A large-bending-degree copper bar welding machine

Abstract

The application relates to a copper bar welding machine with large bending degree, and belongs to the technical field of copper bar welding. The welding machine comprises a rack seat with an operation table, a positioning mechanism and a welding mechanism. The positioning mechanism comprises a positioning plate, a locking assembly, a first pressing assembly, a second pressing assembly and a pushing piece; the positioning plate is fixed to the operation table; the locking assembly applies force to the bending part of the copper bar, so that the side edge of the copper bar abuts against the positioning plate; the first pressing assembly presses one copper bar; the second pressing assembly comprises a first driving piece, a pressing plate and a transmission piece; the transmission piece is telescopically connected between the first driving piece and the pressing plate and has a pushed surface; after the locking assembly abuts against the copper bar, the first pressing assembly presses one copper bar, the first driving piece drives the pressing plate to descend and contact another copper bar, the transmission piece is continuously pressed to be telescopically contracted, the pushed surface moves downward and cooperates with the pushing piece, the copper bar is driven to move towards the pressed copper bar to reduce the joint gap, and then the welding mechanism is used for welding. The copper bar welding machine with large bending degree provided by the application can guarantee the welding quality.

Description

Technical Field

[0001] This application relates to the field of copper busbar welding technology, and more specifically, to a copper busbar welding machine with a large bending degree. Background Technology

[0002] In copper busbar welding operations, it is often necessary to handle copper busbar workpieces with large bending angles. These large-bending copper busbars typically have horizontal sections and inclined bending sections that are not on the same plane. When welding these large-bending copper busbars, it is usually necessary to position the two copper busbars on the operating table of the welding machine for butt welding.

[0003] Existing copper busbar welding machines typically use a positioning block on the operating table in conjunction with a movable clamping component for positioning. After placing two copper busbars on the operating table, a drive mechanism such as a lead screw and nut pushes the outer edge of the busbars, causing the inner edge to press against the positioning block. A pressure plate then presses the busbars firmly in place. However, for copper busbars with large-angle bends, the bent portion often extends beyond the operating table without effective support. This results in a significant weight on the portion of the busbar outside the operating table, causing a noticeable downward tilting or twisting tendency.

[0004] Furthermore, the force application points of existing clamping structures are usually concentrated and located on the outer edge of the copper busbar, some distance from the joint. During the vertical clamping process of the pressure plate on the copper busbar, the concentrated force application points and the gravity of the suspended part work together, causing the copper busbar to be prone to slight tilting. This results in an uneven joint between the two copper busbars, with one side being wider and the other narrower, affecting the subsequent welding quality and product qualification rate.

[0005] Therefore, ensuring uniform and consistent seams in copper busbars with large bends during the positioning process has become a pressing technical problem to be solved. Summary of the Invention

[0006] The purpose of this application is to provide a large bending degree copper busbar welding machine that can guarantee welding quality and improve the above-mentioned problems.

[0007] This application is achieved through the following technical solution: This application provides a large bending angle copper busbar welding machine, which includes a frame base, a positioning mechanism, and a welding mechanism. The frame base is equipped with an operating table. The positioning mechanism includes a positioning plate, a locking assembly, a first clamping assembly, a second clamping assembly, and a pushing component. The positioning plate is fixed to the operating table. The locking assembly is used to apply a pushing force to the bent portions of two copper busbars placed on the operating table, so that the sides of both copper busbars are pressed against the positioning plate. The first clamping assembly is used to press one of the copper busbars onto the operating table. The second clamping assembly includes a first driving component, a pressure plate, and a transmission component, the transmission component being retractable in the vertical direction. The ground is connected between the output end of the first drive member and the pressure plate. The transmission member has a push surface. The push member is fixed to the operating table and is used to cooperate with the push surface. The welding mechanism is used to weld the two copper busbars along the joint. After the locking assembly presses the copper busbar against the positioning plate, the first pressing assembly presses one copper busbar. The first drive member drives the pressure plate to descend until it contacts the other copper busbar and continues to apply pressure. The transmission member is compressed and the push surface descends. The push member pushes the push surface, so that the transmission member and the pressure plate drive the other copper busbar to move toward the already pressed copper busbar, so as to narrow the joint between the two copper busbars. The length direction of the joint is defined as the first direction.

[0008] In the technical solution of this application embodiment, the locking component acts directly on the bent part, offsetting the torsional moment generated by the suspended self-weight of the copper busbar bending section, preventing the copper busbar from tilting or skewing, and ensuring the stability of the positioning posture. While the second clamping component clamps the copper busbar, it utilizes the compression and contraction of the transmission component and the cooperation of the pushing component to simultaneously convert the vertical clamping action into a horizontal pushing action. This allows the copper busbars to be joined to actively approach the fixed copper busbar without the need for an additional independent power source, quickly eliminating uneven joints and ensuring a consistent joint width throughout. The first clamping component first fixes one copper busbar, providing a rigid reference for the movement of the other copper busbar, making the joint reduction process precise and controllable. This solves the problem of uneven joint width on one side and narrowness on the other caused by uneven force on copper busbars with large bends, resulting in a well-formed and high-quality weld after welding.

[0009] In some embodiments, the transmission member includes a first connecting portion, a first elastic unit, a first guide rod, a second connecting portion, a second elastic unit, and a second guide rod. The first connecting portion is connected to the output end of the first driving member. The second connecting portion has a guide groove extending horizontally and perpendicular to a first direction. The first guide rod is connected to the first connecting portion and extends into the guide groove. The first elastic unit is disposed between the first connecting portion and the second connecting portion, and the first elastic unit is parallel to the extension direction of the guide groove. The second guide rod extends vertically and is connected to a pressure plate. The second connecting portion has a through hole for the second guide rod to pass through. The second elastic unit is sleeved on the second guide rod and its two ends abut against the pressure plate and the second connecting portion, respectively. A push surface is disposed on the second connecting portion. When the transmission member is compressed and contracts, the second connecting portion moves along the second guide rod and squeezes the second elastic unit. When the pushing member pushes the push surface, the second connecting portion moves toward the already compressed copper busbar and squeezes the first elastic unit.

[0010] In the technical solution of this application embodiment, the vertical contraction and horizontal tightening actions are decoupled into two independent elastic guiding links. The first connecting part, the second connecting part, and the pressure plate rely on elastic units to transmit force, ensuring that the excessive downward pressure after the pressure plate contacts the copper busbar is accurately converted into vertical movement of the second connecting part. This, in turn, triggers horizontal tightening via a pushing component, resulting in a smooth and impact-free action transition. The cooperation between the first guide rod and the guide groove constrains the second connecting part to move horizontally only in a direction perpendicular to the joint, ensuring precise tightening direction, preventing the copper busbar from swaying during the closing process, and improving the uniformity of the joint. The second guide rod ensures that the pressure plate remains vertically raised and lowered throughout the entire process, without any deviation in the tightening position.

[0011] In some embodiments, the second connecting portion is provided with a guide groove on each of its opposite sides along the first direction, and both grooves cooperate with the corresponding first guide rods; the second connecting portion forms a push surface on the surface of the pressed copper busbar in a horizontal and perpendicular direction to the first direction; the second connecting portion is provided with a protrusion on the side away from the positioning plate, the protrusion is located on the push surface, and the surface of the protrusion is an inclined surface, which gradually approaches the pressed copper busbar in a downward direction.

[0012] In the technical solution of this application embodiment, the second connecting part is allowed to rotate slightly under the thrust difference, so that the pushing force can be distributed as needed, with the wide-slit side obtaining a larger displacement and the narrow-slit side obtaining a smaller displacement. This flexible adaptive capability precisely solves the problem of uneven splicing, resulting in higher weld formation quality. The guide groove and the first guide rod are not subjected to absolute rigid constraints. Through reasonable fitting clearance, normal guiding function is ensured while giving the mechanism the necessary degree of freedom, avoiding jamming or excessive local stress on the copper busbar due to over-constraint, resulting in smoother operation and better protection of the copper busbar surface.

