A harness terminal laser welding apparatus

Abstract

The present application belongs to the technical field of wire harness welding equipment, especially a wire harness terminal laser welding equipment, aiming at the problem of insufficient comprehensiveness of quality detection after welding of the terminal and the wire harness of the prior art, the following scheme is proposed, including a welding main body, the welding main body: including a welding table, a side support, a laser welding head is installed on the side wall of the side support, and an indicator light is fixed on the side of the welding table. The present application is provided with a double-dimension intelligent data determination system, which respectively collects welding stability and welding position precision data through a welding stability detection module and a welding position detection module, generates a comprehensive judgment coefficient through weighted operation, realizes digital and standardized determination of welding quality, replaces the traditional subjective experience determination method, the determination result is accurate and objective, and the qualified products and the unqualified products can be effectively distinguished, and at the same time, the visual early warning is realized through the indicator light, so that the production state can be grasped by the staff in real time, and the equipment exception can be checked in time.

Description

Technical Field

[0001] This invention relates to the field of wire harness welding equipment technology, and more particularly to a laser welding equipment for wire harness terminals. Background Technology

[0002] Wire harness terminals are core components of electrical connection systems in fields such as new energy vehicles, smart home appliances, aerospace, and industrial automation. They mainly realize the conduction and fixation between wire harnesses and circuit terminals. The welding quality directly determines the conductivity stability, safety, reliability, and service life of electrical equipment. With the rapid development of electrical equipment towards miniaturization, high precision, and high integration, the market has put forward higher standards for the welding precision, welding consistency, yield rate, and production efficiency of wire harness terminals. Laser welding, with its advantages of small heat-affected zone, high welding precision, small deformation, high degree of automation, and suitability for welding small and precision workpieces, is gradually replacing traditional crimping, resistance welding, and ultrasonic welding processes, becoming the mainstream technology for precision welding of wire harness terminals.

[0003] For example, Chinese patent document CN117718594B discloses an apparatus for laser welding of wire harness terminals, including a fixed base, a movable base, and an elastic connecting assembly. The method for laser welding of wire harness terminals includes: shielding the area around the welding region of the wire harness before welding; adjusting the positions of the laser welding head, wire feed tube, and protective gas tube, positioning the laser welding head above the wire harness, and positioning the wire feed tube and protective gas tube between the laser welding head and the wire harness, and then performing the welding operation. The aforementioned patent-disclosed technology has the following problems: after welding the terminals to the wire harness, it is impossible to determine core quality indicators such as the internal stability of the weld and the weld joint strength, resulting in insufficient comprehensive quality inspection. Existing technologies do not easily solve these problems; therefore, laser welding equipment for wire harness terminals is urgently needed to address these issues. Summary of the Invention

[0004] To address the technical problem of insufficient comprehensiveness in quality inspection after welding terminals and wire harnesses in existing technologies, this invention proposes a laser welding device for wire harness terminals.

[0005] The present invention proposes a laser welding device for wire harness terminals, comprising a welding body, which includes a welding table and a side support. A laser welding head is installed on the side wall of the side support. An indicator light is fixed on the side of the welding table. A processor is installed inside the welding table. The processor is equipped with a welding stability detection module, a welding position detection module, and a data processing module. A positioning component is installed on the top of the welding station, and a wire harness terminal body is inserted inside the positioning component. A stability detection component is installed on the top of the welding station, and a vision detection component is installed on the bottom of the laser welding head. The stability detection component includes a stepper motor, and the vision detection component includes a vision detection camera. Stability testing component: includes a welding base, with a horizontal welding reference surface on the top of the welding base, and arc-shaped base guide sections on both sides of the welding reference surface.

[0006] Preferably, the positioning component includes a feeding positioning base, a discharging positioning base, and two guiding auxiliary wheels. The two guiding auxiliary wheels are fixed on both sides of the welding table, and the bottom of both the feeding positioning base and the discharging positioning base are provided with guiding ports.

[0007] Preferably, the wire harness terminal body includes a terminal strip, terminals, and a wire harness, with the terminal array fixedly distributed on top of the terminal strip.

