pressing drive assembly 331, a linear bearing assembly 332, a detection pin (not shown in the figure), and a laser beam detection assembly 333. It is used to detect whether the bridging plate 12 is assembled in place, screen out defective products that are missing or misassembled, and prevent unqualified products from flowing into the subsequent welding process.

[0052] During the specific operation, the first pressing drive component 331 drives the linear bearing component 332 and the detection pin to press vertically downwards as a whole. If the bridge plate 12 has been correctly assembled on the motor cover 10, the detection pin will be lifted by the bridge plate 12 when it is pressed down, which will drive the shaft of the linear bearing component 332 to rise. The sensing plate on the shaft will block the light path of the laser beam detection component 333, triggering the positioning signal and determining that the bridge plate 12 is assembled in place. If no positioning signal is detected, the bridge plate 12 is determined to be missing or misassembled and marked as a defective product.

[0053] like Figures 9a to 9c As shown, the welding mechanism 400 is used to weld and fix the first solder joint 21 between the conductive terminal 13 and the bridge plate 12, and the second solder joint 22 between the P-side terminal or Q-side terminal 11 and the bridge plate 12. In this embodiment, the welding mechanism 400 includes a first welding mechanism and a second welding mechanism with completely identical structures. The two welding mechanisms are arranged sequentially along the rotation direction of the turntable mechanism 200, respectively corresponding to the first solder joint 21 and the second solder joint 22 at both ends of the bridge plate 12. For ease of understanding, this embodiment only uses one of them as an example for explanation. The welding mechanism 400 adopts a resistance welding structure, which can complete the welding operation for the two solder joints separately, ensuring the welding firmness.

[0054] like Figure 10a As shown in Figure 10, the solder joint push-pull testing mechanism 500 includes a first push-pull assembly 510 and a second push-pull assembly 520. Both the first push-pull assembly 510 and the second push-pull assembly 520 include a push-pull drive cylinder 501 and a push block 502. The push block 502 of the first push-pull assembly 510 and the push block 502 of the second push-pull assembly 520 are respectively used to apply a pushing force to the bridge plate 12 at the first solder joint 21 and the second solder joint 22 under the drive of the corresponding push-pull drive cylinder 501. The push-pull movement directions of the first push-pull assembly 510 and the second push-pull assembly 520 are perpendicular to each other. As shown in Figure 10, the two sets of push-pull assemblies correspond to the positions of the two solder joints respectively. The mutually perpendicular push-pull directions are designed for the layout of the solder joints at both ends of the bridge plate 12, which can accurately simulate the stress state of the solder joints during actual use and complete the quantitative test of the solder joint firmness.

[0055] like Figure 11As shown, the continuity testing mechanism 600 includes a first probe 610 and a second probe 620. The first probe 610 and the second probe 620 are respectively used to abut against the first solder joint 21 and the second solder joint 22 to form a continuity testing circuit. The first probe 610 and the second probe correspond to the two ends of the welding circuit, and can stably contact the terminals at the corresponding solder joint positions under the drive of the driving structure to form a complete electrical testing circuit, realizing automated testing of the continuity performance of the welding circuit.

[0056] The above-described technical solution in this embodiment, through the turntable mechanism 200 driving the products to flow sequentially, realizes the fully automated operation of the entire process of assembling conductive terminals 13, assembling bridge boards 12, welding, solder joint firmness testing, and conductivity testing. The entire process requires no manual intervention, greatly improving production efficiency. It can be seamlessly matched with the front-end PQ side terminal automated assembly production line, eliminating capacity bottlenecks. By constructing a closed-loop quality control system through multiple sets of automated testing mechanisms, products with poor assembly, poor welding, and poor conductivity can be accurately screened, significantly reducing the product defect rate and ensuring batch stability of motor electrical performance. At the same time, the whole machine is compatible with the processing of both P-side and Q-side motor cover 10 products, eliminating the need for separate line operations and significantly reducing equipment investment and production management costs.

[0057] Based on the above scheme, the following optional optimization schemes are provided.

