Continuous high frequency welding integrated flow process

Abstract

The application discloses a kind of integrated flow process of continuous high-frequency welding, it is related to high-frequency welding field.The equipment of the present application adopts integrated rack structure, effectively suppresses vibration, guarantees running stability;High-frequency welding equipment includes three welding stations and two discharging stations, discharging station is located in the middle of welding station, forms discharging and welding station interval arrangement, control mechanism, equipment main base.High-frequency welding equipment carries welding program storage function and automatic current control system, can store, retrieve multiple groups of welding process parameters, and according to workpiece type, welding position intelligent adaptation welding current.The present application solves the problems of low production efficiency, single equipment action form, high labor cost, poor flexibility of station control, complex multi-process switching, large equipment vibration, complex parameter debugging, weak welding energy adaptability and other problems of traditional equipment, with high production efficiency, stable operation, high positioning accuracy, simple operation, low labor and time cost, strong process versatility and other characteristics.

Description

Technical Field

[0001] This invention belongs to the field of high-frequency welding, and specifically relates to high-frequency welding technology. Background Technology

[0002] High-frequency welding machines utilize high-frequency electromagnetic fields to cause intense collisions and heat generation within plastic materials such as PVC, TPU, and EVA. Combined with mechanical pressure, this heat is used to weld and mold the materials. They are widely used in the processing of plastic products, seals, airbag components, and other products. The fastening, feeding, and alignment structures of a high-frequency welding machine directly determine its level of automation and processing accuracy.

[0003] In the prior art, patent CN15835353B discloses a method for high-frequency compression of multi-layer air bags, using high-frequency compression for airbags. Patent CN1828468B discloses a blood bag production process that uses a high-frequency welding machine to weld blood bags in multiple steps. Patent CN216466254U discloses a high-frequency welding machine fastening device that eliminates the need for manual movement and alignment, relying on an electric slide rail and PLC controller for automatic alignment. However, this equipment is a single-station structure with limited functionality, unable to meet the needs of simultaneous processing of multiple processes and product categories. Patent CN2861943U discloses a fully automatic high-frequency welding machine that relies on a conveying device and programmable controller for automatic feeding and welding. However, its stations are designed with overall linkage, and each station cannot be independently controlled, resulting in poor flexibility in welding modes.

[0004] Currently, most conventional dual-station high-frequency welding machines on the market adopt a single high-frequency system and a station linkage transmission structure. The left and right stations can only complete the same process synchronously and cannot be flexibly matched according to different processes. For common processes such as adhesive tape welding, air nozzle welding, and air bag welding, traditional equipment needs to be configured with independent high-frequency systems. Different processes require multiple machines to form a production line, which results in high equipment costs, large footprint, and manual disassembly and debugging of circuits and mechanical structures during process switching. The operation is cumbersome, and the three processes, including material transfer, take at least 150 seconds.

[0005] Meanwhile, traditional equipment lacks a systematic formula storage function. When changing products, operators need to repeatedly adjust parameters such as welding position, current, and welding time. The adjustment cycle is long, and human error can easily lead to inconsistent quality of batch products. In addition, traditional equipment only supports manual adjustment of current and cannot automatically adapt welding energy according to the thickness and material of the workpiece. Thin materials are prone to weld penetration, while thick materials are prone to defects such as incomplete welding and weak fusion. Summary of the Invention

[0006] The purpose of this invention is to solve the problems of low production efficiency and product quality in welding production, and to provide an integrated process for continuous high-frequency welding. It integrates multiple functions and adopts a single-station design to achieve the fusion of multiple complex processes. It can realize flexible combination operation and can realize segmented continuous welding of various components (air nozzle, body and adhesive strip) to achieve one-time forming.

