A production method for a continuous vacuum brazing production line

Abstract

The application discloses a production method of a continuous vacuum brazing production line, and relates to the field of vacuum brazing production lines.The production method comprises the following steps: after a brazing process in a continuous vacuum brazing device is completed, a control center controls a first shuttle unit or a second shuttle unit to move to the end of the continuous vacuum brazing device, and the first shuttle unit or the second shuttle unit is connected with the continuous vacuum brazing device; a rack loaded with brazing pieces in a vacuum brazing chamber at the end of the continuous vacuum brazing device is transferred into a loading box in the first shuttle unit or the second shuttle unit; then, the control center controls the first shuttle unit to move to one end of a cooling control unit, or controls the second shuttle unit to move to one end of a cooling placement unit or an air cooling unit, and the first shuttle unit or the second shuttle unit is connected with the cooling control unit, the cooling placement unit or the air cooling unit; and the rack loaded with the brazing pieces in the loading box is transferred into the cooling control unit, the cooling placement unit or the air cooling unit to be cooled at different temperatures, cooled by placement or air cooling, respectively.The application is used to improve the production efficiency of the continuous vacuum brazing production line.

Description

Technical Field

[0001] This invention relates to the field of vacuum brazing technology, and more particularly to a production method for a continuous vacuum brazing production line. Background Technology

[0002] Vacuum brazing is an advanced welding process that joins metal materials in a vacuum environment. It is widely used in high-end manufacturing fields such as automobiles, aerospace, and new energy. To meet the demands of modern high-volume, high-efficiency production, vacuum brazing equipment and processes have evolved from intermittent to continuous processes in recent years. Continuous vacuum brazing enables continuous workpiece feeding, heating and brazing, and cooling and unloading without frequent furnace start-ups and shutdowns, thus improving production efficiency and quality consistency. It is well-suited for the needs of large-scale industrial mass production.

[0003] For vacuum brazing of aluminum-based and copper-based workpieces with good thermal conductivity, continuous vacuum brazing demonstrates excellent applicability. However, when processing workpieces with poor thermal conductivity, such as stainless steel and titanium alloys, this type of equipment and process still has significant limitations. Due to the low thermal conductivity of these materials, excessively rapid cooling during the cooling stage of vacuum brazing can generate significant thermal stress, easily leading to workpiece deformation and affecting its dimensional stability. In more severe cases, it can also cause defects such as cracks at the weld joint, reducing weld quality and posing safety hazards for subsequent use. Therefore, for vacuum brazing of workpieces such as stainless steel, tool steel, and titanium alloys, slow cooling methods such as vacuum temperature-controlled cooling and placement cooling are usually required to control thermal stress deformation and ensure the strength of the weld joint. This results in cooling times that often last for several hours, and the long cooling time makes the cooling process a bottleneck in the cycle time of continuous vacuum brazing, not only making it difficult to fully utilize the production continuity advantages of the equipment but also limiting the overall efficiency of vacuum brazing of workpieces made of materials such as stainless steel, tool steel, and titanium alloys. Summary of the Invention

[0004] To address the aforementioned problems, this invention proposes a production method for a continuous vacuum brazing production line, solving the compatibility issue of continuous vacuum brazing equipment for vacuum brazing workpieces with poor thermal conductivity, and improving the production efficiency of the continuous vacuum brazing production line.

[0005] This invention provides a production method for a continuous vacuum brazing production line. The continuous vacuum brazing production line includes a cooling station, a first shuttle unit, a second shuttle unit, a control center, and multiple continuous vacuum brazing devices; the cooling station includes a controlled cooling zone, a released cooling zone, and an air-cooled zone; the controlled cooling zone, the released cooling zone, and the air-cooled zone are respectively separated into multiple controlled cooling units, released cooling units, and air-cooled units by sealing valves; the production method includes: After the brazing process in a continuous vacuum brazing equipment is completed, the control center controls the first shuttle unit or the second shuttle unit to move to the end of the continuous vacuum brazing equipment and connect the first shuttle unit or the second shuttle unit to the continuous vacuum brazing equipment. The material rack carrying the brazed parts in the vacuum brazing chamber at the end of the continuous vacuum brazing equipment is transferred to the material box in the first shuttle unit or the second shuttle unit. Then, the control center controls the first shuttle unit to move to one end of the controlled cooling unit, or controls the second shuttle unit to move to one end of the release cooling unit or the air cooling unit, and connects with the controlled cooling unit, release cooling unit or the air cooling unit. The material rack carrying the brazed parts in the material box is transferred to the controlled cooling unit, release cooling unit or air cooling unit for temperature controlled cooling, placement cooling or air cooling respectively.

[0006] The control center has a pre-installed process library, which includes cooling process data related to the characteristic information of the brazed parts. After receiving the production task for the brazed parts, the control center automatically acquires the characteristic information of the brazed parts and retrieves the cooling process data that matches the characteristic information to implement the cooling treatment of the brazed parts. The characteristic information includes at least one of the material, joint type, and size and shape of the brazed parts. When the first process step of the cooling process is temperature-controlled cooling, the control center selects and dispatches the first shuttle unit equipped with the first heater in the material box to connect with the continuous vacuum brazing equipment and transfers the brazed parts in the vacuum brazing chamber to the temperature-controlled cooling unit. When the first process step of the cooling process is placement cooling or air cooling, the control center selects and dispatches the second shuttle unit to connect with the continuous vacuum brazing equipment and transfers the brazed parts in the vacuum brazing chamber to the release cooling unit or air cooling unit.

