An electromagnetic pulse welding device

Abstract

This invention belongs to the field of electromagnetic pulse welding technology, specifically relating to an electromagnetic pulse welding device. Several working coils each include a busbar section, a working section, and a return section arranged sequentially. The working coils are stacked along their thickness direction, with the working sections of each coil located on the same side of the stacked area. These working sections together form the welding working area. The return section of a single working coil is fixed to the busbar section of another adjacent working coil in the stacking direction. An insulating layer is provided between the unfixed portions of two adjacent working coils in the stacking direction. This invention can generate a greater Lorentz force without increasing the input current, and can more easily and flexibly extend into narrow areas such as the cap-shaped beam cavity, deep pits, or densely arranged busbar gaps inside a power battery pack for welding operations. This improves welding accessibility and broadens the application of electromagnetic pulse welding in the manufacturing of complex vehicle body structural components.

Description

Technical Field

[0001] This invention belongs to the field of electromagnetic pulse welding technology, and specifically relates to an electromagnetic pulse welding device. Background Technology

[0002] As the global new energy vehicle industry rapidly iterates towards 800V high voltage and megawatt-level super-fast charging, the thickness of the core component of the power battery conductive system—the aluminum-copper busbar—has generally increased to over 3mm. With the increasing thickness of the plates, the required welding energy is constantly increasing. Existing electromagnetic pulse (EMP) equipment, limited by the capacity of the energy storage capacitor, struggles to provide the enormous energy needed to drive a high-speed collision of thick plates. Blindly pursuing upgrades to high-energy equipment not only results in extremely high equipment costs but also leads to a bulky system size, making it difficult to meet the economic requirements of production lines. To obtain a high magnetic field at low energy, existing technologies often employ methods such as adding magnet collectors or increasing the size of the working coil. This results in a bulky welding fixture front end. Furthermore, the interior of power battery packs often contains complex structural areas such as cap-shaped beams, narrow gaps, or pits. Traditional bulky working coil structures simply cannot penetrate these narrow spaces to perform welding tasks, limiting the application of EMP welding technology in the manufacturing of complex vehicle body structural components. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide an electromagnetic pulse welding device that can generate a larger Lorentz force without increasing the input current, and can more easily and flexibly extend into narrow areas such as the cap-shaped beam cavity, deep pits or densely arranged busbar gaps inside the power battery pack for welding operations, thereby improving the accessibility of welding and expanding the application of electromagnetic pulse welding in the manufacturing of complex vehicle body structural parts.

[0004] The content of this invention includes: Several working coils are provided, each including a busbar section, a working section and a return section arranged sequentially. The busbar section and the return section are horizontally bent relative to the working section. The several working coils are stacked along their own thickness direction, and the working sections of the several working coils are located on the same side of the stacked area. The working sections of the several working coils together form a welding working area. The return section of a single working coil is fixed to the busbar section of another working coil adjacent in the stacking direction, and an insulating layer is provided between the unfixed parts of two adjacent working coils in the stacking direction. The positive terminal is connected to the busbar of the working coil of the stacked initial layer; The negative terminal is connected to the return section of the working coil of the stacked end layer.

[0005] Furthermore, it also includes an insulating housing, within which several of the working coils, as well as the positive and negative terminals, are disposed, and the surface of the insulating housing has an opening to expose the positive and negative terminals.

[0006] Furthermore, it also includes an insulating base plate, on which several of the working coils are located, and a portion of the insulating base plate passes between two adjacent working coils in the stacking direction to form the insulating layer.

[0007] Furthermore, it also includes fastening bolts, fastening blocks are provided on the insulating shell, and fixing holes are provided on the insulating base plate and several working coils. The fastening bolts pass through the aforementioned fixing holes and are connected to the fastening blocks to fix the several working coils inside the insulating shell.

[0008] Furthermore, several fastening blocks are distributed on the insulating shell, and the number of fixing holes and fastening bolts on the insulating base plate and several working coils are the same as the number of fastening blocks.