[0008] Preferably, the welding base has base side grooves on both sides, and sliding side blocks are installed in the base side grooves on both sides. The welding base also has a sliding groove inside, and the end of the sliding side block is provided with a slider, which is matched and slidably installed with the sliding groove.

[0009] Preferably, a bidirectional lead screw is installed in the slide groove, and the bidirectional lead screw is threadedly connected to the sliders on both sides. End caps are installed on both sides of the welding base to close the slide grooves on both sides. A lead screw motor is fixed on the end cap located on one side, and the output shaft of the lead screw motor is fixed to the bidirectional lead screw.

[0010] Preferably, a pneumatic push rod is fixed to the end of the sliding side block, two air inlet heads are provided on the top of the welding base, the air inlet heads are connected to the pneumatic push rod, a clamping box is fixed to the end of the pneumatic push rod, two rotating rollers are installed inside one side of the clamping box, and a clamping belt is sleeved between the two rotating rollers, the stepper motor is fixed to the rotating shaft of one of the rotating rollers, and the stepper motor is installed inside the clamping box.

[0011] Preferably, the visual inspection component includes: a fixing frame fixed to the bottom of the laser welding head, a mounting cylinder fixed to the bottom of the fixing frame, and the visual inspection camera fixed inside the mounting cylinder.

[0012] Preferably, the welding stability detection module is used to receive the detection data from the stepper motor. During the detection process, the data detected by the stepper motor provides feedback on the welding stability. The module analyzes and processes the detected data to generate a welding stability coefficient F. The welding stability detection module then transmits the generated welding stability coefficient F to the data processing module in the processor.

[0013] Preferably, the welding position detection module is used to receive detection data fed back by the visual inspection camera. During detection, the data detected by the visual inspection camera reflects the welding position effect after welding. The module analyzes and processes the detected data to generate a welding position coefficient D. The welding position detection module then transmits the generated welding position coefficient D to the data processing module in the processor.

[0014] Preferably, the data processing module is used to communicate with the welding stability detection module and the welding position detection module in the processor, receive the welding stability coefficient F and the welding position coefficient D, and perform a weighted calculation on the obtained welding stability coefficient F and welding position coefficient D to obtain the judgment coefficient S. The judgment coefficient S is compared with the preset threshold S1, and the processor controls the state of the indicator light.

[0015] The beneficial effects of this invention are as follows: This laser welding equipment for wire harness terminals is equipped with a dual-dimensional intelligent data judgment system. The welding stability detection module and the welding position detection module collect welding stability and welding position accuracy data respectively. Through weighted calculation, a comprehensive judgment coefficient is generated to realize the digital and standardized judgment of welding quality, replacing the traditional subjective experience judgment method. The judgment results are accurate and objective, and can effectively distinguish between qualified products and defective products. At the same time, visual early warning is provided through indicator lights, which makes it easy for staff to keep abreast of the production status and promptly check for equipment abnormalities. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of a laser welding device for wire harness terminals proposed in this invention; Figure 2 This is a partial structural diagram of the welding table of a laser welding equipment for wire harness terminals proposed in this invention; Figure 3 This is a partial structural diagram of the welding base of a laser welding device for wire harness terminals proposed in this invention; Figure 4 This is a partial structural diagram of the visual inspection component of a laser welding equipment for wire harness terminals proposed in this invention; Figure 5 This is a schematic diagram illustrating the control principle of a laser welding device for wire harness terminals proposed in this invention.

[0017] In the picture: 100. Welding body; 101. Welding table; 102. Side support; 103. Laser welding head; 104. Indicator light; 200. Positioning component; 201. Feeding positioning base; 202. Discharge positioning base; 203. Guide wheel; 300. Stability detection component; 301. Welding base; 302. Base side groove; 303. Air inlet head; 304. Sliding side block; 305. Clamping box; 306. Clamping belt; 307. Pneumatic push rod; 308. Limiting slide rod; 309. Screw motor; 310. Bidirectional screw; 311. Slide groove; 312. Slider; 313. Base guide section; 400. Visual inspection component; 401. Mounting bracket; 402. Mounting cylinder; 403. Visual inspection camera; 500, Wire harness terminal body; 501, Terminal strip; 502, Terminal; 503, Wire harness. Detailed Implementation