[0007] In one possible implementation, when the first shuttle unit is connected to the continuous vacuum brazing equipment, the control center has already adjusted the temperature in the material box of the first shuttle unit to the starting temperature that matches the preset cooling curve of the brazing workpiece by controlling the first heater, and has already adjusted the working vacuum degree in the first shuttle unit to match the working vacuum degree in the vacuum brazing chamber by controlling the first vacuum regulating device set in the first shuttle unit.

[0008] In one possible implementation, during the transfer process of the brazed component carried by the first shuttle unit to the controlled cooling unit, the control center controls the output power of the first heater to make the temperature inside the loading box exhibit dynamic changes that match the preset cooling curve of the brazed component, so that the brazed component undergoes partial temperature controlled cooling in the first shuttle unit; after the first shuttle unit transfers the brazed component to the controlled cooling unit, the brazed component continues to undergo subsequent temperature controlled cooling in the controlled cooling unit.

[0009] In one possible implementation, each cooling unit is equipped with a second heater independently controlled by the control center; when a cooling unit is connected to the first shuttle unit, the control center controls the output power of the second heater in the cooling unit to match the temperature in the cooling unit with the temperature in the loading box; after the brazing workpiece is transferred to the cooling unit, the control center controls the output power of the second heater in the cooling unit to cool the brazing workpiece according to a preset cooling curve.

[0010] In one possible implementation, the control center controls the second vacuum regulating device installed in the cooling control unit and the cooling release unit to regulate the working vacuum level in the cooling control unit and the cooling release unit.

[0011] In one possible implementation, when the brazed component is subjected to temperature-controlled cooling or placement cooling in a controlled cooling unit or a release cooling unit, the control center actively adjusts the working vacuum level within the controlled cooling unit or the release cooling unit to dynamically match the working vacuum level with the temperature change of the brazed component. This active adjustment includes: reducing the flow rate of protective gas entering the controlled cooling unit or the release cooling unit as the temperature of the brazed component decreases, while simultaneously increasing the pumping rate of the second vacuum device installed in the controlled cooling unit or the release cooling unit to improve the working vacuum level. The rate of change of the working vacuum level is proportional to the k-th power of the rate of change of the brazed component temperature, where 1.5 ≤ k ≤ 2.5.

[0012] In one possible implementation, the continuous vacuum brazing production line further includes a third shuttle unit; the production method further includes: according to the cooling process of the brazed parts, the control center controls the third shuttle unit to move to the other end of the controlled cooling unit, the release cooling unit, or the air cooling unit to connect with the controlled cooling unit, the release cooling unit, or the air cooling unit; the second loading box of the third shuttle unit transfers the rack carrying the brazed parts into or out of the controlled cooling unit, the release cooling unit, or the air cooling unit; the third shuttle unit connects to the controlled cooling unit and the release cooling unit successively to transfer the rack carrying the brazed parts from the controlled cooling unit to the release cooling unit for continued placement and cooling treatment; the third shuttle unit connects to the release cooling unit and the air cooling unit successively to transfer the rack carrying the brazed parts from the release cooling unit to the air cooling unit for continued air cooling treatment.

[0013] In one possible implementation, the sealing valves in the controlled cooling zone, the release cooling zone, and the air-cooled zone all have atmosphere isolation and temperature isolation functions, and are opened and closed under the independent control of the control center. When the cooling process conditions in two adjacent controlled cooling units, two adjacent release cooling units, or two adjacent air-cooled units are consistent, the control center controls the sealing valve to open, so that the spaces of the two adjacent units are merged into one, and the brazed parts in the space are cooled uniformly. When the cooling processes in two adjacent controlled cooling units, two adjacent release cooling units, or two adjacent air-cooled units are inconsistent, the control center controls the sealing valve to close, so that each unit executes its own cooling process to cool the brazed parts therein.

[0014] In one possible implementation, when a certain cooling control unit, cooling release unit, or air-cooled unit needs to connect with the first shuttle unit, the second shuttle unit, or the third shuttle unit, the control center first controls the sealing valves on both sides of the unit to close, so that the space of the unit is isolated from other units.

[0015] Each cooling control unit is equipped with a temperature measuring device; when the spaces of adjacent cooling control units are merged into one, the control center uses the temperature feedback signals from each cooling control unit to uniformly allocate the output of the second heater in each cooling control unit, so that the temperature in the merged space remains uniform.

[0016] In one possible implementation, both the first shuttle unit and the second shuttle unit include a first vacuum device connected to the loading bin.

[0017] In one possible implementation, a temperature measuring device is installed in the loading box of the first shuttle unit, and the control center uses the temperature feedback signal from the temperature measuring device to precisely regulate the temperature inside the first shuttle unit.

[0018] In one possible implementation, the second vacuum regulating device controls the flow rate of the protective gas introduced into the cooling control unit and the cooling release unit, and / or the pumping rate of the second vacuum device installed in the cooling control unit and the cooling release unit, to regulate the working vacuum level in the cooling control unit and the cooling release unit.

[0019] In one possible implementation, each air-cooled unit is equipped with an independent third vacuum device and a third vacuum regulating device independently controlled by the control center, which enables the air-cooled unit to switch between an air-cooled working environment and a connecting and conveying working environment.

[0020] In one possible implementation, each air-cooled unit is equipped with an air-cooling device independently controlled by the control center for air-cooling the brazed components within the air-cooled unit.

[0021] In one possible implementation, the third shuttle unit includes a second loading bin, a fourth vacuum regulating device, and a fourth vacuum device connected to the second loading bin.

[0022] In one possible implementation, the first vacuum device, the second vacuum device, the third vacuum device, and the fourth vacuum device are all used to evacuate the corresponding units.

[0023] In one possible implementation, there are multiple third shuttle units; each third shuttle unit is connected to an independent inflation device for filling the third shuttle unit with protective gas.