[0009] Furthermore, the thickness of the area used for fixing in the confluence and return sections is greater than the thickness of other areas in the confluence and return sections as well as the working section.

[0010] Furthermore, it also includes a first connecting block and a first connecting bolt. The return section of a single working coil and the busbar of another working coil adjacent in the stacking direction are both provided with a first connecting hole. The first connecting bolt passes through the aforementioned first connecting hole and is connected to the first connecting block, thereby fixing the return section of a single working coil and the busbar of another working coil adjacent in the stacking direction.

[0011] Furthermore, it also includes a current-guiding coil, one end of which is fixed to the return section of the working coil of the stacked end layer, and the other end of which extends away from the plurality of working coils, with the negative terminal disposed at the other end of the current-guiding coil.

[0012] Furthermore, it also includes a second connecting block and a second connecting bolt. A second connecting hole is provided on one end of the current guiding coil and the return section of the working coil of the stacked end layer. The second connecting bolt passes through the aforementioned second connecting hole and is connected to the second connecting block, thereby fixing one end of the current guiding coil to the return section of the working coil of the stacked end layer.

[0013] Furthermore, the thickness of the insulating layer is less than the thickness of the working section.

[0014] The beneficial effects of this invention are that when current flows through each layer of working coils, the current direction of the working section of each working coil is consistent. The magnetic fields excited by the multi-layer unidirectional currents are vector-superimposed in space, which multiplies the magnetic field strength in the welding working area. This generates a greater Lorentz force without increasing the input current, driving high-speed collisions of aluminum-copper busbars thicker than 3mm. This breaks through the energy bottleneck of traditional single-turn coils, which are limited by the capacity of the energy storage capacitor and cannot weld thick plates. At the same time, the width of the welding working area is narrower, so the width of the front working surface of the welding device can be made narrower, and the overall size can be made smaller. The front end of the welding device can more easily and flexibly reach into narrow areas such as the cap-shaped beam cavity, deep pits, or densely arranged busbar gaps inside the power battery pack for welding operations, improving welding accessibility and broadening the application of electromagnetic pulse welding in the manufacturing of complex vehicle body structural parts. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the electromagnetic pulse welding device of the present invention when it is equipped with an insulating outer shell.

[0016] Figure 2 This is a schematic diagram of the electromagnetic pulse welding device of the present invention after the insulating shell has been removed.

[0017] Figure 3 This is a schematic diagram of the electromagnetic pulse welding device of the present invention after the insulating base plate has been removed.

[0018] Figure 4 This is a current path diagram of the electromagnetic pulse welding device of the present invention during use.

[0019] Figure 5 This is a front view of the welding working area of ​​the electromagnetic pulse welding device of the present invention.

[0020] Figure 6 This is a top view of the welding working area of ​​the electromagnetic pulse welding device of the present invention.

[0021] Figure 7 For the present invention Figure 6 AA sectional view.

[0022] In the diagram: 1. Working coil; 1a. First working coil; 1b. Second working coil; 11. Busbar section; 12. Working section; 13. Return section; 11a. First busbar section; 12a. First working section; 13a. First return section; 11b. Second busbar section; 12b. Second working section; 13b. Second return section; 2. Positive terminal; 3. Negative terminal; 4. First connecting block; 41. First connecting bolt; 5. Conductor coil; 6. Second connecting block; 61. Second connecting bolt; 7. Insulating shell; 8. Insulating base plate; 81. Insulating layer; 9. Fastening block; 91. Fastening bolt. Detailed Implementation