[0018] Reference Figures 1-4 A laser welding device for wire harness terminals includes a welding body 100, which includes a welding table 101 and a side support 102. A laser welding head 103 is installed on the side wall of the side support 102. The laser welding head 103 adopts a fiber laser welding structure, which has a fine spot and low heat input, making it suitable for precision wire harness terminal welding operations. The side support 102 is welded from high-strength aluminum alloy profiles, which has strong structural rigidity and is not easily deformed, ensuring the long-term stability of the installation position of the laser welding head 103. An indicator light 104 is fixed on the side of the welding table 101. A processor is installed inside the welding table 101. The processor is equipped with a welding stability detection module, a welding position detection module, and a data processing module.

[0019] Indicator light 104 corresponds to three working states: equipment standby, welding qualified, and welding abnormal, respectively, realizing a visual display of equipment working status and welding quality.

[0020] A positioning component 200 is installed on the top of the welding table 101, and a wire harness terminal body 500 is installed inside the positioning component 200. A stabilization detection component 300 is installed on the top of the welding table 101, and a vision detection component 400 is installed at the bottom of the laser welding head 103. The stabilization detection component 300 includes a stepper motor, and the vision detection component 400 includes a vision detection camera 403. The vision detection camera 403 is the core component and has high-definition image acquisition, high-speed transmission, and intelligent recognition functions.

[0021] Reference Figures 1-3The stability detection component 300 includes a welding base 301. The top of the welding base 301 is provided with a horizontal welding reference surface. The top of the welding base 301 is ground to form a high-precision horizontal welding reference surface, ensuring the horizontality of the welding operation and avoiding welding deformation from the structural basis. Both sides of the welding reference surface are provided with arc-shaped base guide parts 313. The arc-shaped guide structure can realize the smooth introduction and export of the wire harness terminal body 500, avoid sharp structures scratching the terminal material strip 501 and wire harness 503, and at the same time reduce feeding jamming resistance and improve feeding smoothness. The stability detection component 300 is arranged directly below the laser welding head 103, providing stable clamping support and process detection for the welding operation.

[0022] Reference Figure 1 Furthermore, the positioning component 200 includes a feeding positioning base 201, a discharging positioning base 202, and two guiding auxiliary wheels 203. The two guiding auxiliary wheels 203 are fixed on both sides of the welding table 101, corresponding to the left and right sides of the feeding channel. The bottom of both the feeding positioning base 201 and the discharging positioning base 202 is provided with a guiding port.

[0023] Reference Figure 1 and Figure 2 Furthermore, the wire harness terminal body 500 includes terminal strip 501, terminals 502 and wire harness 503. The terminals 502 are arrayed and fixed on the top of the terminal strip 501. The terminal strip 501 adopts a roll feeding method, which can realize uninterrupted continuous welding production.

[0024] Furthermore, both sides of the welding base 301 are provided with base side grooves 302, and sliding side blocks 304 are installed in both sides of the base side grooves 302. The welding base 301 is also provided with a sliding groove 311. The end of the sliding side block 304 is provided with a slider 312, and the slider 312 is matched with the sliding groove 311 for sliding installation.

[0025] Furthermore, a bidirectional lead screw 310 is installed inside the slide groove 311. The bidirectional lead screw 310 is threadedly connected to the sliders 312 on both sides. The two sections of the bidirectional lead screw 310 have opposite threads but the same pitch, which can drive the sliders 312 on both sides to move synchronously towards or away from each other. End caps are installed on both sides of the welding base 301 to close the slide grooves 311 on both sides. A lead screw motor 309 is fixed on one side of the end cap. The output shaft of the lead screw motor 309 is fixed to the bidirectional lead screw 310. The lead screw motor 309 provides precise driving power to the bidirectional lead screw 310. The opening and closing distance of the sliding side blocks 304 on both sides can be controlled by forward and reverse rotation to adapt to the inspection after welding of terminals 502 of different widths.