[0007] The technical solution adopted by the present invention to solve the above problems is: an integrated process for continuous high-frequency welding, wherein a control mechanism is installed on the main body of the high-frequency welding equipment, and at least three welding stations and two feeding stations are provided. The two feeding stations are located in the middle of the welding stations, forming an interval between the feeding and welding stations. S1: Install the part mold on the material feeding station moving platform, and install the corresponding welding joint on the welding platform; the operator sets and saves the part welding parameter formula on the control mechanism; S2: Place one upper part material 19 and three part air nozzles 21 on the left feeding station and fix them. Start the servo motor 12 to drive the left moving platform 1 to move to the left air nozzle welding joint 4 of the left welding mechanism to perform high-frequency welding of the air nozzles. After the welding is completed, the left moving platform 1 returns to the initial position. S3: Place a lower part material 20 on top of the semi-finished product completed in S2 and fix it. Start the servo motor 12 to drive the left moving platform 1 to move to the airbag welding joint 7 of the middle welding mechanism to perform airbag high-frequency welding. After the welding is completed, the left moving platform 1 returns to the initial position. S4: Place and fix three component adhesive tapes 22 on the semi-finished product completed in S3, start the servo motor 12 to drive the left moving platform 1 to move below the left adhesive tape welding joint 3 for high-frequency welding of the adhesive tape; after the welding is completed, the left moving platform 1 returns to the initial position, and the welding of the finished product 23 is completed.

[0008] Preferably, S1: The component mold is installed on the material feeding station moving platform, and the corresponding welding joint is installed on the welding platform; the operator sets and saves the component welding parameter formula on the control mechanism; S2: Place and fix one upper part material 19 and three part nozzles 21 on the part mold of the left feeding station moving platform 1. Press the start button of the left control mechanism. The servo motor 12 of the left feeding station starts and drives the synchronous belt 10 to rotate, so that the linear slider 13 moves along the linear guide rail 11 and moves the left moving platform 1 to below the left nozzle welding joint 4 of the left welding mechanism. The lifting cylinder 15 rises and drives the left moving platform 1 to rise. At the same time, the left nozzle welding joint 4 descends to complete the high-frequency welding of the nozzle. After the welding is completed, the left nozzle welding joint 4 rises, the lifting cylinder 15 drives the left moving platform 1 to descend, and the servo motor 12 starts and drives the synchronous belt 10 to make the linear slider 13 drive the left moving platform 1 to return to the initial position along the linear guide rail 11. S3: Place and fix a lower layer of component material 20 above the semi-finished product completed in S2. Press the start button of the left control mechanism. The servo motor 12 starts and drives the synchronous belt 10 to rotate, so that the linear slider 13 moves along the linear guide rail 11 and moves the left moving platform 1 to below the airbag welding joint 7 of the middle welding mechanism. The lifting cylinder 15 rises and drives the left moving platform 1 to rise. At the same time, the airbag welding joint 7 descends to complete the airbag high-frequency welding. After the welding is completed, the airbag welding joint 7 rises, the lifting cylinder 15 drives the left moving platform 1 to descend, and the servo motor 12 starts and drives the synchronous belt 10 to make the linear slider 13 drive the left moving platform 1 to return to the initial position along the linear guide rail 11. S4: Place and fix three component adhesive tapes 22 on the semi-finished product completed in S3. Press the start button of the left welding control mechanism. The servo motor 12 starts and drives the synchronous belt 10 to rotate, so that the linear slider 13 moves along the linear guide rail 11 and moves the left moving platform 1 to below the left adhesive tape welding joint 3. The lifting cylinder 15 rises and drives the left moving platform 1 to rise. At the same time, the left adhesive tape welding joint 3 falls to complete the high-frequency welding of the adhesive tape. After the welding is completed, the left adhesive tape welding joint 3 rises, the lifting cylinder 15 drives the left moving platform 1 to fall, the servo motor 12 starts and drives the synchronous belt 10 to make the linear slider 13 move the left moving platform 1 back to the initial position along the linear guide rail 11. The welding of the finished product 23 is completed.

[0009] Preferably, the right welding station performs the same symmetrical operation as the right station, so that the airbag welding joint 7 of the middle welding mechanism can simultaneously weld airbags on both the left and right sides.

[0010] Preferably, the welding joint of the welding mechanism is a replaceable welding joint, and the corresponding welding joint and mold can be replaced as needed to weld the parts.

[0011] Preferably, the left and right workstations are independently controlled by the left control unit 16 and the right control unit 17, respectively, and the welding parameters of the corresponding workstations are set, including welding time, high-frequency power, and holding time. Different welding processes can be set for the left and right workstations.

[0012] Preferably, the adhesive tape welding and air nozzle welding of the left and right welding mechanisms share a high-frequency system, and the current is automatically adjusted through servo control. When changing products, only the formula number corresponding to the new product needs to be entered.