[0013] In some embodiments, the frame base includes an installation section and a processing section, with the operating table located in the processing section and suspended in the air; a positioning plate is disposed along the boundary line between the installation section and the processing section, and the length direction of the positioning plate is perpendicular to the first direction; the welding mechanism includes a welding execution unit and a movable component, the movable component being mounted on the installation section for driving the welding execution unit to move along the seam of two copper busbars located on the operating table; the installation section and the processing section are distributed along the first direction; the orthographic projections of the first clamping component, the second clamping component, and the welding execution unit on the operating table do not exceed the edge of the operating table.

[0014] In the technical solution of this application embodiment, the suspended design of the operating table provides natural clearance for the inclined section of the large-bend copper busbar. The workpiece can be stably placed in the predetermined welding position, and the clamping process is simple and quick, without the need for repeated adjustments. Since the installation section and the processing section are distributed along a first direction parallel to the joint, the movable component is placed on the extension line of the joint, rather than directly above the operating table. This makes the drive path of the welding execution unit and the joint itself spatially collinear. The movement of the movable component will not intersect or encroach on the space of the first and second clamping components pressing down vertically from above, eliminating the problem of motion interference, thereby ensuring that the welding execution unit can move stably along the joint without obstruction, and the welding accuracy and weld quality are reliably guaranteed. Furthermore, by forcibly requiring that the orthographic projections of the first clamping component, the second clamping component, and the welding execution unit on the operating table do not exceed the edge of the operating table, it is clear that the core areas of all welding and fixing actions are strictly limited to the bearing surface of the operating table. This constraint creates a completely free and unobstructed space outside the operating table boundary for the flexible and extensive bending sections of the copper busbar, enabling the equipment to easily adapt to workpieces with various bending angles and sizes, thus demonstrating strong versatility.

[0015] In some embodiments, the locking assembly includes a lead screw and a nut engaging with the lead screw, the axis of the lead screw being parallel to a first direction, and the nut being movable along the lead screw to conform to the edge of a bent portion of a copper busbar placed on the operating table, thereby pressing the copper busbar against the positioning plate.

[0016] In the technical solution of this application embodiment, the locking component, in conjunction with the positioning plate, applies force specifically to the edge of the bent portion of the copper busbar, successfully locking the complex-shaped and partially suspended large-bend copper busbar laterally. The heat generated by welding can accumulate at the bent portion of the copper busbar, causing this portion to soften. The heavier inclined section of the copper busbar may be pulled to rotate under its weight. The nut in this application can limit the change in the bending angle of the copper busbar by pressing against the bent portion, ensuring the stability of the copper busbar's quality.

[0017] In some embodiments, an auxiliary flow channel for containing fluid is provided inside the nut and / or inside the positioning plate, and the auxiliary flow channel inside the nut is an annular structure coaxial with the lead screw.

[0018] In the technical solution of this application embodiment, an auxiliary flow channel is provided inside the nut and / or positioning plate, enabling the locking components and positioning plate, which originally only served a mechanical positioning function, to also possess active thermal management capabilities. When the heat generated during the welding process is conducted to the nut and positioning plate through the copper busbar, it can be promptly carried away by the fluid in the auxiliary flow channel. This suppresses temperature accumulation on the workpiece and positioning components during the welding process, avoids positioning loosening or reference drift caused by thermal expansion, and maintains clamping accuracy during the welding process.

[0019] In some embodiments, the surface of the operating table for placing copper busbars is provided with a mounting groove for mounting a forming tray, and the surface of the forming tray facing the copper busbars is flush with the surface of the operating table facing the copper busbars; a welding groove is provided at the center of the forming tray, and the welding groove is aligned with the joint between the two copper busbars to be welded.

[0020] In the technical solution of this application embodiment, the weld groove opened on the forming pallet is directly opposite the joint, providing a controlled forming space for the back of the weld. During the welding process, the molten metal cools and solidifies in the weld groove, and the shape of the back of the weld is precisely controlled by the contour of the weld groove, ensuring that the weld back has uniform reinforcement, a smooth surface, and no defects such as undercut. The forming pallet has better thermal conductivity than the operating table, allowing the heat in the welding area to be conducted away at a faster rate, avoiding the accumulation of heat in the welding area that could lead to safety accidents.

[0021] In some embodiments, a cooling groove is provided on the side of the forming pallet away from the welding groove. The cooling groove extends along a first direction and forms a main channel for containing fluid with the bottom wall of the mounting groove. The bottom wall of the mounting groove has at least two openings that communicate with the outside.

[0022] In the technical solution of this application embodiment, the cooling tank and the bottom wall of the mounting tank enclose a main channel, which extends along a first direction, making the flow path of the cooling fluid completely consistent with the weld direction. The fluid flows from one end of the weld to the other, always close to the direct below the welding heat source, and can uniformly and synchronously carry away heat along the entire length of the weld, avoiding deformation or residual stress problems caused by uneven cooling rates in different sections of the weld. The cooling tank is located on the side of the forming plate away from the weld pool, separated from the weld pool only by a thin layer of material from the forming plate. This means that the distance between the cooling fluid and the back of the weld pool is compressed to the shortest possible, the heat conduction path is extremely short, and the cooling response speed is fast. The welding heat is carried away by the fluid as soon as it is conducted to the plate, effectively protecting the forming plate from damage due to continuous high temperature, and also accelerating the solidification and forming efficiency of the back of the weld.

[0023] In some embodiments, the sidewall of the mounting groove is further provided with an overflow port, which connects to the main channel and extends to the surface of the operating table facing the copper busbar; each end of the main channel along the first direction is connected to an overflow port.

[0024] In the technical solution of this application embodiment, the opening at the bottom wall of the mounting tank undertakes the majority of the cooling fluid transport task, ensuring sufficient and stable flow in the main channel for forced convection heat transfer, and the overall cooling capacity of the welding area is not affected. The overflow port only diverts a small amount of fluid. The small amount of fluid drawn from both ends of the main channel by the overflow port forms auxiliary wetting cooling on the surface of the operating table. Although the amount of this fluid is small, it directly contacts the bottom surface of the copper busbar, resulting in high heat transfer efficiency. It can fine-tune the local temperature of the bottom surface of the copper busbar with minimal fluid consumption, which is especially helpful for auxiliary heat dissipation at both ends of the weld (the arc initiation and arc termination areas where heat easily accumulates). Each end of the main channel along the first direction is connected to an overflow port, and the small overflow occurs simultaneously from both ends. This helps to slowly discharge any small bubbles or locally overheated fluid that may accumulate at both ends of the main channel, making the flow state and cooling conditions along the main channel more uniform and stable.

[0025] In some embodiments, a plurality of turbulence-disrupting columns are fixed in the inner cavity of the cooling tank, and the turbulence-disrupting columns are arranged alternately along a first direction.

[0026] In the technical solution of this application embodiment, the introduction of turbulence columns transforms the flow state of the fluid in the main channel from a stable laminar flow to a turbulent flow with numerous micro-vortices. The fluid repeatedly splits, collides, and changes direction among the staggered columns, continuously disrupting and renewing the heat transfer boundary layer near the wall, thus increasing the convective heat transfer coefficient between the fluid and the cooling tank wall. Welding heat can be transferred more quickly from the forming tray to the fluid, enhancing cooling efficiency. The turbulence columns are staggered along the first direction, rather than aligned, preventing the fluid from forming a straight, direct flow path within the main channel. The fluid is forced to meander along a tortuous path, flowing through every corner of the cooling tank cavity, avoiding short-circuiting and dead zones. This results in a more uniform cooling effect along the entire length of the weld joint, with the solidification conditions of each section of the weld tending to be the same.

[0027] In some embodiments, the weld pool is provided with outward and downward inclined guide slopes at both ends along its own length direction.