[0058] To further optimize the stability of the welding operation, ensure uniform and controllable welding pressure, avoid damage to the terminals and bridging plate 12 by rigid pressing, and ensure consistent welding quality, this application provides a preferred embodiment, as follows:

[0059] like Figures 9a to 9c As shown, the welding mechanism 400 includes a fixed electrode 410 and a follower electrode 420. The fixed electrode 410 is used to abut against the first side of the first weld point 21 or the second weld point 22, and the follower electrode 420 is used to abut against the second side of the first weld point 21 or the second weld point 22. A first preload spring 430 is connected to the end of the follower electrode 420, and the follower electrode 420 is pressed against the surface of the first weld point 21 or the second weld point 22 by the elastic force of the first preload spring 430.

[0060] In this embodiment, the fixed electrode 410 and the follower electrode 420 correspond to the inner and outer sides of the weld point, respectively. During the welding operation, the fixed electrode 410 first adheres to the reference surface on one side of the weld point, and the follower electrode 420 moves towards the other side of the weld point under the drive of the drive structure. It is pressed against the surface of the weld point by the elastic force of the first preload spring 430, and a preset initial welding pressure is applied. Then, resistance welding is performed by powering on the electrode. The current forms a circuit with the workpiece through the electrode to generate high heat, melting the welding part. The first preload spring 430 continuously outputs the follower elastic pressure to push the melted part to fit tightly until the welding is completed.

[0061] The above-described technical solution in this embodiment provides flexible welding pressure to the follower electrode 420 through the first pre-compression spring 430. It eliminates the need for precise control of the downward stroke of the drive structure, and the welding pressure can be precisely controlled simply by the compression of the spring, reducing the control precision requirements of the drive mechanism. At the same time, the elastic pressure method can adaptively compensate for material deformation during the welding melting process, ensuring continuous and stable pressure during the welding process, avoiding defects such as incomplete welding and weld explosion, and improving the batch consistency of welding quality. In addition, the flexible pressure can avoid rigid extrusion damage to the structure of the terminal and the bridge plate 12, ensuring the product's appearance and structural integrity.

[0062] Furthermore, in actual welding operations, the non-welded structure of the motor cover 10 is prone to interference with the electrode, which not only affects the precise alignment of the welding electrode and the weld point, but may also cause damage to the electrode or cover structure, affecting welding accuracy and equipment operational stability. To solve this technical problem, this application provides a further optimization scheme based on the above-described embodiments:

[0063] like Figure 9b As shown, the fixed electrode 410 and / or the follower electrode 420 are provided with clearance notches 401, which are used to avoid non-welded structures on the motor cover 10.

[0064] In this embodiment, based on the specific structure of the motor cover 10 and the layout of the terminals and solder joints, an clearance notch 401 is provided in the non-welding contact area of ​​the fixed electrode 410 and / or the follower electrode 420. During the welding operation, the non-welding protrusions, ribs and other structures on the motor cover 10 can be accommodated in the clearance notch 401 to avoid contact interference with the electrode body.

[0065] Preferably, the front surfaces of the fixed electrode 410 and the follower electrode 420 are welding contact surfaces for contacting the first weld point 21 or the second weld point 22; the clearance notch 401 is an arc-shaped chamfer structure formed on the back surface of the fixed electrode 410 and / or the back surface of the follower electrode 420.

[0066] In this embodiment, the welding working surface in contact with the weld point is defined as the front side, and the side opposite to the welding working surface is defined as the back side. The clearance notch 401 is formed on the back side of the electrode with a rounded chamfer structure. While avoiding the non-welded structure of the motor cover 10, it ensures that the welding contact surface on the front side of the electrode is a complete plane, which can form a full and stable surface contact with the weld point, ensuring the uniform transmission of welding current and pressure. The rounded chamfer structure can avoid stress concentration, ensure the structural strength of the electrode, and extend the service life of the electrode. At the same time, the rounded transition structure can further reduce the risk of scratching the cover structure.