[0024] In one possible implementation, the control center controls the flow rate of the protective gas introduced into the third shuttle unit and the pumping rate of the fourth vacuum device by controlling the fourth vacuum regulating device, thereby regulating the working vacuum level in the third shuttle unit.

[0025] The applicant discovered that when a single rack carrying brazed components is cooled in a confined space, the temperature distribution uniformity within that space is poor, resulting in a higher proportion of brazed components affected by temperature unevenness due to edge effects. Conversely, when multiple racks carrying brazed components are cooled in a larger space, the temperature distribution is more uniform, and the proportion of brazed components affected by temperature unevenness due to edge effects is lower. In this application, when the cooling processes in two adjacent controlled cooling units, two adjacent venting cooling units, or two adjacent air-cooled units are identical, the control center controls the opening of a sealing valve to merge the spaces of the two adjacent units into one, allowing for unified cooling of the brazed components within that space, thereby improving the consistency of the batch of brazed components' quality.

[0026] In existing continuous vacuum brazing equipment, a cooling chamber is usually included downstream of the vacuum brazing chamber. After the brazing process is completed in the vacuum brazing chamber, the brazed parts continue to enter the cooling chamber for cooling. When this type of vacuum brazing equipment is used for vacuum brazing of workpieces with poor thermal conductivity, the brazed parts need to stay in the cooling chamber for several hours to complete the cooling process, which greatly slows down the production cycle of the brazed parts in the continuous vacuum brazing equipment.

[0027] The continuous vacuum brazing production line of this application includes multiple continuous vacuum brazing devices. The end chamber of the continuous vacuum brazing device is a vacuum brazing chamber, excluding a cooling chamber. The vacuum brazing process of the brazed parts in the continuous vacuum brazing device only proceeds to the brazing step; the subsequent cooling process is centrally completed by a cooling treatment station. Specifically, the control center selects and controls the first or second shuttle unit to connect with the continuous vacuum brazing device and the controlled cooling unit, release cooling unit, or air cooling unit to transfer the brazed parts that have completed the brazing process in the vacuum brazing chamber to the controlled cooling zone, release cooling zone, or air cooling zone for cooling treatment, based on the cooling process requirements of the brazed parts that have completed the brazing process. Since the air cooling zone, release cooling zone, and air cooling zone all include multiple units, the continuous vacuum brazing production line can simultaneously meet the cooling treatment tasks of brazed parts in multiple continuous vacuum brazing devices. This frees the production cycle of the continuous vacuum brazing device from the constraints of the time-consuming cooling process, greatly improving the production efficiency of the continuous vacuum brazing production line.

[0028] When the control center detects that brazed parts awaiting cooling in a continuous vacuum brazing machine require temperature-controlled cooling, it will activate the first shuttle unit to connect with the continuous vacuum brazing machine and transfer the brazed parts from the vacuum brazing chamber to a controlled cooling unit. Conversely, when the control center detects that the first step of the cooling process for brazed parts in a continuous vacuum brazing machine is placement cooling or air cooling that does not require additional heat, it will activate the second shuttle unit to connect with the continuous vacuum brazing machine and transfer the brazed parts from the vacuum brazing chamber to an exhaust cooling or air cooling unit.

[0029] When the second shuttle unit is connected to the continuous vacuum brazing equipment, the control center has already adjusted the working vacuum level in the second shuttle unit to match the working vacuum level in the vacuum brazing chamber by controlling the first vacuum regulating device.

[0030] In the cooling station, when brazed components require further cooling and / or air cooling after temperature-controlled cooling, the control center activates the third shuttle unit to connect sequentially with the controlled cooling unit, the release cooling unit, and / or the air cooling unit to transfer the brazed components to the release cooling and / or air cooling unit for subsequent processing. While the third shuttle unit is connecting to the controlled cooling unit, the release cooling unit, or the air cooling unit, the control center has already adjusted the working vacuum level within the third shuttle unit to match the working vacuum level of the connected controlled cooling unit, the release cooling unit, or the air cooling unit via the fourth vacuum regulating device.

[0031] Through the above process, this application can simultaneously meet the different cooling process requirements of various brazed parts operating in a continuous vacuum brazing production line, realize efficient and flexible production of multiple continuous vacuum brazing equipment, and enable the continuous vacuum brazing production line to operate intelligently.

[0032] Since the first shuttle unit, the second shuttle unit, the third shuttle unit, as well as the controlled cooling unit, the released cooling unit, and the air-cooled unit are all equipped with vacuum devices and vacuum regulation devices, the brazed parts can be conveyed and cooled under a working vacuum atmosphere that strictly meets the cooling process requirements.

[0033] In this application, when the first, second, and third shuttle units connect with the receiving object, the working vacuum level within each shuttle unit is adjusted to match the working vacuum level within the receiving object. This ensures a stable atmosphere within the vacuum seal formed during connection and prevents the connection activity from significantly impacting the existing atmosphere within the receiving object. Furthermore, maintaining a stable atmosphere within the vacuum seal formed during connection is particularly beneficial for the connection of the first shuttle unit with continuous vacuum brazing equipment or a controlled cooling unit. This prevents unplanned temperature fluctuations caused by atmosphere flow factors, helps maintain stable brazed component temperatures, and avoids adverse effects on the strength of the welded joint.

[0034] In one possible implementation, the second vacuum regulating device includes a first controller and a second controller; the first controller is used to precisely control the flow rate of the protective gas entering the cooling control unit and the cooling release unit, and the second controller is used to precisely control the pumping rate of the second vacuum device; the control center precisely regulates the working vacuum level in each cooling control unit and the cooling release unit by controlling the coordinated operation of the first controller and the second controller.