[0028] In the technical solution of this application embodiment, the guide ramps are set at both ends of the weld pool along its length, directly addressing the problem of excessive molten material accumulation at the arc-starting and arc-ending ends of the weld. Excess molten material flows out along the ramps, no longer lingering at the ends of the weld pool to form weld beads or protrusions. The back of the weld is uniformly and neatly formed along its entire length, reducing the workload of post-weld grinding and cleaning of burrs at both ends. The outward and downward sloping design utilizes gravity, allowing excess molten material to naturally slide away from the welding area. The molten material will not flow back into the weld pool and interfere with the forming weld body, nor will it overflow and stick to the copper busbar surface or pressure plate, ensuring the continuity of the welding process and the cleanliness of the workpiece appearance.

[0029] In some embodiments, the positioning mechanism further includes a second driving member connected to the mounting section; the orthographic projections of the first clamping component and the second clamping component on the operating table are respectively located on both sides of the seam between the two copper busbars; both clamping components are connected to the output end of the second driving member and move up and down synchronously under the drive of the second driving member; the second driving member is an electric cylinder.

[0030] In the technical solution of this application embodiment, the second driving component is responsible for long-distance lifting and lowering according to the copper busbar thickness, while the first driving component is responsible for the final short-distance clamping, forming a two-level collaborative driving architecture of macroscopic coarse adjustment and microscopic fine adjustment. Regardless of the change in copper busbar thickness, the second driving component can quickly deliver the first and second clamping components to the most suitable starting position, while the first driving component only needs to complete the clamping force within a very short stroke. The equipment's adaptability to copper busbars of different thicknesses is enhanced, and there is no need to manually adjust the height of the first and second clamping components during production changeovers, resulting in a high degree of automation. The second driving component, driven by an electric cylinder, has precise stroke control capabilities and self-locking characteristics. The electric cylinder accurately positions itself according to the copper busbar thickness parameters, ensuring that the two clamping components reach the same height synchronously, preventing bias pressure problems caused by inconsistent heights on both sides. The precise pre-positioning of the long stroke also creates stable initial conditions for the subsequent short-stroke fine pressure application of the first driving component.

[0031] In some embodiments, the positioning mechanism further includes two centering components arranged opposite each other with the operating table as the center, each centering component including a push rod that extends and retracts in a direction perpendicular to the first direction, the end of the push rod being used to push the side of the copper busbar.

[0032] In the technical solution of this application embodiment, two centering components are arranged opposite each other with the operating table as the center. By utilizing the relative extension and retraction movement of the double-sided push rods, the sides of the copper busbar are pushed from both sides towards the center, realizing the automatic centering of the copper busbar in a direction perpendicular to the first direction. This solves the problem of difficulty in ensuring precise alignment of two copper busbars when manually placing them, and reliably ensures the consistency and repeatability of the splice position.

[0033] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0034] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0035] Figure 1 A schematic diagram of the overall structure of a large-bending copper busbar welding machine provided for some embodiments of this application; Figure 2 A partial structural schematic diagram of a large-bending copper busbar welding machine provided for some embodiments of this application; Figure 3 A side view of a large bending degree copper busbar welding machine provided for some embodiments of this application; Figure 4 for Figure 2 Enlarged view of point A in the middle; Figure 5 Cross-sectional views of nuts provided for some embodiments of this application; Figure 6 This application provides schematic diagrams of the structure of an operating console for some embodiments. Figure 7 This is a schematic diagram of the structure of the mounting slot on the operating table provided in some embodiments of this application; Figure 8 Cross-sectional views of the worktable provided in some embodiments of this application; Figure 9 This is a schematic diagram of the cooling groove of the molding tray provided in some embodiments of this application; Figure 10 This application provides schematic diagrams of the structure of an operating console for other embodiments. Figure 11 for Figure 10 Enlarged view of point B in the middle; Figure 12 A schematic diagram of the overall structure of a large-bend copper busbar welding machine including a centering component, provided for some embodiments of this application; Figure 13 This is a schematic diagram of the structure of a transmission component provided in some embodiments of this application; Figure 14 This is a partial structural schematic diagram of the positioning mechanism provided in some embodiments of this application; Figure 15This is a partial structural schematic diagram of a positioning mechanism provided in some other embodiments of this application.

[0036] Icons: 1-Frame base; 10-Installation section; 11-Processing section; 12-Operating table; 120-Installation slot; 1201-Overflow port; 13-Locking assembly; 130-Screw rod; 131-Nut; 1310-Auxiliary flow channel; 14-Forming tray; 140-Welding groove; 1400-Guiding slope; 141-Cooling groove; 1410-Breakthrough column; 2-Copper busbar; 3-Positioning mechanism; 30-Second clamping assembly; 300-First driving component; 301-Pressure plate; 302 - Transmission component; 3020 Push surface; 3021 First connecting part; 3022 First elastic unit; 3023 First guide rod; 3024 Second connecting part; 3025 Second elastic unit; 3026 Second guide rod; 3027 Guide groove; 31 Positioning plate; 32 Second driving component; 33 Centering component; 34 First pressing component; 35 Pushing component; 4- Welding mechanism; 40 Welding execution unit; 41 Movable component; X- First direction. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0038] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used in the description of this application is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms "comprising" and "having," and any variations thereof, in the description, claims, and accompanying drawings of this application are intended to cover non-exclusive inclusion. The terms "first," "second," etc., in the description, claims, or accompanying drawings of this application are used to distinguish different objects, not to describe a specific order or hierarchy.

[0039] In this application, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this application can be combined with other embodiments.

[0040] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "attachment" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0041] In this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, in this application, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0042] In this application, "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0043] According to some embodiments of this application, optionally, such as Figure 1 As shown, this application provides a large bending degree copper busbar 2 welding machine, which includes a frame base 1, a positioning mechanism 3, and a welding mechanism 4. The frame base 1 is provided with an operating table 12; the positioning mechanism 3 includes a positioning plate 31, a locking assembly 13, a first pressing assembly 34, a second pressing assembly 30, and a pushing member 5; the positioning plate 31 is fixed to the operating table 12; the locking assembly 13 is used to apply a pushing force to the bent parts of the two copper busbars 2 placed on the operating table 12, so that the sides of the two copper busbars 2 are pressed against the positioning plate 31; the first pressing assembly 34 is used to press one of the copper busbars 2 onto the operating table 12; the second pressing assembly 30 includes a first driving member 300, a pressure plate 301, and a transmission member 302, the transmission member 302 being retractably connected in the vertical direction to the... The output end of the first driving member 300 is between the pressure plate 301 and the transmission member 302, which has a push surface 3020. The push member 5 is fixed to the operating table 12 and is used to cooperate with the push surface 3020. The welding mechanism 4 is used to weld the two copper busbars 2 along the joint. After the locking assembly 13 presses the copper busbar 2 against the positioning plate 31, the first pressing assembly 34 presses one copper busbar 2. The first driving member 300 drives the pressure plate 301 to descend to contact the other copper busbar 2 and continue to apply pressure. The transmission member 302 is compressed and the push surface 3020 descends. The push member 5 pushes the push surface 3020, so that the transmission member 302 and the pressure plate 301 drive the other copper busbar 2 to move toward the pressed copper busbar 2 to narrow the joint between the two copper busbars 2. The length direction of the joint is defined as the first direction X.

[0044] In practical application, two copper busbars 2 with large bending angles (both with horizontal sections and bent sections extending outwards from the operating table 12) are placed on the operating table 12 of the frame base 1, so that a seam extending along the first direction X is formed between the mating edges of the two copper busbars 2. A positioning plate 31 is fixed on the operating table 12, which serves as a positioning reference. First, the locking component 13 in the positioning mechanism 3 applies a pushing force to the bent parts of the two copper busbars 2. Since the bent parts are suspended and heavy, they are prone to warping. The locking component 13 applies force directly from the bent parts, pushing the two copper busbars 2 to rotate around the seam area, so that the sides of the two copper busbars 2 are tightly against the positioning plate 31, completing the initial positioning. Subsequently, the first pressing component 34 is activated, pressing one of the copper busbars 2 (the first fixed side) tightly against the operating table 12, establishing a fixed positioning reference. Next, the second clamping assembly 30 begins operation. The first driving component 300 drives the pressure plate 301 to descend vertically, and the pressure plate 301 first contacts the upper surface of the other copper busbar 2 (the side to be joined). The first driving component 300 continues to apply pressure, and the transmission component 302, connected between the output end of the first driving component 300 and the pressure plate 301, begins to contract vertically under pressure, and the push surface 3020 on the transmission component 302 descends accordingly. At this time, the pusher 5 fixed on the operating table 12 engages with the descending push surface 3020, and the pusher 5 applies a pushing force to the push surface 3020 in the direction of the already clamped copper busbar 2. This pushing force is transmitted to the copper busbar 2 on the side to be joined through the transmission component 302 and the pressure plate 301, causing the copper busbar 2 to move horizontally towards the already clamped copper busbar 2, thereby actively narrowing the joint and making the two copper busbars 2 fit tightly together along the joint with a uniform gap. Finally, the welding mechanism 4 welds the joint along the first direction X to complete the welding.