[0067] Furthermore, to accurately test the weld strength of the weld joints, adapt to the narrow installation space of the motor cover 10, avoid interference with the internal structure of the cover during the testing process, and simultaneously achieve precise and controllable adjustment of the thrust, this application provides a core optimized implementation method for the weld joint push-pull testing mechanism 500:

[0068] like Figure 10a As shown, the weld point push-pull testing mechanism 500 also includes a lifting drive assembly 503 and a thrust adjustment spring 504. The output end of the lifting drive assembly 503 is fixedly connected to the push-pull drive cylinder 501 and is used to drive the push-pull drive cylinder 501 and the push block 502 to move up and down in the vertical direction. The output end of the push-pull drive cylinder 501 is connected to the push block 502 through the thrust adjustment spring 504. The thrust adjustment spring 504 is used to output a preset thrust to the push block 502. The push block 502 has an L-shaped structure. The horizontal section 502-1 of the push block 502 is connected to the thrust adjustment spring 504. The vertical section 502-2 of the push block 502 is used to extend into the mounting position of the bridge plate 12 of the motor cover 10 and abut against the corresponding position of the weld point of the bridge plate 12.

[0069] In this embodiment, as Figure 10a As shown, the lifting drive assembly 503 adopts a cylinder drive structure, which can drive the push-pull drive cylinder 501 and the push block 502 to rise and fall in the vertical direction as a whole, realizing the switching between the test position and the avoidance position. The push-pull drive cylinder 501 is arranged horizontally, and its output end is rigidly connected to the horizontal section 502-1 of the push block 502 through the thrust adjustment spring 504. The vertical section 502-2 of the push block 502 extends downward to form an L-shaped cantilever structure. During testing, the lifting drive assembly 503 first drives the push block 502 to descend to the test position, so that the vertical section 502-2 of the push block 502 extends into the installation space of the motor cover 10, directly facing the protruding part at the weld point of the bridge plate 12; then the push-pull drive cylinder 501 is activated, and the push block 502 is pushed horizontally by the thrust adjustment spring 504, so that the vertical section 502-2 of the push block 502 applies a preset thrust to the bridge plate 12. The magnitude of the thrust can be precisely controlled by replacing the thrust adjustment spring 504 with a different elastic coefficient or by adjusting the initial compression of the spring.

[0070] The above-described technical solution in this embodiment, through the design of the L-shaped push block 502, allows the vertical section 502-2 of the push block 502 to penetrate deep into the narrow installation space of the motor cover 10, precisely abutting the corresponding position of the solder joint of the bridge plate 12. This effectively avoids interference with other structures inside the cover during the testing process and perfectly adapts to the shape characteristics of the PQ terminal product. Through the structure of the push-pull drive cylinder 501 in conjunction with the thrust adjustment spring 504, precise and controllable thrust output is achieved. The thrust can be flexibly adjusted according to the product's testing standards to ensure the accuracy and consistency of the test results. At the same time, the cooperation between the lifting drive component 503 and the push-pull drive cylinder 501 realizes the full automation of the testing action without manual intervention, greatly improving the testing efficiency.

[0071] To further quantify the weld strength test results, improve the accuracy of defect determination, and achieve accurate identification of hidden weld defects and weld detachment, this application adds a displacement detection structure to the above-mentioned push-pull test mechanism:

[0072] like Figure 10a As shown, the solder joint push-pull test mechanism 500 also includes a displacement sensor 505. The detection end of the displacement sensor 505 is linked with the push block 502 to detect the displacement of the push block 502 during the push-pull process.

[0073] In this embodiment, the displacement sensor 505 is a contact-type telescopic displacement sensor, whose detection end is fixedly connected to the push block 502, and can collect the horizontal displacement of the push block 502 in real time during the pushing and pulling process. During the test, if the solder joint is firmly welded, the bridge plate 12 and the terminal will not be relatively displaced under the preset pushing force, and the displacement of the push block 502 will remain within the preset qualified threshold. If the solder joint has defects such as poor soldering or detachment, the bridge plate 12 will separate from the terminal under the pushing force, and the displacement of the push block 502 will exceed the preset qualified threshold. The equipment control system can directly determine that the product is defective based on the detection data of the displacement sensor 505.

[0074] Furthermore, to achieve dual verification of weld strength, avoid missing latent crack defects, and further improve the comprehensiveness and reliability of welding quality inspection, this application adds a visual inspection structure to the mechanical thrust test:

[0075] like Figure 10b As shown, the solder joint push-pull test mechanism 500 also includes a first vision inspection component 530. The lens shooting area of ​​the first vision inspection component 530 corresponds to the positions of the first solder joint 21 and the second solder joint 22, and is used to detect whether there are crack defects in the solder joint after push-pull.