[0023] like Figures 1-7 As shown, the present invention provides an electromagnetic pulse welding device, including several working coils 1, and a positive terminal 2 and a negative terminal 3. Each of the several working coils 1 includes a busbar section 11, a working section 12, and a return section 13 arranged sequentially along the current flow direction. The width of the working section 12 is smaller than the width of the busbar section 11 and the return section 13, such that the current density passing through the working section 12 is greater than the current density passing through the busbar section 11 and the return section 13. The busbar section 11 and the return section 13 are horizontally bent relative to the working section 12, that is, the busbar section 11 and the return section 13 of each working coil 1 are located on the same horizontal plane as the working section 12, and the busbar section 11 and the return section 13 are bent relative to the working section 12. Several working coils 1 are stacked along their own thickness direction, and the working segments 12 of the several working coils 1 are located on the same side of the stacked area. The stacked area is the area formed by the stacking of several working coils 1. Based on this arrangement, the working segments 12 of the several working coils 1 are arranged in the same direction, and the working segments 12 of the several working coils 1 together form the welding working area of ​​the present invention. The location of the welding working area is shown in [the diagram]. Figures 5-7 The area outlined by the dashed line. The return section 13 of a single working coil 1 is fixed to the bus section 11 of another adjacent working coil 1 in the stacking direction, so that several working coils 1 are connected in series in the stacking direction. An insulating layer 81 is provided between the unfixed portions of two adjacent working coils 1 in the stacking direction to serve as an insulating separation.

[0024] Several working coils 1 are stacked, with each layer constituting one working coil 1. Since the working coils 1 are connected in series along the stacking direction, the first working coil 1 through which the current enters is considered the stacking start layer, and the last working coil 1 through which the current flows is considered the stacking end layer. The positive terminal 2 is connected to the bus section 11 of the working coil 1 in the stacking start layer, and the negative terminal 3 is connected to the return section 13 of the working coil 1 in the stacking end layer.

[0025] Based on the above configuration, the insulating layer 81 effectively avoids electrical short circuits in non-connected areas between layers, ensures current flow along a predetermined series path, and guarantees the orderliness of magnetic field superposition and the safety of the welding process. Since the several working coils 1 are arranged in a vertically stacked manner along their own thickness direction, the current flows along the flow path of the several working coils 1 as follows... Figure 4As shown, when current flows through each layer of working coil 1, the current direction of each working section 12 of working coil 1 is consistent. The magnetic fields excited by the multi-layer unidirectional currents are vector-superimposed in space, which multiplies the magnetic field strength in the welding working area. This generates a greater Lorentz force without increasing the input current, driving high-speed collisions of aluminum-copper busbars thicker than 3mm. This breaks through the energy bottleneck of traditional single-turn coils, which are limited by the capacity of the energy storage capacitor, making it impossible to weld thick plates. At the same time, the width of the welding working area is narrower, so the width of the front working surface of the welding device can be made narrower, and the overall size is smaller. The front end of the welding device can more easily and flexibly reach into narrow areas such as the cap-shaped beam cavity, deep pits, or densely arranged busbar gaps inside the power battery pack for welding operations, improving welding accessibility and broadening the application of electromagnetic pulse welding in the manufacturing of complex vehicle body structural parts.

[0026] The invention also includes an insulating housing 7, within which several of the working coils 1, as well as the positive and negative terminals 2 and 3, are disposed. The insulating housing 7 has openings on its surface to expose the positive and negative terminals 2 and 3. The insulating housing 7 provides insulating and rigid support for the working coils 1, ensuring structural rigidity during high-voltage discharge. The opening design ensures that the positive and negative terminals 2 and 3 can be easily electrically connected to an external pulse power supply.

[0027] The present invention also includes an insulating base plate 8, on which several working coils 1 are located. A portion of the insulating base plate 8 is inserted between two adjacent working coils 1 in the stacking direction to form the insulating spacer layer 81. Based on this arrangement, the insulating base plate 8 can serve as a supporting structure for the working coils 1, and can also be used as an insulating layer between the working coils 1 through a portion of its own area. The specific shape or number of insulating base plates 8 depends on the working coils 1 used in the actual application.