[0045] The locking component 13 acts directly on the bent section, offsetting the torsional moment caused by the suspended weight of the copper busbar 2, preventing it from tilting or skewing and ensuring stable positioning. The second clamping component 30, while clamping the copper busbar 2, utilizes the compression of the transmission component 302 and the cooperation of the pushing component 5 to simultaneously convert the vertical clamping action into a horizontal pushing action. This eliminates the need for an independent power source, allowing the copper busbars to be joined to actively approach the fixed copper busbar 2, quickly eliminating uneven seams and ensuring a consistent seam width. The first clamping component 34 first fixes one copper busbar 2, providing a rigid reference for the movement of the other copper busbar 2. This makes the seam reduction process precise and controllable, solving the problem of uneven seam width on one side due to uneven force on large-bend copper busbars. The resulting weld has good shape and high quality. The entire process is continuous, with automatic linkage between positioning and seam reduction, improving work efficiency and welding qualification rate.

[0046] According to some embodiments of this application, optionally, such as Figures 13-15As shown, the transmission component 302 includes a first connecting portion 3021, a first elastic unit 3022, a first guide rod 3023, a second connecting portion 3024, a second elastic unit 3025, and a second guide rod 3026. The first connecting portion 3021 is connected to the output end of the first driving component 300. The second connecting portion 3024 has a guide groove 3027 extending horizontally and perpendicular to the first direction X. The first guide rod 3023 connects to the first connecting portion 3021 and extends into the guide groove 3027. The first elastic unit 3022 is disposed between the first connecting portion 3021 and the second connecting portion 3024, and the first elastic unit 3022 is parallel to the guide groove 3027. The extension direction; the second guide rod 3026 extends vertically and is connected to the pressure plate 301. The second connecting part 3024 has a through hole for the second guide rod 3026 to pass through. The second elastic unit 3025 is sleeved on the second guide rod 3026 and its two ends abut against the pressure plate 301 and the second connecting part 3024 respectively. The push surface 3020 is provided on the second connecting part 3024. When the transmission member 302 is compressed and contracted, the second connecting part 3024 moves along the second guide rod 3026 and squeezes the second elastic unit 3025. When the push member 5 pushes the push surface 3020, the second connecting part 3024 moves toward the already compressed copper busbar 2 and squeezes the first elastic unit 3022.

[0047] In practical application, after placing two large-bend copper busbars 2 on the operating table 12, the locking assembly 13 presses the sides of the two copper busbars 2 against the positioning plate 31, and the first pressing assembly 34 presses and fixes one of the copper busbars 2. The first driving member 300 drives the first connecting part 3021 to descend, and through the first elastic unit 3022 and the first guide rod 3023, it drives the second connecting part 3024 to move down, and the pressure plate 301 descends and contacts the copper busbar 2 to be assembled. The first driving member 300 continues to apply pressure, and the pressure plate 301 can no longer move down. The second connecting part 3024 slides down along the second guide rod 3026, compressing the second elastic unit 3025, and the push surface 3020 fixed on the second connecting part 3024 descends accordingly. When the push surface 3020 descends to contact the push member 5 fixed on the operating table 12, the push member 5 abuts against the push surface 3020. As the second connecting part 3024 continues to move downward, the pushing member 5 applies a horizontal thrust to the pushed surface 3020 toward the already pressed copper busbar 2. This thrust causes the second connecting part 3024 to move as a whole toward the already pressed copper busbar 2, squeezing the first elastic unit 3022. During this process, the guide grooves 3027 on both sides of the second connecting part 3024 along the first direction X respectively cooperate with the corresponding first guide rods 3023, constraining the second connecting part 3024 to slide smoothly only in a horizontal direction perpendicular to the first direction X. The second connecting part 3024 drives the pressure plate 301 and the copper busbar 2 to be joined to move laterally synchronously through the second guide rod 3026, so that the copper busbar 2 fits tightly against the fixed copper busbar 2, eliminating the joint gap. Subsequently, the welding mechanism 4 completes the welding along the first direction X.

[0048] This embodiment decouples the vertical contraction and horizontal tightening actions into two independent elastic guiding links. The first connecting part 3021, the second connecting part 3024, and the pressure plate 301 rely on elastic units to transmit force. This ensures that the excessive downward pressure of the pressure plate 301 after contacting the copper busbar 2 is precisely converted into vertical movement of the second connecting part 3024, which in turn triggers horizontal tightening via the pusher 5. The action transition is smooth and impact-free. The cooperation between the first guide rod 3023 and the guide groove 3027 constrains the second connecting part 3024 to move horizontally only in a direction perpendicular to the joint, ensuring accurate tightening direction and preventing the copper busbar 2 from swaying during the approach process, thus improving the uniformity of the joint. The second guide rod 3026 ensures that the pressure plate 301 remains vertically raised and lowered throughout the entire process, without shifting its tightening position. The first elastic unit 3022 and the second elastic unit 3025 not only transmit power but also provide restoring force, allowing each component to automatically return to its initial state after the tightening and pressing actions are completed, preparing for the next welding cycle and improving the continuous operation capability and reliability of the equipment. The push surface 3020 is integrated on the second connecting part 3024, and its cooperation with the pusher 5 directly drives the entire pressure plate 301 assembly to move laterally, eliminating the need for an additional power source and intermediate mechanism. The structure is compact and the manufacturing cost is low.

[0049] According to some embodiments of this application, optionally, such as Figures 14-15 As shown, the second connecting part 3024 has a guide groove 3027 on each of its two opposite sides along the first direction X, and both of them cooperate with the corresponding first guide rod 3023; the second connecting part 3024 forms a push surface 3020 on the surface of the compressed copper busbar 2 in a horizontal and perpendicular direction to the first direction X; the second connecting part 3024 has a protrusion on the side away from the positioning plate 31, the protrusion is located on the push surface 3020, and the surface of the protrusion is an inclined surface, which gradually approaches the compressed copper busbar 2 from top to bottom.

[0050] The guide groove 3027 and the first guide rod 3023 are not tightly fitted, but have a small gap, or an elastic bushing is provided at the groove opening. In this way, when the thrust on both sides is balanced, the second connecting part 3024 still performs overall translation; when the protrusion causes a thrust deviation, the guide groove 3027 on this side can produce a small tilt displacement along the first guide rod 3023, so that the second connecting part 3024 can rotate controllably around the vertical axis.

[0051] In practical applications, when the seam between two copper busbars 2 is wider on one side and narrower on the other side along the first direction X after they are joined, the structure of this embodiment can actively adapt to and correct this unevenness by means of the slight rotation generated by the second connecting part 3024 when the force is uneven.