[0026] Furthermore, a pneumatic push rod 307 is fixed to the end of the sliding side block 304, and two air inlet heads 303 are provided on the top of the welding base 301. The air inlet heads 303 are connected to the pneumatic push rod 307. A clamping box 305 is fixed to the end of the pneumatic push rod 307. Two rotating rollers are installed inside one side of the clamping box 305, and a clamping belt 306 is sleeved between the two rotating rollers. A stepper motor is fixed to the rotating shaft of one of the rotating rollers. The stepper motor is installed inside the clamping box 305. When testing the welding stability effect, the lead screw motor 309 first clamps the clamping boxes 305 on both sides and the terminal 502. The operator holds the wire harness 503, and then the pneumatic push rod 307 retracts. At this time, due to the clamping effect, the clamping belt 306 will give the stepper motor a rotation effect. The stepper motor rotates and feeds the data back to the stability detection module.

[0027] Furthermore, the visual inspection component 400 includes: a mounting bracket 401 fixed to the bottom of the laser welding head 103, a mounting cylinder 402 fixed to the bottom of the mounting bracket 401, and a visual inspection camera 403 fixed inside the mounting cylinder 402.

[0028] Welding stability detection module: This module receives detection data from the stepper motor. During the detection process, the data detected by the stepper motor reflects the welding stability. The module analyzes and processes the detected data to generate a welding stability coefficient F. The welding stability detection module then transmits the generated welding stability coefficient F to the data processing module in the processor.

[0029] Welding position detection module: Used to receive detection data fed back by visual inspection camera 403. During detection, the data detected by visual inspection camera 403 reflects the welding position effect after welding. The module analyzes and processes the detected data to generate welding position coefficient D. The welding position detection module transmits the generated welding position coefficient D to the data processing module in the processor.

[0030] Data processing module: Used to communicate with the welding stability detection module and welding position detection module in the processor, receive the welding stability coefficient F and welding position coefficient D, and perform weighted calculation on the obtained welding stability coefficient F and welding position coefficient D to obtain the judgment coefficient S. The judgment coefficient S is compared with the preset threshold S1. The processor controls the state of the indicator light 104. The calculation expression of the judgment coefficient S is as follows.

[0031] S = α × F + β × D Where: α is the weighting coefficient of welding stability coefficient F, and β is the weighting coefficient of welding position coefficient D.

[0032] During the intelligent judgment and detection process, if S≤S1, it means that the welding of terminal 502 and wire harness 503 is qualified, and indicator light 104 lights up green; if S>S1, it means that the welding of terminal 502 and wire harness 503 is unqualified, and indicator light 104 lights up red; during the welding process, indicator light 104 is yellow, indicating that the equipment is performing welding detection work.

[0033] When using this invention: The first step is equipment debugging and parameter setting. The staff connects the power supply and pneumatic air source of the equipment, and presets the welding parameters, detection weighting coefficient, and judgment coefficient threshold S1 through the equipment control panel. According to the width and thickness specifications of the wire harness terminal body 500 to be processed, the appropriate feeding positioning base 201, discharging positioning base 202 and guiding auxiliary wheel 203 on the top are replaced to complete the equipment adaptation and debugging.

[0034] The second step is material threading and alignment. The coiled terminal strip 501 is threaded into the feed port of the feeding positioning base 201, passes through the welding reference surface of the welding base 301, and exits from the feed port of the discharge positioning base 202. The guide wheels 203 on both sides complete the limiting and guiding, ensuring that the feeding path of the wire harness terminal body 500 is straight and without deviation. The docking position of the terminal 502 and the wire harness 503 is adjusted to complete the initial alignment.

[0035] The third step is automated welding. The automatic operation program of the equipment is started. During the feeding process, the operation of the feeding and discharging equipment is matched with the array spacing of the terminals 502, ensuring that each terminal 502 accurately corresponds to the welding point of the laser welding head 103. The operator places the wire harness 503 on top of the terminal 502. After the material is fed in place, the laser welding head 103 is started to complete the laser welding operation between the terminal 502 and the wire harness 503.