[0013] Preferably, the control mechanism adopts PLC intelligent recipe management, and each workstation supports the storage and memorization of key parameters such as welding position and current. When used for the first time, the operator sets and saves the parameter recipe, and the corresponding recipe can be directly retrieved when changing products in the future.

[0014] This invention is an integrated continuous production process that allows for the combined processing of three or more welding processes on a single work platform. While saving labor, it significantly improves production efficiency and product yield. The innovation lies in the seamless integration of the material feeding station and the welding station into a single, unified device. A servo motor drives a moving platform below the material feeding station, moving it left and right to the corresponding welding head according to the product's process requirements. Equipped with an automatic current control system, it intelligently switches and adjusts the welding current based on the needs of different products and welding locations, achieving fully automated adaptation of the welding process. This ensures that all types of workpieces receive precise and stable welding energy, further improving welding quality and process adaptability.

[0015] This invention also reduces manual labor; workers only need to place materials at the unloading station, eliminating the need for component transfer. The operation is simple, further ensuring manufacturing efficiency and product quality. This process only requires the lateral movement of a mobile platform and the matching of molds and multi-welding joints on the platform to achieve high-frequency welding of corresponding product types. With the replacement of molds and multi-welding joints, it is applicable to various types of complex products, and multiple unified and continuous high-frequency welding processes, thus broadening its application.

[0016] The preferred design of the equipment used in this invention, which is equipped with two feeding stations, takes into account the cost-effectiveness of the 25kW machine head and uses it for production on both sides, allowing two products to be processed simultaneously, thus optimizing costs.

[0017] The integrated frame structure of the equipment used in this invention not only shortens the process flow to the maximum extent but also ensures stable machine operation. This fundamentally guarantees the overall rigidity and operational stability of the equipment, effectively suppressing vibrations during processing and providing a solid hardware foundation for high-precision welding. Attached Figure Description

[0018] Figure 1 This is a process flow diagram of the present invention.

[0019] Figure 2 This is a schematic diagram of the welding equipment structure of the present invention; Figure 3 yes Figure 2 The diagram shows the material feeding station of the welding equipment. Figure 4 yes Figure 2 A schematic diagram of the lifting mechanism of the welding equipment shown; Figure 5 yes Figure 2 A schematic diagram of the welding mold fixing of the welding equipment shown; Figure 6 This is an exploded view of the airbag component to be processed; Figure 7This is a schematic diagram of the completed airbag structure.

[0020] In the diagram: 1. Left moving platform; 2. Right moving platform; 3. Left adhesive tape welding joint; 4. Left air nozzle welding joint; 5. Control mechanism; 6. Main body of equipment; 7. Airbag welding joint; 8. Right adhesive tape welding joint; 9. Right air nozzle welding joint; 10. Synchronous belt; 11. Linear guide rail; 12. Servo motor; 13. Linear slider; 14. Positioning column; 15. Lifting cylinder; 16. Left control unit; 17. Right control unit; 18. Upper limit magnetic switch; 19. Upper layer material; 20. Lower layer material; 21. Nozzle; 22. Adhesive tape; 23. Component; 24. Positioning pin; 25. Positioning hole; 26. Fixing screw; 27. Fixing hole. Detailed Implementation

[0021] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments, but the present invention is not limited to the embodiments.

[0022] like Figures 2-5 The high-frequency welding equipment shown has a control mechanism installed on the main body 6 of the equipment, as well as at least three welding stations and two feeding stations. The two feeding stations are located in the middle of the welding stations, and the feeding stations are spaced apart from the welding stations. The control mechanism 5 includes a left control unit 16 and a right control unit 17, which can independently complete parameter setting, program calling, and equipment start / stop control. The welding mechanism is provided with three independent welding mechanisms, namely the left welding mechanism, the middle welding mechanism and the right welding mechanism; the lower end of the left welding mechanism is equipped with a left adhesive tape welding head 3 and a left air nozzle welding head 4, the lower end of the middle welding mechanism is equipped with an airbag welding head 7, and the lower end of the right welding mechanism is equipped with a right adhesive tape welding head 8 and a right air nozzle welding head 9. The welding mechanisms are uniformly mounted on the base of the main body 6 of the equipment. The left control unit 16 is arranged between the left welding mechanism and the middle welding mechanism, and the right control unit 17 is arranged between the middle welding mechanism and the right welding mechanism. The left control unit 16 is directly below the material feeding station 1, where the operator can load the workpiece and unload the finished product through the material loading and unloading port 1. The right control unit 17 is directly below the material feeding station 2, which enables independent loading and unloading on the other side. The welding molds are respectively assembled and fixed on the material feeding station 1 and the material feeding station 2. Both material feeding stations include a moving platform. The moving platforms on both sides move independently and are interlocked in the middle position, without interfering with each other.