[0052] The specific operation process is as follows: Two large-bend copper busbars 2 are placed on the operating table 12. The locking component 13 pushes the bent part of the copper busbar 2 so that its side is pressed against the positioning plate 31. The first pressing component 34 presses and fixes one of the copper busbars 2. At this time, it is observed that the width of the joint between the unpressed copper busbar 2 and the fixed copper busbar 2 is different, and the wider gap area is exactly facing the side with the protrusion on the second connecting part 3024. The first driving component 300 drives the first connecting part 3021 to descend, and the pressure plate 301 contacts the copper busbar 2 to be joined first through the first elastic unit 3022 and the second connecting part 3024. The first driving component 300 continues to apply pressure, the transmission component 302 retracts, and the second connecting part 3024 moves down along the second guide rod 3026 and compresses the second elastic unit 3025. The pushed surface 3020 and the protrusion on it descend synchronously. When the inclined surface of the protrusion contacts the pusher 5 fixed to the operating table 12, the force exerted by the pusher 5 on the inclined surface on the side opposite to the positioning plate 31 creates a large local thrust on that side. A certain clearance or allowance is maintained between the guide groove 3027 and the first guide rod 3023, allowing the second connecting part 3024 to rotate slightly when subjected to unequal pushing forces on both sides. Specifically, the side with the protrusion experiences a larger thrust, resulting in a greater displacement of the second connecting part 3024 towards the already pressed copper busbar 2; while the side away from the protrusion experiences a relatively smaller thrust and less displacement. This differentiated displacement is transmitted to the pressure plate 301 via the second guide rod 3026, causing the pressure plate 301 to apply a greater lateral pushing force to the wide-slot side of the copper busbar 2, and a smaller pushing force to the narrow-slot side. The second connecting part 3024 exhibits a slight rotation, causing the pressure plate 301 and the copper busbar 2 to be assembled to move closer to the fixed copper busbar 2 by pushing more in wider areas and less in narrower areas, ultimately making the entire seam more uniform along its length. After the seam is adjusted to the correct position, the welding mechanism 4 completes the welding along the first direction X. During unloading, the first elastic unit 3022 pushes the second connecting part 3024 to return to its horizontal position, and the second elastic unit 3025 pushes the pressure plate 301 to return to its vertical position, and the second connecting part 3024 also returns to its initial non-rotating state.

[0053] This embodiment allows the second connecting part 3024 to rotate slightly under the thrust difference, enabling the pushing force to be distributed as needed, with a larger displacement on the wide-slit side and a smaller displacement on the narrow-slit side. This flexible adaptive capability precisely solves the problem of uneven seam, resulting in higher weld formation quality. The guide groove 3027 and the first guide rod 3023 are not subjected to absolute rigid constraints. Through a reasonable fit gap, normal guiding function is ensured while giving the mechanism the necessary degree of freedom, avoiding jamming or excessive local stress on the copper busbar 2 due to over-constraint, resulting in smoother operation and better protection of the surface of the copper busbar 2.

[0054] According to some embodiments of this application, optionally, such as Figures 1-3As shown, the frame base 1 includes an installation section 10 and a processing section 11. The operating table 12 is located in the processing section 11 and is suspended in the air. The positioning plate 31 is set along the boundary line between the installation section 10 and the processing section 11, and the length direction of the positioning plate 31 is perpendicular to the first direction X. The welding mechanism 4 includes a welding execution unit 40 and a movable component 41. The movable component 41 is installed in the installation section 10 and is used to drive the welding execution unit 40 to move along the joint of the two copper busbars 2 located on the operating table 12. The installation section 10 and the processing section 11 are distributed along the first direction X. The orthographic projections of the first clamping component 34, the second clamping component 30 and the welding execution unit 40 on the operating table 12 do not exceed the edge of the operating table 12.

[0055] Welding, also known as fusion welding, is a manufacturing process and technology that joins metals or other thermoplastic materials such as plastics by heating, high temperature or high pressure.

[0056] The welding method used for the copper busbar 2 in this application is TIG welding. Arc welding is the most widely used welding method in industrial production. It involves using the metal to be welded as one electrode and the welding rod as the other. When the two electrodes are close together, an electric arc is generated. The heat generated by the arc discharge (commonly known as arc combustion) melts the welding rod and the workpiece together, and after solidification, a weld is formed, thus obtaining a strong joint. TIG welding, also known as non-consumable electrode inert gas welding, is an arc welding method that generates heat between a non-consumable electrode and the workpiece; it is often referred to as tungsten inert gas welding.

[0057] The solder used in welding copper busbar 2 is copper welding wire.

[0058] The fluid can be a liquid or a gas. For example, when the fluid is a gas, it can be air; or when the fluid is a liquid, it can be, but is not limited to, water, oil, or a mixture of water and ethylene glycol. This application describes the fluid as a liquid.

[0059] The term "suspended" for the control panel 12 does not simply mean that there is no space below it, but rather emphasizes that the control panel 12 is an independent supporting platform, with no other components of the frame base 1 outside its edges. Therefore, regardless of whether the bent section of the copper busbar 2 curves upward or extends downward, it can obtain free accommodation space outside the edges of the control panel 12.

[0060] In practical applications, when welding large-bend copper busbars 2, the operator first places the two copper busbars 2 to be welded on the processing section 11 of the frame base 1. The processing section 11 is equipped with a suspended operating table 12. The horizontal sections of the copper busbars 2 are supported on the table surface of the operating table 12 and joined together, so that the seam between the two copper busbars 2 is located above the operating table 12. Due to the large-angle bend of the copper busbars 2, their inclined bending sections extend outward from the edge of the operating table 12, naturally entering the suspended area below or above the operating table 12. Thanks to the suspended setting of the operating table 12, these extended bending parts will not touch or squeeze other structures of the frame base 1. Next, the positioning mechanism 3 starts to work. The first driving component 300 drives the pressure plate 301 to descend within the processing section 11, firmly pressing the horizontal sections of the two copper busbars 2 onto the operating table 12, completing the positioning of the workpiece. Because the orthographic projections of the first clamping component 34 and the second clamping component 30 on the operating table 12 do not exceed the edge of the operating table 12, the pressure plate 301 will neither contact the inclined bending section of the copper busbar 2 nor block or occupy the area outside the operating table 12.

[0061] After the workpiece is fixed, the welding mechanism 4 enters the working state. The movable component 41 is installed on the mounting section 10 and drives the welding torch of the welding execution unit 40 to move. Since the mounting section 10 and the processing section 11 are distributed along the first direction X, that is, parallel to the length direction of the weld seam, the movable component 41 is located on the side of the operating table 12 (e.g., on one side of the start or end of the weld seam). The movable component 41 is installed on the mounting section 10, which drives the welding torch of the welding execution unit 40 to extend from this side above the operating table 12 and move stably from one end to the other along the weld seam parallel to the first direction X, completing the welding of the entire weld seam.

[0062] Throughout the entire operation, the orthographic projections of the first clamping assembly 34, the second clamping assembly 30, and the welding execution unit 40 onto the operating table 12 never extend beyond the edge of the operating table 12. This means that the pressure plate 301 is only responsible for clamping the horizontal section on the table surface, while the welding execution unit 40 only moves along the seam above the table surface. All functional components are precisely converged within the table surface area of ​​the operating table 12, without interfering with the bent portion extending from the copper busbar 2.

[0063] The suspended design of the operating table 12 provides natural clearance for the inclined section of the large-bend copper busbar 2. The workpiece can be stably placed in the predetermined welding position, and the clamping process is simple and quick, without repeated adjustments. Since the mounting section 10 and the processing section 11 are distributed along the first direction X parallel to the joint, the movable component 41 is placed on the extension line of the joint, rather than directly above the operating table 12. This makes the drive path of the welding execution unit 40 collinear with the joint itself in space. The movement of the movable component 41 will not intersect or encroach on the trajectory of the first clamping component 34 and the second clamping component 30 pressing vertically downward from above. The problem of movement interference is eliminated, thereby ensuring that the welding execution unit 40 can move stably along the joint without obstruction, and the welding accuracy and weld quality are reliably guaranteed. Furthermore, by forcibly requiring that the orthographic projections of the first clamping component 34, the second clamping component 30, and the welding execution unit 40 on the operating table 12 do not exceed the edge of the operating table 12, it is clear that the core area of ​​all welding and fixing actions is strictly limited to the bearing surface of the operating table 12. This constraint creates a completely free and unobstructed accommodating space outside the boundary of the operating table 12 for the flexible and extensive bending sections of the copper busbar 2, enabling the equipment to easily adapt to workpieces with various bending angles and sizes, and making it highly versatile.