[0028] The invention also includes a fastening bolt 91, and a fastening block 9 is provided on the insulating shell 7, with a threaded hole on the fastening block 9. The insulating base plate 8 and the plurality of working coils 1 are each provided with fixing holes. The fastening bolt 91 passes through the aforementioned fixing holes and connects to the fastening block 9, thereby clamping the insulating base plate 8 and the plurality of working coils 1 between the head of the fastening bolt 91 and the fastening block 9, thus fixing the plurality of working coils 1 inside the insulating shell 7. This arrangement achieves reliable fixation of the plurality of working coils 1 within the insulating shell 7, effectively resisting the huge transient electromagnetic force impact generated during electromagnetic pulse welding, preventing the working coils 1 from shifting or separating during high-voltage discharge, and ensuring the electrical connection stability and magnetic field superposition consistency between the layers of working coils 1. Simultaneously, this fixing method makes the assembly and disassembly of the plurality of working coils 1 more convenient, providing a structural basis for subsequent maintenance and single-layer replacement.

[0029] like Figure 1 As shown, several fastening blocks 9 are distributed on the insulating shell 7. The fastening blocks 9 are specifically embedded inside the insulating shell 7 and do not occupy the thickness of the insulating shell 7. Figure 2 As shown, the number of fixing holes, fastening bolts 91, and fastening blocks 9 on the insulating base plate 8 and several working coils 1 are the same. This multi-point distributed fastening structure ensures more uniform clamping force across the working coils 1, further enhancing the overall structural rigidity of the device under high-voltage pulse impact, and ensuring reliability and stability during long-term repeated use. The fastening bolts 91 and fastening blocks 9 can be made of non-conductive materials or have an insulating layer on their surface to avoid interference with interlayer current paths.

[0030] like Figure 3 As shown, the thickness of the area used for fixing in the confluence section 11 and return section 13 is greater than the thickness of other areas in the confluence section 11 and return section 13, as well as the thickness of the working section 12. Based on this setting, as... Figure 5 and Figure 7 As shown, after the return section 13 of a single working coil 1 is fixed to the bus section 11 of another working coil 1 adjacent in the stacking direction, there is a certain gap between the unfixed parts of the two adjacent working coils 1, and this gap is the arrangement space of the insulating layer 81.

[0031] The present invention also includes a first connecting block 4 and a first connecting bolt 41. The first connecting block 4 has a threaded hole. A first connecting hole is provided on the return section 13 of each individual working coil 1 and the busbar section 11 of another adjacent working coil 1 in the stacking direction. Specifically, the first connecting hole is located in the area where the busbar section 11 and the return section 13 are fixed. The first connecting bolt 41 passes through the aforementioned first connecting hole and connects to the first connecting block 4, so that the return section 13 of the working coil 1 and the busbar section 11 of another adjacent working coil 1 in the stacking direction are clamped between the head of the first connecting bolt 41 and the first connecting block 4, thereby fixing the return section 13 of each individual working coil 1 and the busbar section 11 of another adjacent working coil 1 in the stacking direction. This fixing method allows for reliable fixing between the working coils 1 in each layer, making the assembly and disassembly of the working coils 1 in each layer more convenient, and providing a structural basis for subsequent maintenance and single-layer replacement.

[0032] In this invention, the insulating base plate 8 and the working coil 1 are preferably separate components. The insulating base plate 8 is fixed to the working coil 1 by fastening bolts 91 and fastening blocks 9, and the insulating layer 81 is in close contact with the adjacent working coil 1. Combined with the method of fixing the interlayer working coil 1 by the first connecting block 4 and the first connecting bolt 41, the whole is designed as a flexible modular design, which includes easy maintenance: if a working coil 1 of a certain layer is damaged due to fatigue, the working coil 1 can be replaced simply by unscrewing the fastening bolt 91, without scrapping the whole thing, which greatly reduces the cost of use; and it also includes scalability: according to the thickness requirements of the workpiece to be welded, the number of working coils 1 can be increased or decreased more flexibly, and the number of insulating base plates 8 and the fastening bolts 91 of the corresponding length can be increased or decreased accordingly, so as to realize "building block" assembly and adapt to welding tasks of different specifications.