[0023] The left moving platform 1 and right moving platform 2 of the feeding station have the same structure, both adopting a servo synchronous belt linear transmission structure. The moving platform is equipped with a linear guide rail 11, a linear slider 13, a servo motor 12, and a synchronous belt 10. The linear slider is slidably engaged on the linear guide rail 11, and the moving platform is fixed above the linear slider 13. The output shaft of the servo motor 12 is connected to the drive wheel, which drives the synchronous belt 10 for transmission. The synchronous belt is rigidly locked to the bottom of the moving platform. The servo motor pulls the moving platform to move back and forth precisely along the linear guide rail 11 through the synchronous belt. Compared with the traditional cylinder transmission, the servo drive has higher positioning accuracy, better consistency in repeated processing, and is suitable for high-precision plastic welding processing.

[0024] A lifting cylinder 15 and a positioning column are vertically fixed on the linear slider 13. The lifting cylinder is connected to the moving platform for lifting. An upper limit magnetic switch 18 is installed on the outer side of the cylinder body of the lifting cylinder 15. The lifting cylinder 15 moves synchronously with the moving platform. When the moving platform carries the workpiece and the welding mold to directly below the corresponding welding joint, the piston rod of the lifting cylinder 15 extends upward, driving the moving platform to rise and lift the workpiece and the welding mold to fit against the upper welding joint. When the piston rod of the lifting cylinder 15 rises completely to the upper limit position, the magnetic ring inside the cylinder triggers the upper limit magnetic switch 18 on the outside. The magnetic switch generates an inductive signal and transmits it to the corresponding left control unit 16 or right control unit 17. After receiving the positioning signal, the control unit automatically starts the corresponding welding mechanism to execute the high-frequency welding program. There is no need for manual confirmation of the workstation position, realizing fully automatic positioning and triggering welding, improving the automation level of the equipment, reducing manual labor time, improving work efficiency, and avoiding positioning deviations caused by manual operation.

[0025] The bottom of the welding mold and the top surface of the left / right moving platform are respectively provided with corresponding positioning holes 25 and mold fixing holes 27, and mold positioning pins 24 and mold fixing screws 26 are provided. The assembly process of the welding mold is as follows: First, insert the mold positioning pin 24 into the positioning hole 25 of the moving platform and the welding mold, and use the positioning pin 24 to complete the pre-positioning limit of the welding mold, initially lock the horizontal position of the mold, and prevent the mold from slipping or misaligning when the screws are tightened later; after the pre-positioning is completed, insert the mold fixing screw 26 into the mold fixing hole 27 and tighten it to fasten the welding mold and the moving platform into one piece.

[0026] With the dual fixing structure of positioning pins and screws, the alignment accuracy of mold changing is greatly improved, and there is no need for repeated debugging and correction when changing molds for different product specifications. On the other hand, the screw detachable connection method facilitates quick disassembly and replacement of welding molds, adapting to the welding production needs of various workpieces such as adhesive tape, air nozzles, and air bags, and shortening the product changeover and debugging time.