[0036] The fourth step is real-time detection and intelligent judgment. Throughout the welding process, after a single weld is completed, the pneumatic push rod 307 extends to both sides of the welded terminal 502. The lead screw motor 309 drives the clamping boxes 305 on both sides to approach the terminal 502, and clamps the terminal 502 through the clamping belt 306. The operator holds the wire harness 503, and then the pneumatic push rod 307 retracts. At this time, due to the clamping effect, the clamping belt 306 will give the stepper motor a rotation effect. The stepper motor rotates and feeds the data back to the stability detection module to calculate the welding stability coefficient F. After a single weld is completed, the visual inspection camera 403 instantly captures the weld image, and the welding position detection module calculates the welding position coefficient D. The data processing module completes the weighted calculation to obtain the judgment coefficient S, and combines it with the threshold S1 to complete the welding quality judgment. The welding result is displayed through the indicator light 104.

[0037] The fifth step involves continuous production and troubleshooting. The equipment repeats the feeding, welding, and inspection processes described above to achieve automated batch production. If a red alert is issued, the equipment can stop or mark defective products according to a preset program. Staff can promptly check for issues such as clamping status, feeding accuracy, and laser parameters, and resume production after troubleshooting.

[0038] To further verify the actual performance, testing accuracy, and mass production adaptability of the equipment of the present invention, this embodiment uses the aforementioned laser welding equipment for wire harness terminals to conduct a batch welding processing test on low-voltage wire harness terminals for new energy vehicles. A conventional mass-produced wire harness terminal body is selected, wherein the terminal strip width is 18mm and the thickness is 0.3mm, the terminal is a copper-plated gold precision terminal, and the wire harness is a 24-strand 0.12mm tin-plated copper wire harness, matching the mainstream precision welding process requirements of the industry. In this embodiment, all parameters, weighting coefficients, and judgment coefficient thresholds of the equipment adopt the optimal parameters for industrial mass production. A control group is also set up for performance comparison with traditional welding equipment.

[0039] The equipment debugging parameters in this embodiment are set as follows: the lead screw motor drives the bidirectional lead screw to adjust the clamping distance on both sides to adapt to the current width of the terminal, so that the clamping belts on both sides can fit tightly with the two sides of the terminal, and the clamping pressure is kept constant at 0.2MPa, which not only ensures that the clamping is tight and there is no loosening, but also avoids excessive pressure squeezing and deforming the terminal, and ensures that the feeding speed is uniform and stable; the laser welding head uses a continuous fiber laser, with the welding power set to 80W, the welding speed to 50mm / s, and the spot diameter to 0.8mm, which is suitable for the precision welding requirements of copper terminals and tin-plated wire harnesses.

[0040] The detection system parameters are configured as follows: Based on the welding process standards for new energy wiring harnesses, the system emphasizes welding stability and conductive connection reliability. The weighting is adjusted to α=0.6 and β=0.4 to strengthen the judgment proportion of the welding stability coefficient, which meets the high stability requirements of vehicle wiring harnesses. The quality judgment threshold S1 is set to 0.6, consistent with the general precision welding judgment standard. The welding stability detection module collects the stepper motor speed fluctuation and load torque data in real time, with the sampling frequency set to 100Hz to ensure that no data is missed throughout the welding process. The visual inspection camera has 20 million pixels and an image sampling frame rate of 30 frames / second. After welding is completed, the weld image is captured instantly to complete the alignment accuracy and weld formation detection.

[0041] Welding qualification condition: After the terminal and wire harness are welded, the welding stability coefficient F fed back by the welding stability detection module is 0.5 and the welding position coefficient D fed back by the welding position detection module is 0.8. Then S=0.6×0.5+0.4×0.3=0.42. Therefore, S≤0.6 indicates that the welding of the terminal and wire harness is qualified and the indicator light turns green.

[0042] Welding failure condition: After the terminal and wire harness are welded, the welding stability coefficient F fed back by the welding stability detection module is 0.7 and the welding position coefficient D fed back by the welding position detection module is 0.8. Then S=0.6×0.7+0.4×0.8=0.74. S>0.6 indicates that the welding of the terminal and wire harness is unqualified, and the indicator light will turn red.