[0064] In practice, the clamping assembly can be expanded into multiple independently driven pressure plates 301 arranged along the first direction X. When the horizontal section of the copper busbar 2 is long, the multiple pressure plates 301 can apply pressure independently in segments without exceeding the edge of the operating table 12. This can adapt to uneven surfaces of the horizontal section of the workpiece, ensuring that the entire joint area is uniformly and reliably clamped, further improving welding stability.

[0065] According to some embodiments of this application, optionally, such as Figures 2-4 As shown, the locking assembly 13 includes a lead screw 130 and a nut 131 that engages with the lead screw 130. The axial direction of the lead screw 130 is parallel to the first direction X. The nut 131 can move along the lead screw 130 to fit against the edge of the bent portion of the copper busbar 2 placed on the operating table 12, thereby pressing the copper busbar 2 against the positioning plate 31.

[0066] The positioning plate 31 is set at the boundary line between the installation section 10 and the processing section 11, with its long side perpendicular to the first direction X. This is equivalent to establishing a common reference perpendicular to the seam on the side of the operating table 12 near the installation section 10. The two copper busbars 2 only need to abut against this plate with their respective contours facing that side to achieve common reference positioning of the two workpieces in the first direction X, ensuring the alignment consistency of the seam.

[0067] In practical application, the operator first places each copper busbar 2 against the positioning plate 31, with one edge or end face facing the mounting section 10. Then, the locking assembly 13 located in the processing section 11 intervenes. Because the axis of the lead screw 130 is parallel to the first direction X, the nut 131 can move smoothly along the lead screw 130. The operator drives the nut 131 forward, causing it to conform from the outside of the copper busbar 2 to the edge of the bent portion of the copper busbar 2. As the nut 131 continues to advance, this edge is pushed towards the positioning plate 31 until the copper busbar 2 is reliably pressed against the positioning plate 31. At this point, although the bent section of the copper busbar 2 is suspended, the entire structure is firmly locked in the first direction X.

[0068] The locking assembly 13, in conjunction with the positioning plate 31, applies force specifically to the edge of the bent portion of the copper busbar 2, successfully locking the complex-shaped and partially suspended large-bend copper busbar 2 laterally. The nut 131 moves along a first direction X parallel to the joint, pressing the copper busbar 2 against the positioning plate 31 by conforming to the edge of the bent portion. This movement path is completely parallel to the joint and does not extend directly above the operating table 12, thus having no spatial overlap with the pressure plate 301 that presses down from above. This layout fundamentally avoids movement interference between the pressing component and the lateral locking component, with each performing its own function to ensure a smooth positioning process. Since the engagement stroke of the lead screw 130 and the nut 131 is continuously adjustable, the final stopping position of the nut 131 can flexibly adapt to the actual position of different bent portions of the copper busbar 2. The heat generated during welding can accumulate at the bent part of the copper busbar 2, causing the part to soften. The heavier section of the inclined copper busbar 2 may be pulled to rotate under the weight. The nut 131 in this application can limit the change of the bending angle of the copper busbar 2 by pressing against the bent part of the copper busbar 2, thus ensuring the stability of the quality of the copper busbar 2.

[0069] In the specific implementation process, a small-angle-swinging contact block is added to one end of the nut 131 at the edge facing the bent part of the copper busbar 2. When the bent edge of the copper busbar 2 is not completely perpendicular to the first direction X, the contact block can automatically adjust its posture to fit tightly against the edge, increase the contact area, avoid point contact slippage, and improve the stability of lateral locking.

[0070] According to some embodiments of this application, optionally, the locking assembly 13 further includes an elastic compensation sleeve fitted onto the lead screw 130, the elastic compensation sleeve being located between the nut 131 and the copper busbar 2, and having a sealed cavity filled with compressible gas inside.

[0071] During welding, the movable component 41 drives the welding torch of the welding execution unit 40 to move along the seam, and the welding heat is conducted to the copper busbar 2. Upon heating, the copper busbar 2 undergoes a slight thermal expansion, and the expansion force is transferred to the elastic compensation sleeve through the edge of the bent section. The compressible gas in the sealed cavity inside the elastic compensation sleeve is further compressed, absorbing this expansion displacement and preventing the copper busbar 2 from bending or deforming due to rigid support, or the positioning plate 31 from shifting. After welding, as the temperature drops, the gas inside the elastic compensation sleeve automatically recovers, maintaining a stable clamping force.

[0072] An elastic compensation sleeve introduces a flexible compensation element between the nut 131 and the copper busbar 2. Its internal sealed cavity is filled with compressible gas, essentially acting as a miniature gas spring. When the welding heat causes the copper busbar 2 to thermally expand, the gas spring absorbs the expansion displacement, preventing the workpiece from being excessively constrained and bending under rigid locking. During the welding process, the copper busbar 2 is always subjected to a stable and non-excessive lateral constraint force, ensuring both positioning accuracy and workpiece integrity. The elastic compensation sleeve is fitted onto the lead screw 130, located between the nut 131 and the copper busbar 2, without altering the meshing relationship and movement of the nut 131 and the lead screw 130. The nut 131 still moves axially along the lead screw 130; however, the pushing force is transmitted to the copper busbar 2 through the elastic compensation sleeve. The compressible gas within the sealed cavity acts as an elastic medium, its stiffness increasing non-linearly with the compression amount. This provides a gentle contact force during the initial tightening stage, preventing indentations or scratches on the edges of the bent portion of the copper busbar 2 when the nut 131 is excessively screwed in. Meanwhile, the thermal response characteristics of the gas allow the elastic compensation sleeve to automatically adjust the internal air pressure when the temperature changes, maintaining a suitable clamping force, making it more adaptable than a mechanical spring.

[0073] According to some embodiments of this application, optionally, such as Figure 5 As shown, the nut 131 and / or the positioning plate 31 are provided with an auxiliary flow channel 1310 for accommodating fluid. The auxiliary flow channel 1310 in the nut 131 is an annular structure coaxial with the lead screw 130.

[0074] An auxiliary flow channel 1310 is provided inside the nut 131 and / or the positioning plate 31, enabling the locking components and positioning plate 31, which originally only served a mechanical positioning function, to also possess active thermal management capabilities. When the heat generated during the welding process is conducted to the nut 131 and positioning plate 31 through the copper busbar 2, it can be promptly carried away by the fluid in the auxiliary flow channel 1310. This suppresses temperature accumulation on the workpiece and positioning components during the welding process, preventing positioning loosening or reference drift due to thermal expansion, and maintaining clamping accuracy during welding. The auxiliary flow channel 1310 inside the nut 131 is designed as a ring-shaped structure coaxial with the lead screw 130. This shape fully utilizes the cylindrical or sleeve-shaped contour of the nut 131 itself, achieving the circumferential flow of fluid without increasing the external dimensions of the nut 131. The heat exchange area between the fluid and the nut 131 body is large, the heat exchange efficiency is high, and the cooling effect is concentrated and uniform.

[0075] According to some embodiments of this application, optionally, such as Figures 1-2 and Figure 6 As shown, the surface of the operating table 12 for placing the copper busbar 2 is provided with an installation groove 120 for installing the forming tray 14. The surface of the forming tray 14 facing the copper busbar 2 is flush with the surface of the operating table 12 facing the copper busbar 2. A welding groove 140 is provided at the center of the forming tray 14, and the welding groove 140 is directly opposite the joint between the two copper busbars 2 to be welded.

[0076] The molded pallet 14 is made of a material that has both heat resistance and thermal conductivity, such as graphite.

[0077] The weld groove 140 on the forming plate 14 faces the joint, providing a controlled forming space for the back of the weld. During welding, the molten metal cools and solidifies within the weld groove 140, and the shape of the back of the weld is precisely controlled by the contour of the weld groove 140, ensuring uniform weld reinforcement, a smooth surface, and no defects such as undercut. The forming plate 14 has better thermal conductivity than the operating table 12, allowing heat from the welding area to be conducted away at a faster rate, preventing heat accumulation in the welding area and potential safety accidents.