[0027] The above-mentioned equipment is used for airbag welding, and the airbag to be processed is as follows: Figure 6 and7 As shown, the specific process is as follows: S1: Install the part mold on the material feeding station moving platform, and install the corresponding welding joint on the welding platform; the operator sets the corresponding welding parameters for the station on the control mechanism, including welding time, high frequency power, and holding time, and saves the part welding parameter formula. S2: Place and fix one upper part material 19 and three part nozzles 21 on the part mold of the left feeding station moving platform 1. Press the start button of the left control mechanism. The servo motor 12 of the left feeding station starts and drives the synchronous belt 10 to rotate, so that the linear slider 13 moves along the linear guide rail 11 and moves the left moving platform 1 to below the left nozzle welding joint 4 of the left welding mechanism. The lifting cylinder 15 rises and drives the left moving platform 1 to rise. At the same time, the left nozzle welding joint 4 descends to complete the high-frequency welding of the nozzle. After the welding is completed, the left nozzle welding joint 4 rises, the lifting cylinder 15 drives the left moving platform 1 to descend, and the servo motor 12 starts and drives the synchronous belt 10 to make the linear slider 13 drive the left moving platform 1 to return to the initial position along the linear guide rail 11. S3: Place and fix a lower layer of component material 20 above the semi-finished product completed in S2. Press the start button of the left control mechanism. The servo motor 12 starts and drives the synchronous belt 10 to rotate, so that the linear slider 13 moves along the linear guide rail 11 and moves the left moving platform 1 to below the airbag welding joint 7 of the middle welding mechanism. The lifting cylinder 15 rises and drives the left moving platform 1 to rise. At the same time, the airbag welding joint 7 descends to complete the airbag high-frequency welding. After the welding is completed, the airbag welding joint 7 rises, the lifting cylinder 15 drives the left moving platform 1 to descend, and the servo motor 12 starts and drives the synchronous belt 10 to make the linear slider 13 drive the left moving platform 1 to return to the initial position along the linear guide rail 11. S4: Place and fix three component adhesive tapes 22 on the semi-finished product completed in S3. Press the start button of the left welding control mechanism. The servo motor 12 starts and drives the synchronous belt 10 to rotate, so that the linear slider 13 moves along the linear guide rail 11 and moves the left moving platform 1 to below the left adhesive tape welding joint 3. The lifting cylinder 15 rises and drives the left moving platform 1 to rise. At the same time, the left adhesive tape welding joint 3 falls to complete the high-frequency welding of the adhesive tape. After the welding is completed, the left adhesive tape welding joint 3 rises, the lifting cylinder 15 drives the left moving platform 1 to fall, the servo motor 12 starts and drives the synchronous belt 10 to make the linear slider 13 move the left moving platform 1 back to the initial position along the linear guide rail 11. The welding of the finished product 23 is completed.

[0028] Repeat steps S2-S4 again to begin the cycle for the next product.

[0029] At the same time, the same symmetrical operation is carried out on the right moving platform 2, so that the large 7-airbag welding joint in the middle can be used as a common welding joint on both sides, thereby ensuring the maximum utilization rate of the equipment.

[0030] The welding equipment used in this invention adopts a zoned independent control mode: the left control unit 16 independently controls the welding actions of the left welding mechanism and the middle welding mechanism, and the right control unit 17 independently controls the welding actions of the middle welding mechanism and the right welding mechanism; the middle welding mechanism serves as a shared workstation, which can be called by both the left and right control units, enabling three working modes: single-sided independent processing, double-sided synchronous processing, and left-right differentiated process processing, thus solving the defect of traditional dual-station equipment that can only execute the same process synchronously.

[0031] This invention realizes an integrated process for continuous high-frequency welding of materials in stages by one person at the same workstation. Experiments have shown that the welding of a single part takes 55 seconds. Including the time for manual placement and removal, the welding of a finished product can be completed in 70 seconds. Previously, the three processes including material transfer took 150 seconds, improving the efficiency of a single part by 110%. By adopting dual-sided synchronous manufacturing, the efficiency is doubled again.

Claims

1. An integrated process for continuous high-frequency welding, characterized in that, The high-frequency welding equipment is equipped with a control mechanism, at least three welding stations and two feeding stations. The two feeding stations are located in the middle of the welding stations, forming an interval between the feeding and welding stations. S1: Install the part mold on the material feeding station moving platform, and install the corresponding welding joint on the welding platform; the operator sets and saves the part welding parameter formula on the control mechanism; S2: Place one upper part material (19) and three part nozzles (21) on the left feeding station and fix them. Start the servo motor (12) to drive the left moving platform to move to the left nozzle welding joint (4) of the left welding mechanism to perform high-frequency welding of the nozzles. After the welding is completed, the left moving platform (1) returns to the initial position. S3: Place a lower part material (20) on top of the semi-finished product completed in S2 and fix it. Start the servo motor (12) to drive the left moving platform to move to the airbag welding joint (7) of the middle welding mechanism to perform airbag high-frequency welding. After the welding is completed, the left moving platform returns to the initial position. S4: Place three component adhesive tapes (22) on the semi-finished product completed in S3 and fix them. Start the servo motor (12) to drive the left moving platform to move below the left adhesive tape welding joint (3) for high-frequency welding of the adhesive tape. After the welding is completed, the left moving platform returns to the initial position and the finished product (23) welding is completed.