[0035] The applicant discovered that existing vacuum brazing processes often lack active control over the working vacuum level during the temperature-controlled cooling process. While the cooling process of the brazed parts is controlled precisely to match the pre-designed cooling curve, the joint strength still falls short of design expectations. Microscopic analysis of these brazed parts revealed a small number of subtle micropore defects in the weld joint cross-section. Research indicates that during temperature-controlled cooling, as the surface temperature decreases, the adsorption effect of gas molecules on the brazed surface gradually outweighs the desorption effect, accumulating diffusion potential energy. Since the brazed part temperature remains relatively high at this point, and the interface at the weld joint still possesses residual activity, the adsorbed gas molecules preferentially diffuse at the weaker interface structure of the weld joint, causing these micropore defects and affecting the joint strength.

[0036] In one possible implementation of this application, when the brazed parts are subjected to temperature-controlled cooling or placement cooling in a controlled cooling unit or a release cooling unit, the control center actively adjusts the working vacuum level within the controlled cooling unit or release cooling unit, so that the working vacuum level dynamically matches the temperature change of the brazed parts. Through this control method, the micropore defects at the weld joint profile are significantly improved, thereby further increasing the joint strength of the brazed parts and improving the welding quality.

[0037] The beneficial effects of this invention are: 1. In the production method of the continuous vacuum brazing production line of this application, the cooling process of the continuous vacuum brazing equipment is separated from the equipment body and centrally undertaken by the cooling treatment station in the production line. This allows the continuous vacuum brazing equipment to focus solely on the brazing process, without reducing the production cycle due to excessive cooling time. The controlled cooling zone, release cooling zone, and air cooling zone in the cooling treatment station are all separated into multiple independent units by sealing valves. These units can simultaneously handle the cooling tasks of brazed parts from multiple continuous vacuum brazing equipment, achieving parallel processing of the cooling process. This solves the core problem of the cooling process dragging down the overall production cycle in traditional continuous vacuum brazing equipment. Simultaneously, the first shuttle unit can perform some temperature-controlled cooling operations while conveying the brazed parts, further shortening the overall cooling time and significantly improving the vacuum brazing production efficiency.

[0038] 2. The cooling station is equipped with three cooling zones: controlled cooling, ventilated cooling, and air cooling. These zones, coupled with flexibly scheduled first, second, and third shuttle units, allow for precise matching of cooling process requirements for brazed parts of different materials, joint types, and sizes. For workpieces with poor thermal conductivity, such as stainless steel, tool steel, and titanium alloys, the controlled cooling unit enables slow, controlled cooling according to a preset temperature curve, controlling thermal stress and preventing defects such as workpiece deformation and weld joint cracks. For workpieces that do not require additional heat during cooling, the ventilated cooling unit provides natural slow cooling, or the air cooling unit provides rapid air cooling, achieving personalized adaptation of the cooling process. Furthermore, the control center has a pre-set process library that can intelligently retrieve matching cooling processes based on the characteristics of the brazed parts, improving the efficiency and accuracy of cooling process adaptation and expanding the applicability of the continuous vacuum brazing production line.

[0039] 3. All shuttle and cooling units are equipped with independent vacuum devices, vacuum regulation devices, and gas filling devices, which can precisely control the working vacuum and protective gas atmosphere within the unit. This ensures that the brazed parts are transported and cooled in a vacuum environment that meets process requirements, preventing oxidation defects caused by air ingress. When the cooling processes of adjacent cooling units are consistent, the control center can control the opening of the sealing valve to merge unit spaces, reduce temperature unevenness caused by edge effects, improve the temperature distribution uniformity of batch brazed parts, and ensure consistent welding quality. By actively controlling the working vacuum of the controlled cooling unit and the uncontrolled cooling unit, the vacuum level is dynamically matched with the temperature of the brazed parts, significantly reducing the adsorption and micro-diffusion of gas molecules at the weld joint, effectively improving the micropore defects in the weld joint profile, significantly improving the joint strength of the brazed parts, reducing safety hazards in subsequent use, and solving the problem of unsatisfactory welding quality caused by only controlling temperature without controlling vacuum in traditional controlled cooling processes.

[0040] 4. Intelligent control via the control center enables automatic scheduling of shuttle units, continuous vacuum brazing equipment, and cooling units. It automatically retrieves cooling processes and adjusts temperature and vacuum levels, eliminating the need for manual operation and reducing errors caused by human intervention, thus improving the stability and reliability of the production process. Simultaneously, each cooling unit can be independently isolated via sealing valves. Connecting or maintaining one unit will not interfere with the normal cooling operation of other units, ensuring the continuity of the cooling station's operation. The combination of multiple shuttle units and multiple cooling units allows for flexible transfer of brazed parts between different cooling units, meeting the needs of step-by-step implementation of complex cooling processes and achieving flexible and intelligent operation of the production line.

[0041] 5. The number of units in the controlled cooling zone, venting cooling zone, and air cooling zone can be flexibly adjusted according to the production line scale, and the number of shuttle units can also be configured as needed, adapting to the requirements of continuous vacuum brazing production lines with different capacities. Simultaneously, the main cooling station can directly interface with existing continuous vacuum brazing equipment through shuttle units, eliminating the need for large-scale modifications to existing equipment and reducing the cost and difficulty of production line upgrades. Furthermore, the flexible control design of the sealing valves allows for both independent unit operation and combined unit operation, accommodating the needs of both small-batch personalized production and large-batch standardized production.

[0042] In summary, this invention effectively solves the problems of insufficient adaptability and low production efficiency of existing continuous vacuum brazing methods when handling workpieces with poor thermal conductivity. It realizes centralized, intelligent, and flexible processing of the vacuum brazing cooling process, which not only improves production line efficiency and product quality, but also expands the scope of application of the production line and reduces production and upgrade costs. It has outstanding substantive features and significant progress.