[0078] According to some embodiments of this application, optionally, such as Figures 7-8 As shown, a cooling groove 141 is provided on the side of the forming tray 14 away from the welding groove 140. The cooling groove 141 extends along the first direction X and forms a main channel for containing fluid with the bottom wall of the mounting groove 120. The bottom wall of the mounting groove 120 has at least two openings that communicate with the outside.

[0079] In practical applications, operators connect external fluid circulation pipes to two openings on the bottom wall of the mounting tank 120 that connect to the outside, one as a fluid inlet and the other as a fluid outlet. Before welding begins, hot water is injected into the main channel to preheat the operating table 12 and the copper busbars 2, ensuring that the temperature of each set of copper busbars 2 is nearly uniform before welding, and that the temperature changes and expansion of each set of copper busbars 2 during welding are maintained within a safe range. At the start of welding, cooling fluid enters the main channel through one opening in the bottom wall of the mounting tank 120, flowing from one end of the seam to the other along the first direction X. During its flow, it undergoes thorough heat exchange with the forming support plate 14, carrying away the heat conducted to the support plate during welding. It then flows out through the other opening, is cooled by an external cooling device, and is recycled. Simultaneously, the moving component 41 drives the welding execution unit 40's torch to move along the seam for welding, and molten metal forms within the weld tank 140. After welding is completed, the cooling fluid continues to circulate for a period of time to accelerate the cooling of the weld area.

[0080] The cooling tank 141 and the bottom wall of the mounting tank 120 form a main channel, which extends along the first direction X, ensuring that the flow path of the cooling fluid is completely consistent with the weld direction. The fluid flows from one end of the weld to the other, remaining directly below the welding heat source throughout, uniformly and synchronously carrying away heat along the entire weld length, thus avoiding deformation or residual stress problems caused by uneven cooling rates in different sections of the weld. The cooling tank 141 is located on the side of the forming support plate 14 away from the weld pool 140, separated from the weld pool 140 only by a thin layer of material from the forming support plate 14. This means that the distance between the cooling fluid and the back of the weld pool is minimized, resulting in a very short heat conduction path and a fast cooling response. The welding heat is carried away by the fluid as soon as it reaches the support plate, effectively protecting the forming support plate 14 from damage due to continuous high temperatures, while also accelerating the solidification and forming efficiency of the back of the weld.

[0081] In practice, the cross-sectional dimensions of the cooling tank 141 can be varied regularly as it extends along the first direction X. For example, the channel can be locally enlarged or deepened at the arc-starting and arc-ending ends of the weld (areas where heat accumulation is usually more severe) to increase the fluid throughput and heat exchange area in these areas; or guide protrusions can be set in the channel to regulate the local flow rate, thereby achieving zoned differential cooling along the weld length and more precisely controlling the weld temperature field.

[0082] According to some embodiments of this application, optionally, such as Figure 6 As shown, the side wall of the mounting groove 120 is also provided with an overflow port 1201, which is connected to the main channel and extends to the surface of the operating table 12 facing the copper busbar 2; the two opposite ends of the main channel along the first direction X are each connected to an overflow port 1201.

[0083] The opening in the bottom wall of the mounting slot 120 forms a high-flow-rate main circulation loop, while the overflow port 1201 forms a low-flow-rate auxiliary overflow loop. The main loop fulfills the process requirements of forced convection cooling, while the overflow loop only provides auxiliary interface wetting or a small amount of venting and does not participate in the heat transfer of the power stage. This clear distinction between primary and secondary fluid distribution strategies balances cooling efficiency with the economy of fluid consumption.

[0084] In practical applications, operators connect the external circulation pipes to at least two openings on the bottom wall of the mounting tank 120, one as an inlet and the other as an outlet, forming the main circulation loop for the cooling fluid. After the copper busbar 2 is placed, positioned, and clamped, welding begins. The cooling fluid enters the main flow channel from one opening in the bottom wall, flows in the first direction X, absorbs the heat conducted to the forming support plate 14 during welding, and then flows out from the other opening. After external cooling, it is recycled. This is the main inflow and outflow path of the fluid. During the continuous circulation of the main fluid, a small amount of fluid in the main flow channel will slowly overflow from the overflow ports 1201 at both ends. This small amount of fluid seeps upward along the overflow ports 1201 to the surface of the operating table 12 facing the copper busbar 2, forming an extremely thin liquid film or a small amount of wetting between the operating table 12 and the bottom surface of the copper busbar 2.

[0085] The bottom opening of the mounting slot 120 handles the majority of the cooling fluid transport, ensuring a sufficient and stable flow rate for forced convection heat transfer within the main channel, thus maintaining the overall cooling capacity of the welding area. The overflow port 1201 diverts only a small amount of fluid. This small amount of fluid, drawn from both ends of the main channel, forms auxiliary wetting cooling on the surface of the operating table 12. Although the volume of this fluid is small, it directly contacts the bottom surface of the copper busbar 2, resulting in high heat exchange efficiency. It allows for localized temperature adjustments to the bottom surface of the copper busbar 2 with minimal fluid consumption, particularly beneficial for auxiliary heat dissipation at both ends of the weld (the arc initiation and termination areas where heat easily accumulates). Each end of the main channel along the first direction X is connected to an overflow port 1201, with small overflows occurring simultaneously from both ends. This helps to slowly discharge any small air bubbles or locally overheated fluid that may accumulate at the ends of the main channel, making the flow and cooling conditions along the main channel more uniform and stable.

[0086] According to some embodiments of this application, optionally, such as Figure 9 As shown, multiple turbulence columns 1410 are fixed in the inner cavity of the cooling tank 141, and the turbulence columns 1410 are arranged alternately along the first direction X.

[0087] The turbulence columns 1410 are arranged in an alternating rather than aligned manner along the first direction X, forcing the fluid flowing on both sides of the previous column to re-merge and mix in front of the next column, and then be split again. This splitting and merging flow pattern covers all areas between adjacent columns, eliminating the static flow zone behind the columns that may occur under aligned arrangement, so that the entire cavity of the cooling tank 141 participates in effective heat exchange.

[0088] The introduction of the turbulence columns 1410 transforms the flow state of the fluid in the main channel from a stable laminar flow to a turbulent flow with numerous micro-vortices. The fluid repeatedly splits, collides, and changes direction between the staggered columns, continuously disrupting and renewing the heat transfer boundary layer near the wall, thus increasing the convective heat transfer coefficient between the fluid and the wall of the cooling tank 141. Welding heat can be transferred more quickly from the forming plate 14 to the fluid, enhancing cooling efficiency. The staggered arrangement of the turbulence columns 1410 along the first direction X, rather than aligned, prevents the fluid from forming a straight, direct flow path within the main channel. The fluid is forced to meander along a tortuous path, flowing through every corner of the cooling tank 141's interior, avoiding short-circuiting and dead zones. This results in a more uniform cooling effect along the entire length of the weld, with the solidification conditions of each section of the weld tending to be the same.

[0089] In practice, the cross-sectional shape of each turbulence column 1410 can be optimized according to flow requirements. For example, a teardrop-shaped or elliptical cross-section can be used to reduce the resistance of fluid flow and make the eddy currents fall off more orderly; or a cross-section with a round front and square rear can be used to enhance the turbulence intensity at the tail of the column.

[0090] According to some embodiments of this application, optionally, such as Figures 10-11 As shown, the weld pool 140 has outward and downward inclined guide surfaces 1400 at both ends along its length.