[0033] The invention also includes a current-guiding coil 5, one end of which is fixed to the return section 13 of the working coil 1 of the laminated end layer, and the other end of which extends away from the plurality of working coils 1. The negative terminal 3 is disposed at the other end of the current-guiding coil 5. This arrangement allows the negative terminal 3 to be positioned further away from the working coils 1, reducing the impact of impact forces on the negative terminal 3 during welding. The current-guiding coil 5 is fixed to the insulating shell 7 and the insulating base plate 8 in the same manner as the working coils 1.

[0034] The invention also includes a second connecting block 6 and a second connecting bolt 61. The second connecting block 6 has a threaded hole, and a second connecting hole is provided on one end of the flow guiding coil 5 and the return section 13 of the working coil 1 of the stacked end layer. The second connecting bolt 61 passes through the aforementioned second connecting hole and connects to the second connecting block 6, so that one end of the flow guiding coil 5 and the return section 13 of the working coil 1 of the stacked end layer are clamped between the head of the second connecting bolt 61 and the second connecting block 6, thereby fixing one end of the flow guiding coil 5 to the return section 13 of the working coil 1 of the stacked end layer. This fixing method can reliably fix the coil and makes disassembly and assembly more convenient, providing a structural basis for subsequent maintenance and single-layer replacement.

[0035] The thickness of working coil 1 is Figure 5 and Figure 7 The height of a single working coil 1 as seen from this angle, and the width of the welding working area are respectively... Figure 5 and Figure 7 The height of the area outlined by the dashed line from the viewing angle. Preferably, the thickness of the insulating layer 81 is less than the thickness of the working section 12 to avoid excessively occupying the width of the welding working area and to facilitate a narrow design of the welding working area width. The width of the working surface at the front end of the welding device is the dimension of the insulating shell 7 along the width direction of the welding working area (which can be regarded as the thickness dimension of the shell).

[0036] In one embodiment of the present invention, the insulating shell 7 is disposed through the back side, and several working coils 1 and insulating base plate 8 are installed inside the insulating shell 7 along the back side of the insulating shell 7, with the outermost insulating base plate 8 forming the back plate of the insulating shell 7. In other embodiments of the present invention, a back plate is also provided on the back side of the insulating shell 7. After several working coils 1 and insulating base plate 8 are installed inside the insulating shell 7 along the back side of the insulating shell 7, the back plate is fixed to the back side of the insulating shell 7 by bolts to achieve sealing.

[0037] like Figures 2-7 As shown, taking an example with two working coils 1, the two working coils 1 are a first working coil 1a and a second working coil 1b. The first working coil 1a includes a first busbar section 11a, a first working section 12a, and a first return section 13a arranged sequentially. The second working coil 1b includes a second busbar section 11b, a second working section 12b, and a second return section 13b arranged sequentially. The positive terminal 2 is disposed on the first busbar section 11a. The first busbar section 11a is fixed to the second busbar section 11b by a first connecting block 4 and a first connecting bolt 41. One end of the current-conducting coil 5 is fixed to the second return section 13b by a second connecting block 6 and a second connecting bolt 61. The negative terminal 3 is disposed on the other end of the current-conducting coil 5. The first working section 12a and the second working section 12b are stacked in the thickness direction. The current path is as follows. Figure 4 As shown, the magnetic fields generated by the two layers of unidirectional currents passing through the first working section 12a and the second working section 12b are vector superimposed in space.

[0038] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of protection of this application is limited to these examples; within the framework of this application, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of one or more embodiments of this application as described above, which are not provided in detail for the sake of brevity.

[0039] One or more embodiments in this application are intended to cover all such substitutions, modifications, and variations that fall within the broad scope of this application. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of one or more embodiments in this application should be included within the protection scope of this application.