[0043] The above general description and the description below are exemplary and illustrative only and are not intended to limit this application. Attached Figure Description

[0044] One or more embodiments are illustrated by way of example with reference to the accompanying drawings. These illustrations and drawings do not constitute a limitation on the embodiments. Elements having the same reference numerals in the drawings are shown as similar elements, and the drawings do not constitute a limitation of scale. Wherein: Figure 1 This is a schematic diagram of the structural layout of a continuous vacuum brazing production line provided in an embodiment of this application.

[0045] Figure 2 This is a schematic flowchart of a production method for a continuous vacuum brazing production line provided in an embodiment of this application.

[0046] Figure label: 2. Continuous vacuum brazing equipment; 101, Cooling controlled zone; 1011, Cooling controlled sealing valve; 1012, Cooling controlled unit; 1013, Second heater; 1014, First connecting valve; 102, Cooling release zone; 1021, Cooling release sealing valve; 1022, Cooling release unit; 103, Air-cooled zone; 1031, Air-cooled sealing valve; 1032, Air-cooled unit; 1033, Air-cooled device; 20, First shuttle unit; 201, First heater; 202, Second connection valve; 30, Second Shuttle Unit; 40. Control Center; 50, Inflation device; 60, First vacuum device; 70, Third shuttle unit; 701, Fourth connecting valve; 702, Fourth vacuum device; 80, Vehicle; 90, Vacuum brazing chamber; 100, the third connecting valve; 110, Material container; 120, Second loading bin. Detailed Implementation

[0047] The specific embodiments of the present invention are further described below with reference to the accompanying drawings. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. In the following description, for ease of explanation, several details are used to provide a full understanding of the invention. However, the invention can still be practiced without these details. In other instances, well-known structures and apparatuses may be shown in a simplified manner to simplify the drawings.

[0048] The terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of the invention described herein.

[0049] In this invention, the terms "upper," "lower," "inner," "middle," "outer," "front," and "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this invention and are not intended to limit the indicated device, element, or component to having a specific orientation, or to require it to be constructed and operated in a specific orientation. Furthermore, some of the aforementioned terms may have other meanings besides indicating orientation or positional relationship; for example, the term "upper" may in some cases indicate a dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0050] Furthermore, the terms "set up," "connect," and "fix" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0051] This application provides a production method for a continuous vacuum brazing production line. This production method is applied to a continuous vacuum brazing production line, such as... Figure 1As shown, in one embodiment, the continuous vacuum brazing production line includes a cooling station, a first shuttle unit 20, a second shuttle unit 30, a control center 40, and multiple continuous vacuum brazing devices 2. The cooling station includes a controlled cooling zone 101, a released cooling zone 102, and an air-cooled zone 103. The controlled cooling zone 101, released cooling zone 102, and air-cooled zone 103 are respectively separated into multiple controlled cooling units 1012, released cooling units 1022, and air-cooled units 1032 by sealing valves. The chamber at the end of the continuous vacuum brazing device 2 is a vacuum brazing chamber 90. The vacuum brazing chamber 90 contains a rack carrying brazed parts. Both the first shuttle unit 20 and the second shuttle unit 30 include a material container 110. A first heater 201 is also installed in the material container 110 of the first shuttle unit 20. The power output of the first heater 201 is controlled by the control center 40.

[0052] The control center has a pre-installed process library. The process library includes cooling process data related to the characteristic information of the brazed parts. The characteristic information includes at least one of the following: material, joint type, and size / shape of the brazed parts.

[0053] In one implementation, such as Figure 1 As shown, each cooling control unit 1012 is equipped with a second heater 1013 that is independently controlled by the control center 40.

[0054] In one implementation, each cooling control unit is equipped with a temperature measuring device.

[0055] In one implementation, such as Figure 1 As shown, each cooling control unit 1012, cooling release unit 1022, and air-cooled unit 1032 is equipped with a first connection valve 1014 at both ends. Each first shuttle unit 20, second shuttle unit 30, cooling control unit 1012, cooling release unit 1022, and air-cooled unit 1032 is connected to an independent gas filling device 50 for filling each unit with protective gas.

[0056] In one implementation, each controlled cooling unit and cooled air release unit is equipped with an independent second vacuum device and a second vacuum regulating device independently controlled by the control center, which is used to ensure that the unit has a controllable working vacuum.

[0057] In one specific implementation, the second vacuum regulating device includes a first controller and a second controller; the first controller is used to precisely control the flow rate of the protective gas entering the cooling control unit and the cooling release unit, and the second controller is used to precisely control the pumping rate of the second vacuum device; the control center precisely regulates the working vacuum level in each cooling control unit and the cooling release unit by controlling the coordinated operation of the first controller and the second controller.

[0058] In one implementation, such as Figure 1As shown, the first shuttle unit 20 and the second shuttle unit 30 also include a first vacuum regulating device, a first vacuum device 60 connected to the material box 110, and a second connecting valve 202 disposed at the end of the material box 110.

[0059] In one implementation, such as Figure 1 As shown, a third connection valve 100 is provided at the end of the vacuum brazing chamber 90.

[0060] In one implementation, such as Figure 1 As shown, there are multiple first shuttle units 20 and multiple second shuttle units 30.

[0061] In one implementation, a temperature measuring device is installed in the loading box of the first shuttle unit, and the control center uses the temperature feedback signal from the temperature measuring device to precisely regulate the temperature in the first shuttle unit.

[0062] In one implementation, each air-cooled unit is equipped with an independent third vacuum device and a third vacuum regulating device independently controlled by the control center, which enables the air-cooled unit to switch between an air-cooled working environment and a connecting and conveying working environment.