2. The integrated process for continuous high-frequency welding according to claim 1, characterized in that, S1: Install the part mold on the material feeding station moving platform, and install the corresponding welding joint on the welding platform; the operator sets and saves the part welding parameter formula on the control mechanism; S2: Place one upper part material (19) and three part nozzles (21) onto the part mold of the left feeding station moving platform (1) and fix them. Press the start button of the left control mechanism. The servo motor (12) of the left feeding station starts and drives the synchronous belt (10) to rotate, so that the linear slider (13) moves along the linear guide rail (11) and moves the left moving platform (1) to below the left nozzle welding joint (4) of the left welding mechanism. The lifting cylinder (15) rises and drives the left moving platform to rise. At the same time, the left nozzle welding joint descends to complete the high-frequency welding of the nozzle. After the welding is completed, the left nozzle welding joint rises, the lifting cylinder drives the left moving platform 1 to descend, and the servo motor starts and drives the synchronous belt to make the linear slider drive the left moving platform back to the initial position along the linear guide rail. S3: Place a lower layer material (20) of a component above the semi-finished product completed in S2 and fix it. Press the start button of the left control mechanism. The servo motor (12) starts and drives the synchronous belt (10) to rotate, so that the linear slider (13) moves along the linear guide rail (11) and drives the left moving platform (1) to move below the airbag welding joint (7) of the middle welding mechanism. The lifting cylinder (15) rises and drives the left moving platform to rise. At the same time, the airbag welding joint descends to complete the airbag high-frequency welding. After the welding is completed, the airbag welding joint rises, the lifting cylinder drives the left moving platform to descend, and the servo motor starts and drives the synchronous belt to make the linear slider drive the left moving platform to return to the initial position along the linear guide rail. S4: Place three component adhesive tapes (22) on the semi-finished product completed in S3 and fix them. Press the start button of the left welding control mechanism. The servo motor (12) starts and drives the synchronous belt (10) to rotate, so that the linear slider (13) moves along the linear guide rail (11) and drives the left moving platform (1) to move below the left adhesive tape welding joint (3). The lifting cylinder (15) rises and drives the left moving platform to rise. At the same time, the left adhesive tape welding joint descends to complete the high-frequency welding of the adhesive tape. After the welding is completed, the left adhesive tape welding joint rises, the lifting cylinder drives the left moving platform to descend, the servo motor starts and drives the synchronous belt to drive the linear slider to drive the left moving platform to return to the initial position along the linear guide rail. The welding of the finished product (23) is completed.

3. The integrated process for continuous high-frequency welding according to claim 1 or 2, characterized in that, The right welding station performs the same symmetrical operation as the right station, so that the airbag welding joint (7) of the middle welding mechanism can simultaneously weld the airbags on both sides.

4. The integrated process for continuous high-frequency welding according to claim 1 or 2, characterized in that, The welding joint of the welding mechanism is a replaceable welding joint, and the corresponding welding joint and mold can be replaced as needed to weld the parts.

5. The integrated process for continuous high-frequency welding according to claim 1 or 2, characterized in that, The left and right workstations are independently controlled by the left control unit (16) and the right control unit (17), respectively, and the corresponding welding parameters of the workstations are set, including welding time, high frequency power, and holding time. Different welding processes can be set for the left and right workstations.

6. The integrated process for continuous high-frequency welding according to claim 1 or 2, characterized in that, The adhesive tape welding and air nozzle welding of the left and right welding mechanisms share a high-frequency system. The current is automatically adjusted through servo control. When changing products, only the formula number corresponding to the new product needs to be entered.

7. The integrated process for continuous high-frequency welding according to claim 1 or 2, characterized in that, The control mechanism adopts PLC intelligent recipe management. Each workstation supports the storage and memorization of key parameters such as welding position and current. When used for the first time, the operator sets and saves the parameter recipe. When changing products later, the corresponding recipe can be directly retrieved.

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