[0043] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A laser welding device for wire harness terminals, comprising a welding body (100), characterized in that, Welding body (100): includes welding table (101) and side support (102). A laser welding head (103) is installed on the side wall of the side support (102). An indicator light (104) is fixed on the side of the welding table (101). A processor is installed inside the welding table (101). The processor is equipped with a welding stability detection module, a welding position detection module, and a data processing module. A positioning component (200) is installed on the top of the welding table (101), and a wire harness terminal body (500) is inserted inside the positioning component (200). A stability detection component (300) is installed on the top of the welding table (101), and a vision detection component (400) is installed on the bottom of the laser welding head (103). The stability detection component (300) includes a stepper motor, and the vision detection component (400) includes a vision detection camera (403). Stable detection component (300): includes a welding base (301), the top of the welding base (301) is provided with a horizontal welding reference surface, and both sides of the welding reference surface are provided with an arc-shaped base guide part (313).

2. The laser welding equipment for wire harness terminals according to claim 1, characterized in that, The positioning component (200) includes a feeding positioning base (201), a discharging positioning base (202), and two guiding auxiliary wheels (203). The two guiding auxiliary wheels (203) are fixed on both sides of the welding table (101), and the bottom of the feeding positioning base (201) and the discharging positioning base (202) are provided with guiding ports.

3. The laser welding equipment for wire harness terminals according to claim 1, characterized in that, The wire harness terminal body (500) includes a terminal strip (501), terminals (502) and a wire harness (503), with the terminals (502) arranged in an array and fixed on the top of the terminal strip (501).

4. The laser welding equipment for wire harness terminals according to claim 1, characterized in that, Both sides of the welding base (301) are provided with base side grooves (302), and sliding side blocks (304) are installed in both sides of the base side grooves (302). The welding base (301) is also provided with a sliding groove (311). The end of the sliding side block (304) is provided with a slider (312), and the slider (312) is matched with the sliding groove (311) for sliding installation.

5. The laser welding equipment for wire harness terminals according to claim 4, characterized in that, A bidirectional lead screw (310) is installed in the slide groove (311). The bidirectional lead screw (310) is threadedly connected to the sliders (312) on both sides. End caps are installed on both sides of the welding base (301) to close the slide grooves (311) on both sides. A lead screw motor (309) is fixed on the end cap located on one side. The output shaft of the lead screw motor (309) is fixed to the bidirectional lead screw (310).

6. The laser welding equipment for wire harness terminals according to claim 5, characterized in that, The end of the sliding side block (304) is fixed with a pneumatic push rod (307). The top of the welding base (301) is provided with two air inlet heads (303). The air inlet heads (303) are connected to the pneumatic push rod (307). The end of the pneumatic push rod (307) is fixed with a clamping box (305). Two rotating rollers are installed inside one side of the clamping box (305), and a clamping belt (306) is sleeved between the two rotating rollers. The stepper motor is fixed to the rotating shaft of one of the rotating rollers. The stepper motor is installed inside the clamping box (305).

7. The laser welding equipment for wire harness terminals according to claim 1, characterized in that, The visual inspection component (400) includes: a mounting bracket (401) fixed to the bottom of the laser welding head (103), a mounting cylinder (402) fixed to the bottom of the mounting bracket (401), and the visual inspection camera (403) fixed inside the mounting cylinder (402).

8. The laser welding equipment for wire harness terminals according to claim 1, characterized in that, Welding stability detection module: This module receives detection data from the stepper motor. During the detection process, the data detected by the stepper motor reflects the welding stability. The module analyzes and processes the detected data to generate a welding stability coefficient F. The welding stability detection module then transmits the generated welding stability coefficient F to the data processing module in the processor.

9. A laser welding device for wire harness terminals according to claim 8, characterized in that, Welding position detection module: used to receive detection data fed back by visual inspection camera (403). During detection, the data detected by visual inspection camera (403) reflects the welding position effect after welding. The detected data is analyzed and processed to generate welding position coefficient D. The welding position detection module transmits the generated welding position coefficient D to the data processing module in the processor.

10. A laser welding device for wire harness terminals according to claim 1, characterized in that, Data processing module: used to communicate with the welding stability detection module and welding position detection module in the processor, receive the welding stability coefficient F and welding position coefficient D, and perform weighted calculation on the obtained welding stability coefficient F and welding position coefficient D to obtain the judgment coefficient S. The judgment coefficient S is compared with the preset threshold S1, and the status of the indicator light (104) is controlled by the processor.

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