[0063] In one implementation, such as Figure 1 As shown, each air-cooled unit 1032 is equipped with an air-cooling device 1033 independently controlled by the control center 40, which is used to air-cool the brazed parts in the air-cooled unit 1032.

[0064] In one implementation, such as Figure 1 As shown, the continuous vacuum brazing production line also includes a third shuttle unit 70.

[0065] In one implementation, such as Figure 1 As shown, the third shuttle unit 70 includes a second loading box 120, a fourth vacuum regulating device, a fourth vacuum device 702 connected to the second loading box 120, and a fourth connecting valve 701 disposed at the end of the second loading box 120.

[0066] In one implementation, the first vacuum device, the second vacuum device, the third vacuum device, and the fourth vacuum device are all used to evacuate the corresponding units.

[0067] In one implementation, such as Figure 1 As shown, there are multiple third shuttle units 70. Each third shuttle unit 70 is connected to an independent inflation device 50 for filling the third shuttle unit 70 with protective gas.

[0068] In one implementation, such as Figure 1As shown, the first shuttle unit 20, the second shuttle unit 30, and the third shuttle unit 70 all include a carrier 80 and a movable power supply device. The material container 110 and the second material container 120 are respectively mounted on the carrier 80. The carrier 80 can move while carrying the material container 110 or the second material container 120. The movable power supply device can supply power to the carrier 80 and each device of the first shuttle unit 20, the second shuttle unit 30, and the third shuttle unit 70. The power signal of the movable power supply device can be fed back to the control center 40. If the control center 40 detects that the power of the movable power supply device is low, it can control the shuttle unit to move to a charging station for charging.

[0069] Based on the aforementioned continuous vacuum brazing production line, this application provides a method for producing such a line. For example... Figure 2 As shown, the production method includes steps S201-S202.

[0070] S201, after the brazing process in a certain continuous vacuum brazing equipment is completed, the control center controls the first shuttle unit or the second shuttle unit to move to the end of the continuous vacuum brazing equipment and connects the first shuttle unit or the second shuttle unit with the continuous vacuum brazing equipment, so as to transfer the material rack carrying the brazed parts in the vacuum brazing chamber at the end of the continuous vacuum brazing equipment to the material box in the first shuttle unit or the second shuttle unit.

[0071] S202, the control center then controls the first shuttle unit to move to one end of the controlled cooling unit, or controls the second shuttle unit to move to one end of the cooling release unit or air-cooling unit, and connects with the controlled cooling unit, cooling release unit or air-cooling unit to transfer the material rack containing the brazed parts in the material box to the controlled cooling unit, cooling release unit or air-cooling unit for temperature controlled cooling, placement cooling or air cooling respectively.

[0072] Upon receiving a production task for the brazed component, the control center automatically acquires the component's characteristic information and retrieves matching cooling process data to implement the cooling process. When the first step of the cooling process is temperature-controlled cooling, the control center selects and activates the first shuttle unit, equipped with a first heater in the material container, to connect with the continuous vacuum brazing equipment, transferring the brazed component from the vacuum brazing chamber to the temperature-controlled cooling unit. When the first step of the cooling process is placement cooling or air cooling, the control center selects and activates the second shuttle unit to connect with the continuous vacuum brazing equipment, transferring the brazed component from the vacuum brazing chamber to the release cooling unit or air cooling unit.

[0073] In one specific implementation, the first shuttle unit or the second shuttle unit is connected to the continuous vacuum brazing equipment via the docking of the second and third docking valves.

[0074] In one specific implementation, the first shuttle unit or the second shuttle unit is connected to the cooling control unit, cooling release unit or air-cooling unit through the docking of the second connecting valve and the first connecting valve.

[0075] In one implementation, when the first shuttle unit is connected to the continuous vacuum brazing equipment, the control center has adjusted the temperature in the material box of the first shuttle unit to the starting temperature that matches the preset cooling curve of the brazing workpiece by controlling the first heater, and has adjusted the working vacuum degree in the first shuttle unit to match the working vacuum degree in the vacuum brazing chamber by controlling the first vacuum regulating device set in the first shuttle unit.

[0076] In one implementation, the control center controls the flow rate of the protective gas introduced into the first shuttle unit or the second shuttle unit and the pumping rate of the first vacuum device by controlling the first vacuum regulating device, thereby regulating the working vacuum level in the first shuttle unit or the second shuttle unit.

[0077] In one specific implementation, when the brazed component is subjected to temperature-controlled cooling or placement cooling in the controlled cooling unit or the release cooling unit, the control center actively adjusts the working vacuum level in the controlled cooling unit or the release cooling unit so that the working vacuum level dynamically matches the change in the temperature of the brazed component; the active adjustment includes: as the temperature of the brazed component decreases, reducing the flow rate of the protective gas entering the controlled cooling unit or the release cooling unit, while increasing the pumping speed of the second vacuum device to improve the working vacuum level, and the rate of change of the working vacuum level is proportional to the k-th power of the rate of change of the temperature of the brazed component.

[0078] For example, 1.5 ≤ k ≤ 2.5.

[0079] In one implementation, during the transfer process from the first shuttle unit carrying the brazed component to the controlled cooling unit, the control center controls the output power of the first heater to make the temperature inside the loading box dynamically change in accordance with the preset cooling curve of the brazed component, so that the brazed component undergoes partial temperature controlled cooling in the first shuttle unit; after the first shuttle unit transfers the brazed component to the controlled cooling unit, the brazed component continues to undergo subsequent temperature controlled cooling in the controlled cooling unit.