[0076] In this embodiment, optionally, the first visual inspection component 530 includes a CCD visual camera 531, a light source component 532, and an image processing unit (not shown in the figure). The lens of the CCD visual camera 531 is directly facing the solder joint area of ​​the motor cover 10 on the turntable fixture 210. The light source component 532 provides uniform illumination to the imaging area to ensure image clarity. After the push-pull test is completed, the first visual inspection component 530 captures an image of the solder joint area. The image processing unit analyzes and processes the image to detect whether there are defects such as cracks or gaps at the solder joint after the push-pull test. If a defect is detected, the product is determined to be defective.

[0077] The above-described technical solution in this embodiment achieves dual verification of weld joint firmness by combining mechanical thrust testing and visual inspection. It can identify overall weld joint detachment defects through displacement detection and microscopic cracking defects through visual inspection, thus realizing full-dimensional inspection of welding quality and significantly reducing the rate of missed inspections of defective products. At the same time, the visual inspection process can be completed simultaneously with the push-pull test action without the need for additional product transfer stations, which improves the comprehensiveness of inspection while ensuring the production efficiency of the equipment.

[0078] Furthermore, to improve the contact stability between the probe and the terminal during continuity testing, avoid damage to the terminal from rigid crimping, eliminate test result deviations caused by poor contact, and ensure the accuracy of continuity performance testing, this application provides an optimized implementation method for the continuity testing mechanism 600:

[0079] like Figure 11 As shown, the continuity testing mechanism 600 also includes a continuity tester (not shown), a second downward driving component 630, and an upward driving component 640. The output end of the second downward driving component 630 is connected to the first probe 610, and the first probe 610 is mounted on the lower end of the second downward driving component 630 via a second preload spring. The output end of the upward driving component 640 is connected to the second probe 620. Optionally, the second probe 620 is mounted on the upper end of the upward driving component 640 via a third preload spring. Both the first probe 610 and the second probe 620 are connected to the continuity tester for signal transmission.

[0080] In this embodiment, as Figure 11As shown, the second downward driving component 630 adopts a vertically arranged cylinder structure. The first probe 610 is floatingly mounted on the lower end of the output end of the second downward driving component 630 through the second preload spring, and is an upper sliding probe. The upper driving component 640 also adopts a vertically arranged cylinder structure. The second probe 620 is floatingly mounted on the upper end of the output end of the upper driving component 640 through the third preload spring, and is a lower diamond pin. The first probe 610 and the second probe 620 are respectively connected to the corresponding detection channels of the continuity tester through signal lines. During testing, the second downward driving component 630 drives the first probe 610 downward, causing the first probe 610 to abut against the upper end face of the terminal. The upward driving component 640 drives the second probe 620 upward, causing the second probe 620 to abut against the lower end face of the terminal. The upper and lower probes form a stable flexible contact with the terminal through the elastic force of the second and third pre-compression springs. Subsequently, the continuity tester passes a preset test current into the test circuit to detect the continuity status and continuity resistance of the soldering circuit. If the circuit is not continuous or the continuity resistance exceeds the preset range, the product is determined to be a defective product with poor soldering or open circuit.

[0081] The above-described technical solution in this embodiment adopts a spring-cylinder composite pressing method. The second and third pre-press springs provide flexible contact pressure for the probe, which not only ensures stable contact between the probe and the terminal, eliminating detection errors caused by poor contact and improving the accuracy of the detection results, but also avoids scratches and deformation damage to the terminal surface caused by rigid pressing, ensuring the appearance and structural integrity of the product. The upper and lower double probe structure design can form a complete test circuit from the upper and lower ends of the terminal, accurately detecting the conductivity of the welding circuit, adapting to the terminal layout characteristics of the motor cover 10, and achieving higher detection efficiency and accuracy.

[0082] The welding process can easily cause terminal deformation. Continuity tests alone cannot identify precision defects in terminal mounting height and pin spacing. These precision defects can lead to poor contact and assembly failures during subsequent motor assembly. To achieve a comprehensive final assessment of finished product quality, this application, based on the above-described implementation method, further adds a post-weld visual inspection structure:

[0083] The frame 100 is also equipped with a second vision inspection component 800. The second vision inspection component 800 is arranged downstream of the continuity test mechanism 600 along the rotation direction of the turntable mechanism 200. The lens of the second vision inspection component 800 is facing the terminal welding area of ​​the motor cover 10, and is used to detect whether the installation height and pin spacing of the welded terminal meet the preset accuracy requirements.