Claims

1. An electromagnetic pulse welding apparatus, characterized in that it comprises: Several working coils (1) are provided, each of which includes a busbar (11), a working section (12) and a return section (13) arranged in sequence. The busbar (11) and the return section (13) are arranged in a horizontally bent manner relative to the working section (12). The several working coils (1) are stacked along their own thickness direction, and the working sections (12) of the several working coils (1) are located on the same side of the stacked area. The working sections (12) of the several working coils (1) together form a welding working area. The return section (13) of a single working coil (1) is fixed to the busbar (11) of another working coil (1) adjacent in the stacking direction. An insulating layer (81) is provided between the unfixed parts of two adjacent working coils (1) in the stacking direction. The positive terminal (2) is connected to the bus section (11) of the working coil (1) of the stacked starting layer; The negative terminal (3) is connected to the return section (13) of the working coil (1) of the stacked end layer.

2. The electromagnetic pulse welding apparatus as described in claim 1, characterized in that, It also includes an insulating shell (7), several of the working coils (1) and the positive terminal (2) and negative terminal (3) are disposed inside the insulating shell (7), and the surface of the insulating shell (7) is provided with an opening to expose the positive terminal (2) and negative terminal (3).

3. The electromagnetic pulse welding apparatus as described in claim 2, characterized in that, It also includes an insulating base plate (8), on which several of the working coils (1) are located, and a portion of the insulating base plate (8) is inserted between two adjacent working coils (1) in the stacking direction to form the insulating layer (81).

4. The electromagnetic pulse welding apparatus as described in claim 3, characterized in that, It also includes fastening bolts (91), fastening blocks (9) are provided on the insulating shell (7), and fixing holes are provided on the insulating base plate (8) and several working coils (1). The fastening bolts (91) pass through the aforementioned fixing holes and are connected to the fastening blocks (9) so that the several working coils (1) are fixed inside the insulating shell (7).

5. The electromagnetic pulse welding apparatus as described in claim 4, characterized in that, Several fastening blocks (9) are distributed on the insulating shell (7). The number of fixing holes and fastening bolts (91) on the insulating base plate (8) and several working coils (1) are the same as the number of fastening blocks (9).

6. The electromagnetic pulse welding apparatus according to any one of claims 1-5, characterized in that, The thickness of the area used for fixing in the confluence section (11) and return section (13) is greater than the thickness of the other areas of the confluence section (11) and return section (13) and the working section (12).

7. The electromagnetic pulse welding apparatus as described in claim 6, characterized in that, It also includes a first connecting block (4) and a first connecting bolt (41). The return section (13) of a single working coil (1) and the busbar section (11) of another working coil (1) adjacent in the stacking direction are both provided with a first connecting hole. The first connecting bolt (41) passes through the aforementioned first connecting hole and is connected to the first connecting block (4), thereby fixing the return section (13) of a single working coil (1) and the busbar section (11) of another working coil (1) adjacent in the stacking direction.

8. The electromagnetic pulse welding apparatus according to any one of claims 3-5, characterized in that, It also includes a current-guiding coil (5), one end of which is fixed to the return section (13) of the working coil (1) of the stacked end layer, the other end of which extends away from the working coils (1), and the negative terminal (3) is disposed at the other end of the current-guiding coil (5).

9. The electromagnetic pulse welding apparatus as described in claim 8, characterized in that, It also includes a second connecting block (6) and a second connecting bolt (61). A second connecting hole is provided on one end of the flow guiding coil (5) and the return section (13) of the working coil (1) of the stacked end layer. The second connecting bolt (61) passes through the aforementioned second connecting hole and is connected to the second connecting block (6), thereby fixing one end of the flow guiding coil (5) to the return section (13) of the working coil (1) of the stacked end layer.

10. The electromagnetic pulse welding apparatus according to any one of claims 1-5, 7, and 9, characterized in that, The thickness of the insulating layer (81) is less than the thickness of the working section (12).

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