[0080] In one implementation, when a cooling control unit is connected to the first shuttle unit, the control center controls the output power of the second heater in the cooling control unit to match the temperature in the cooling control unit with the temperature in the material box; after the brazing workpiece is transferred to the cooling control unit, the control center controls the output power of the second heater in the cooling control unit to cool the brazing workpiece according to a preset cooling curve.

[0081] In one implementation, the control center controls the second vacuum regulating device installed in the cooling control unit and the cooling release unit to regulate the working vacuum level in the cooling control unit and the cooling release unit.

[0082] In some embodiments, the method further includes: according to the cooling process of the brazed parts, the control center controls the third shuttle unit to move to the other end of the controlled cooling unit, the release cooling unit, or the air cooling unit to connect with the controlled cooling unit, the release cooling unit, or the air cooling unit; the second loading box of the third shuttle unit transfers the rack carrying the brazed parts into or out of the controlled cooling unit, the release cooling unit, or the air cooling unit; the third shuttle unit connects to the controlled cooling unit and the release cooling unit in sequence to transfer the rack carrying the brazed parts from the controlled cooling unit to the release cooling unit for continued placement and cooling treatment; the third shuttle unit connects to the release cooling unit and the air cooling unit in sequence to transfer the rack carrying the brazed parts from the release cooling unit to the air cooling unit for continued air cooling treatment.

[0083] In one specific implementation, the control center controls the third shuttle unit to move to the other end of the controlled cooling unit, the decooling unit, or the air-cooling unit, and connects to the controlled cooling unit, the decooling unit, or the air-cooling unit through the docking of the fourth docking valve and the first docking valve. The material rack carrying the brazed parts is transferred into or out of the controlled cooling unit, the decooling unit, or the air-cooling unit through the second material box.

[0084] In one implementation, the control center controls the flow rate of the protective gas introduced into the third shuttle unit and the pumping rate of the fourth vacuum device by controlling the fourth vacuum regulating device, thereby regulating the working vacuum level in the third shuttle unit.

[0085] In one implementation, such as Figure 1 As shown, the sealing valves in the controlled cooling zone 101, the release cooling zone 102, and the air-cooled zone 103 are controlled cooling sealing valve 1011, release cooling sealing valve 1021, and air-cooled sealing valve 1031, respectively. All three valves have atmosphere isolation and temperature isolation functions and are opened and closed independently under the control of the control center. When the cooling process conditions in two adjacent controlled cooling units, two adjacent release cooling units, or two adjacent air-cooled units are consistent, the control center controls the opening of the controlled cooling sealing valve, release cooling sealing valve, or air-cooled sealing valve, merging the spaces of the two adjacent units into one, and uniformly cooling the brazed components within that space. When the cooling processes in two adjacent controlled cooling units, two adjacent release cooling units, or two adjacent air-cooled units are inconsistent, the control center controls the closing of the controlled cooling sealing valve, release cooling valve, or air-cooled sealing valve, allowing each unit to execute its own cooling process to cool the brazed components within it.

[0086] In one implementation, when a controlled cooling unit, venting cooling unit, or air-cooled unit needs to connect with the first shuttle unit, the second shuttle unit, or the third shuttle unit, the control center first controls the sealing valves on both sides of the unit to close, isolating the unit's space from other units. This ensures that the connection of the unit will not interfere with the normal cooling process in other units.

[0087] In one implementation, when adjacent cooling units are merged into one space, the control center uses the temperature feedback signals from each cooling unit to uniformly allocate the output of the second heater in each cooling unit, so that the temperature in the merged space remains uniform.

[0088] In one implementation, when the brazed part has completed all cooling treatment in the cooling station, the rack carrying the brazed part is transferred to the unloading area by the third shuttle unit for unloading.

[0089] When the first or second shuttle unit is connected to the continuous vacuum brazing equipment, the vacuum brazing chamber and the material container are connected to form a vacuum-sealed body isolated from the atmospheric environment. When the first or second shuttle unit is connected to the controlled cooling unit, the cooling release unit, or the air-cooling unit, the material container is connected to the controlled cooling unit, the cooling release unit, or the air-cooling unit to form a vacuum-sealed body isolated from the atmospheric environment. When the third shuttle unit is connected to the controlled cooling unit, the cooling release unit, or the air-cooling unit, the second material container is connected to the controlled cooling unit, the cooling release unit, or the air-cooling unit to form a vacuum-sealed body isolated from the atmospheric environment.

Claims

1. A production method for a continuous vacuum brazing production line, characterized in that, The continuous vacuum brazing production line includes a cooling station, a first shuttle unit, a second shuttle unit, a control center, and multiple continuous vacuum brazing devices. The cooling station includes a controlled cooling zone, a release cooling zone, and an air-cooled zone. The controlled cooling zone, release cooling zone, and air-cooled zone are respectively separated into multiple controlled cooling units, release cooling units, and air-cooled units by sealing valves. The production method includes: After the brazing process in a continuous vacuum brazing equipment is completed, the control center controls the first shuttle unit or the second shuttle unit to move to the end of the continuous vacuum brazing equipment and connect the first shuttle unit or the second shuttle unit to the continuous vacuum brazing equipment. The material rack carrying the brazed parts in the vacuum brazing chamber at the end of the continuous vacuum brazing equipment is transferred to the material box in the first shuttle unit or the second shuttle unit. Then, the control center controls the first shuttle unit to move to one end of the controlled cooling unit, or controls the second shuttle unit to move to one end of the decooling unit or the air-cooling unit, and connects with the controlled cooling unit, decooling unit or the air-cooling unit. The material rack carrying the brazed parts in the material box is transferred to the controlled cooling unit, decooling unit or the air-cooling unit for controlled cooling, placement cooling or air cooling respectively. The control center has a pre-installed process library, which includes cooling process data related to the characteristic information of the brazed parts. After receiving the production task for the brazed parts, the control center automatically acquires the characteristic information of the brazed parts and retrieves the cooling process data that matches the characteristic information to implement the cooling treatment of the brazed parts. The characteristic information includes at least one of the material, joint type, and size and shape of the brazed parts. When the first process step of the cooling process is temperature-controlled cooling, the control center selects and dispatches the first shuttle unit equipped with the first heater in the material box to connect with the continuous vacuum brazing equipment and transfers the brazed parts in the vacuum brazing chamber to the temperature-controlled cooling unit. When the first process step of the cooling process is placement cooling or air cooling, the control center selects and dispatches the second shuttle unit to connect with the continuous vacuum brazing equipment and transfers the brazed parts in the vacuum brazing chamber to the release cooling unit or air cooling unit.