[0084] In this embodiment, as Figure 12As shown, the second vision inspection component 800 includes a high-precision CCD vision camera 810, a ring light source component 820, and an image processing unit (not shown in the figure). The lens of the high-precision CCD vision camera 810 is vertically downward and directly faces the welding area of ​​the motor cover 10 terminal on the turntable fixture 210. The ring light source component 820 provides multi-angle uniform illumination for the inspection area, eliminating the influence of shadows on the inspection accuracy. After the product completes the continuity test, the turntable moves the product to this station. The second vision inspection component 800 captures a high-definition image of the terminal welding area. The image processing unit analyzes and processes the image using image algorithms, accurately measuring the installation height of the welded terminal and the spacing between adjacent pins, and comparing it with the preset accuracy standard. If the detected value exceeds the tolerance range, the product is determined to be defective. Unlike the simple front-end inspection that only checks whether the terminal is pressed in place, this mechanism performs a final accuracy judgment on the finished product after welding, which can effectively identify dimensional deviations caused by welding deformation.

[0085] The above-described technical solution in this embodiment achieves automated and precise detection of the post-weld terminal installation height and pin spacing through a high-precision visual inspection component, completing the final all-dimensional judgment of the finished product quality. This effectively prevents products with substandard precision caused by welding deformation from flowing into downstream processes, ensuring the smooth progress of subsequent motor assembly. At the same time, the accuracy of visual inspection can reach the micron level, which is far higher than the accuracy of manual inspection, and the inspection efficiency is fully matched with the automated production line without the need to increase the production cycle.

[0086] To achieve closed-loop processing of the entire inspection process, automatically sort and discharge defective products to prevent them from flowing into downstream processes, and simultaneously collect qualified and defective products separately, this application further adds a material unloading and sorting mechanism based on the above-described implementation method:

[0087] The frame 100 is also equipped with a feeding mechanism (not shown in the figure). The feeding mechanism includes a defective product discharge component, which is connected to the solder joint push-pull test mechanism 500, the continuity test mechanism 600 and the second vision inspection component 800 respectively. It is used to discharge products that are determined to be unqualified by the solder joint push-pull test mechanism 500, the continuity test mechanism 600 or the second vision inspection mechanism.

[0088] The above-described technical solution in this embodiment achieves automated sorting and discharge of qualified and defective products through signal linkage between the feeding mechanism and the full-process inspection mechanism. It constructs a fully automated closed loop from assembly, welding, inspection to sorting, without the need for manual intervention throughout the process, which further improves production efficiency. At the same time, it completely eliminates the risk of defective products flowing into downstream processes and ensures the quality stability of the products leaving the factory.

[0089] In summary, this invention discloses a bridge board assembly terminal welding machine for assembling and welding bridge boards on motor covers with pre-installed P-side or Q-side terminals. The machine includes a frame with a turntable mechanism, and assembly, welding, solder joint push-pull testing, and continuity testing mechanisms arranged sequentially along the rotation direction of the turntable mechanism. The assembly mechanism assembles the conductive terminals and bridge boards to the motor cover; the welding mechanism welds the first solder joint between the conductive terminals and the bridge board, and the second solder joint between the P / Q-side terminals and the bridge board; the solder joint push-pull testing mechanism includes two push-pull components with mutually perpendicular movement directions for detecting solder joint firmness; the continuity testing mechanism forms a continuity detection circuit using dual probes. This invention automates the entire assembly, welding, and testing process, improving production efficiency and product qualification rate, solving the problems of low automation and inaccurate testing in existing technologies, and is suitable for mass production needs.