2. The production method of the continuous vacuum brazing production line according to claim 1, characterized in that, When the first shuttle unit is connected to the continuous vacuum brazing equipment, the control center has adjusted the temperature in the material box of the first shuttle unit to the starting temperature that matches the preset cooling curve of the brazing workpiece by controlling the first heater, and has adjusted the working vacuum degree in the first shuttle unit to match the working vacuum degree in the vacuum brazing chamber by controlling the first vacuum regulating device set in the first shuttle unit.

3. The production method of the continuous vacuum brazing production line according to claim 1, characterized in that, During the transfer process of the brazing workpiece carried by the first shuttle unit to the controlled cooling unit, the control center controls the output power of the first heater to make the temperature in the loading box show a dynamic change that matches the preset cooling curve of the brazing workpiece, so that the brazing workpiece performs partial temperature controlled cooling in the first shuttle unit. After the first shuttle unit transfers the brazed component to the controlled cooling unit, the brazed component continues to undergo subsequent temperature control and cooling in the controlled cooling unit.

4. The production method of the continuous vacuum brazing production line according to claim 1, characterized in that, Each cooling control unit is equipped with a second heater that is independently controlled by the control center. When a cooling control unit is connected to the first shuttle unit, the control center controls the output power of the second heater in that cooling control unit to match the temperature in the cooling control unit with the temperature in the material box. After the brazing workpiece is transferred to the cooling control unit, the control center controls the output power of the second heater in that cooling control unit to cool the brazing workpiece according to a preset cooling curve.

5. The production method of the continuous vacuum brazing production line according to claim 1, characterized in that, The control center controls the second vacuum regulating device installed in the cooling control unit and the cooling release unit to regulate the working vacuum level in the cooling control unit and the cooling release unit.

6. The production method of the continuous vacuum brazing production line according to claim 5, characterized in that, When the brazed parts are subjected to temperature-controlled cooling or placement cooling in the controlled cooling unit or the release cooling unit, the control center actively adjusts the working vacuum level in the controlled cooling unit or the release cooling unit to dynamically match the working vacuum level with the temperature change of the brazed parts. This active adjustment includes: as the temperature of the brazed parts decreases, reducing the flow rate of the protective gas entering the controlled cooling unit or the release cooling unit, while increasing the pumping rate of the second vacuum device set in the controlled cooling unit or the release cooling unit to improve the working vacuum level. The rate of change of the working vacuum level is proportional to the k-th power of the rate of change of the temperature of the brazed parts, where 1.5≤k≤2.

5.

7. The production method of the continuous vacuum brazing production line according to claim 1, characterized in that, The continuous vacuum brazing production line also includes a third shuttle unit; the production method also includes: According to the cooling process of the brazed parts, the control center controls the third shuttle unit to move to the other end of the controlled cooling unit, the release cooling unit, or the air cooling unit to connect with the controlled cooling unit, the release cooling unit, or the air cooling unit. The second loading box of the third shuttle unit transfers the rack carrying the brazed parts into or out of the controlled cooling unit, the release cooling unit, or the air cooling unit. The third shuttle unit connects to the controlled cooling unit and the release cooling unit in sequence to transfer the rack carrying the brazed parts from the controlled cooling unit to the release cooling unit for continued placement and cooling. The third shuttle unit connects to the release cooling unit and the air cooling unit in sequence to transfer the rack carrying the brazed parts from the release cooling unit to the air cooling unit for continued air cooling.

8. The production method of the continuous vacuum brazing production line according to claim 1, characterized in that, The sealing valves in the controlled cooling zone, the release cooling zone, and the air-cooled zone all have atmosphere isolation and temperature isolation functions, and are opened and closed under the independent control of the control center. When the cooling process conditions in two adjacent controlled cooling units, two adjacent release cooling units, or two adjacent air-cooled units are the same, the control center controls the sealing valve to open, so that the space of the two adjacent units is merged into one, and the brazed parts in the space are cooled uniformly. When the cooling processes in two adjacent controlled cooling units, two adjacent release cooling units, or two adjacent air-cooled units are inconsistent, the control center controls the sealing valve to close, so that each unit executes its own cooling process to cool the brazed parts.

9. The production method of the continuous vacuum brazing production line according to claim 8, characterized in that, When a certain cooling control unit, cooling release unit, or air-cooled unit needs to connect with the first shuttle unit, the second shuttle unit, or the third shuttle unit, the control center first controls the sealing valves on both sides of the unit to close, so that the space of the unit is isolated from other units.

10. The production method of the continuous vacuum brazing production line according to claim 8, characterized in that, Each cooling control unit is equipped with a temperature measuring device; when the spaces of adjacent cooling control units are merged into one, the control center uses the temperature feedback signals from each cooling control unit to uniformly allocate the output of the second heater in each cooling control unit, so that the temperature in the merged space remains uniform.

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