[0090] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and these modifications or substitutions should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A bridge plate assembly terminal welding machine for assembling a welding bridge plate on a motor rubber cap on which a P-side terminal or a Q-side terminal has been installed, characterized by, The system includes a frame, on which a turntable mechanism is mounted, and an assembly mechanism, a welding mechanism, a solder joint push-pull testing mechanism, and a continuity testing mechanism arranged sequentially along the rotation direction of the turntable mechanism. The assembly mechanism is used to sequentially assemble the conductive terminals and the bridge plate to the corresponding mounting positions of the motor cover; The welding mechanism is used to weld and fix the first solder joint between the conductive terminal and the bridge plate, and the second solder joint between the P-side terminal or Q-side terminal and the bridge plate. The push-pull test mechanism for solder joints includes a first push-pull assembly and a second push-pull assembly. Both the first push-pull assembly and the second push-pull assembly include a push-pull drive cylinder and a push block. The push block of the first push-pull assembly and the push block of the second push-pull assembly are respectively used to apply a pushing force to the bridging plate at the first solder joint and the second solder joint under the drive of the corresponding push-pull drive cylinder. The push-pull movement directions of the first push-pull assembly and the second push-pull assembly are perpendicular to each other. The continuity testing mechanism includes a first probe and a second probe, which are respectively used to contact the first solder joint and the second solder joint to form a continuity detection circuit.

2. The bridge panel assembly terminal welder of claim 1, wherein, The welding mechanism includes a fixed electrode and a follower electrode. The fixed electrode is used to abut against a first side of the first weld point or the second weld point, and the follower electrode is used to abut against a second side of the first weld point or the second weld point. A first preload spring is connected to the end of the follower electrode, and the follower electrode is pressed against the surface of the first weld point or the second weld point by the elastic force of the first preload spring.

3. The bridge panel assembly terminal welder of claim 2, wherein, The fixed electrode and / or the follower electrode are provided with clearance notches, which are used to avoid non-welded structures on the motor cover.

4. The bridge panel assembly terminal welder of claim 3, wherein, The front surfaces of the fixed electrode and the follower electrode are welding contact surfaces, used to abut against the first weld point or the second weld point; the clearance notch is formed on the back of the fixed electrode, and / or, the arc-shaped chamfer structure on the back of the follower electrode.

5. The bridge panel assembly terminal welder of claim 1, wherein, The weld joint push-pull testing mechanism also includes a lifting drive assembly and a thrust adjustment spring, wherein... The output end of the lifting drive assembly is fixedly connected to the push-pull drive cylinder, and is used to drive the push-pull drive cylinder and the push block to move up and down in the vertical direction; The output end of the push-pull drive cylinder is connected to the push block through the thrust adjustment spring, and the thrust adjustment spring is used to output a preset thrust to the push block; The push block has an L-shaped structure. The horizontal section of the push block is connected to the thrust adjustment spring, and the vertical section of the push block is used to extend into the bridge plate mounting position of the motor cover and abut against the corresponding position of the weld point of the bridge plate.

6. The bridge panel assembly terminal welder of claim 5, wherein, The push-pull test mechanism for the weld joint also includes a displacement sensor. The detection end of the displacement sensor is linked with the push block to detect the displacement of the push block during the push-pull process.

7. The bridge board assembly terminal welding machine according to claim 5, characterized in that, The solder joint push-pull testing mechanism also includes a first vision detection component. The lens shooting area of ​​the first vision detection component corresponds to the positions of the first solder joint and the second solder joint, and is used to detect whether there are crack defects in the solder joint after push-pull.

8. The bridge panel assembly terminal welder of claim 1, wherein, The continuity testing mechanism further includes a continuity tester, a downward driving component, and an upward driving component, wherein... The output end of the pressure drive assembly is connected to the first probe, and the first probe is mounted on the lower end of the pressure drive assembly by a second preload spring; The output end of the upper drive assembly is connected to the second probe, and the second probe is mounted on the upper end of the upper drive assembly by a third preload spring; Both the first probe and the second probe are connected to the signal of the continuity tester.

9. The bridge panel assembly terminal welder of any of claims 1-8, wherein, The frame is also equipped with a second vision inspection component, which is arranged downstream of the continuity testing mechanism along the rotation direction of the turntable mechanism. The lens of the second vision inspection component is facing the terminal welding area of ​​the motor cover, and is used to detect whether the installation height and pin spacing of the welded terminal meet the preset accuracy requirements.

10. The bridge panel assembly terminal welder of claim 9, wherein, The frame is also equipped with a feeding mechanism, which includes a defective product discharge component. The defective product discharge component is connected to the solder joint push-pull test mechanism, the continuity test mechanism, and the second vision detection component, respectively, and is used to discharge products that are determined to be unqualified by the solder joint push-pull test mechanism, the continuity test mechanism, or the second vision detection component.

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