[0091] In practical applications, two large-bend copper busbars 2 are placed on the processing section 11, with the horizontal section abutting against the plane formed by the operating table 12 and the forming support plate 14. The two ends of the joint are located directly above the guide slopes 1400 at both ends of the weld pool 140. At the start of welding, the movable component 41 drives the welding execution unit 40's torch head to move from one end of the joint to the other. During the arc initiation stage, as the weld pool is just formed, some molten metal overflows towards the end of the joint. This excess molten material flows into the guide slope 1400 at that end and is guided downwards and outwards away from the main body of the weld pool 140. When the welding execution unit 40 moves to the end of the joint to terminate the arc, slightly more molten metal is generated at the termination point, and this excess molten material is also guided out by the guide slope 1400 at the other end. Throughout the welding process, the main body of the weld groove 140 constrains and shapes the back of the weld, while the guide slopes 1400 at both ends are responsible for orderly guiding away the excess molten material generated at the arc initiation and arc termination.

[0092] The guide ramps 1400 are positioned at both ends of the weld pool 140 along its length, directly addressing the issue of excessive molten material accumulation at the weld's arc initiation and termination points. Excess molten material flows out along the ramps, no longer accumulating at the ends of the weld pool 140 to form weld beads or protrusions. This results in a uniform and regular weld formation along the entire back of the weld, reducing the workload of post-weld grinding and cleaning of burrs at both ends. The outward and downward sloping design utilizes gravity, allowing excess molten material to naturally slide away from the welding area. The molten material will not flow back into the weld pool 140, interfering with the forming weld body, nor will it overflow and stick to the surface of the copper busbar 2 or the pressure plate 301, ensuring the continuity of the welding process and the cleanliness of the workpiece appearance.

[0093] In practice, an anti-stick coating or polishing process is applied to the surface of the guide slope 1400 to reduce the adhesion between the solidified metal and the guide slope 1400. After welding, the excess solidified metal on the guide slope 1400 can be easily peeled off without the need for tool-assisted cleaning, further improving operational efficiency and the reuse life of the forming tray 14.

[0094] According to some embodiments of this application, optionally, such as Figures 1-3 As shown, the positioning mechanism 3 also includes a second driving component 32, which is connected to the mounting section 10; the orthographic projections of the first clamping component and the second clamping component 30 on the operating table 12 are located on both sides of the seam between the two copper busbars 2; both clamping components are connected to the output end of the second driving component 32 and move up and down synchronously under the drive of the second driving component 32; the second driving component 32 is an electric cylinder.

[0095] The two clamping components mentioned in this application are the first clamping component 34 and the second clamping component 30.

[0096] In practical application, the electric cylinder drives the two clamping components to descend rapidly from an initial high position based on the acquired copper busbar 2 thickness data, performing a long macroscopic stroke. Since both clamping components are connected to the output end of the second drive unit 32, they synchronously approach the operating table 12 until they reach a preset height position matching the thickness of the copper busbar 2. At this time, the pressure plates 301 of the two clamping components are suspended above the copper busbars 2 on both sides of the seam, with only a small gap between them and the surface of the copper busbar 2. Subsequently, the first drive units 300 of each of the two clamping components start to work. They drive their respective pressure plates 301 to descend precisely over a short distance, so that the pressure plates 301 smoothly contact the surface of the copper busbar 2 and apply the set clamping force, firmly pressing the two copper busbars 2 onto the operating table 12. Due to the extremely short stroke, the process of the pressure plates 301 contacting the copper busbar 2 is gentle and controllable, without causing impact. After clamping is completed, the movable component 41 drives the welding execution unit 40's torch head to move along the seam to complete the welding.

[0097] The second drive component 32 is responsible for long-distance lifting and lowering based on the thickness of the copper busbar 2, while the first drive component 300 is responsible for the final short-distance clamping, forming a two-level collaborative drive architecture of macroscopic coarse adjustment and microscopic fine adjustment. Regardless of the thickness of the copper busbar 2, the second drive component 32 can quickly deliver the clamping assembly to the most suitable starting position, while the first drive component 300 only needs to complete the clamping force within a very short stroke. The equipment's adaptability to copper busbars 2 of different thicknesses is enhanced, and there is no need to manually adjust the height of the clamping assembly during production changeovers, resulting in a high degree of automation. The second drive component 32, powered by an electric cylinder, has precise stroke control capabilities and self-locking characteristics. The electric cylinder accurately positions itself based on the thickness parameters of the copper busbar 2, ensuring that the two clamping components reach the same height synchronously, preventing bias pressure problems caused by inconsistent heights on both sides. The precise pre-positioning of the long stroke also creates stable initial conditions for the subsequent short-stroke fine pressure application of the first drive component 300. The first driving component 300 only needs to be driven for a short distance to complete the clamping. Its stroke is minimized, the response speed is fast, and the impact force when the pressure plate 301 contacts the copper busbar 2 is small, so it is not easy to produce indentations or scratches on the surface of the copper busbar 2.

[0098] According to some embodiments of this application, optionally, such as Figure 12 As shown, the positioning mechanism 3 also includes two centering components 33, which are arranged opposite each other with the operating table 12 as the center. Each centering component 33 includes a push rod that extends and retracts in a direction perpendicular to the first direction X. The end of the push rod is used to push the side of the copper busbar 2.

[0099] In practical application, the operator first places two copper busbars 2 on the processing section 11 of the frame base 1. The horizontal section of the copper busbars 2 rests on the suspended operating table 12 and completes the initial docking, with the seam between the two copper busbars 2 extending along the first direction X. Due to deviations caused by manual placement, the two copper busbars 2 may be offset in a direction perpendicular to the first direction X. At this time, the two centering components 33 in the positioning mechanism 3 begin to work. The two centering components 33 are arranged opposite each other with the operating table 12 as the center, located on both sides of the operating table 12. The push rods included in each centering component 33 extend synchronously or sequentially in a direction perpendicular to the first direction X, and their ends contact and push the side of the corresponding copper busbar 2. The push rods on both sides work together to push the two copper busbars 2 from both sides towards the center of the operating table 12 until the docking sides of the two copper busbars 2 are tightly fitted, and the seam reaches the preset centering position. After alignment, the first drive component 300 of the clamping assembly drives the pressure plate 301 to descend, pressing the aligned horizontal section of the copper busbar 2 onto the operating table 12. Subsequently, the push rod can be held or retracted, and the movable component 41 drives the welding torch of the welding execution unit 40 to move along the seam to complete the welding. The entire process ensures accurate seam positioning through the alignment component 33, laying the foundation for subsequent welding quality.

[0100] Two centering components 33 are positioned opposite each other with the operating table 12 as the center. By utilizing the relative extension and retraction of the double-sided push rods, the sides of the copper busbar 2 are pushed from both sides towards the center, achieving automatic centering of the copper busbar 2 in the direction perpendicular to the first direction X. This solves the problem of difficulty in ensuring precise alignment of the two copper busbars 2 when manually placing them, and reliably guarantees the consistency and repeatability of the splicing position.

[0101] Although this application has been described with reference to preferred embodiments, various modifications can be made thereto and components can be replaced with equivalents without departing from the scope of this application. In particular, the technical features mentioned in the various embodiments can be combined in any manner, provided there is no structural conflict. This application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A large bending angle copper busbar welding machine, characterized in that, include: The frame base is equipped with an operating console; Positioning mechanisms, including: A positioning plate is fixed to the operating table; The locking assembly is used to apply a pushing force to the bent parts of the two copper busbars placed on the operating table, so that the sides of the two copper busbars are pressed against the positioning plate. The first clamping assembly is used to clamp one of the copper busbars onto the operating table; The second clamping assembly includes a first driving member, a pressure plate, and a transmission member. The transmission member is retractably connected in the vertical direction between the output end of the first driving member and the pressure plate, and the transmission member has a pushing surface. A pusher, fixed to the operating table, is used to cooperate with the push surface; Welding mechanism, used to weld two copper busbars along the joint; After the locking assembly presses the copper busbar against the positioning plate, the first pressing assembly presses one copper busbar. The first driving member drives the pressure plate to descend until it contacts another copper busbar and continues to apply pressure. The transmission member contracts under pressure, causing the pushing surface to descend. The pushing member pushes the pushing surface, causing the transmission member and the pressure plate to move the other copper busbar toward the already pressed copper busbar, thereby reducing the gap between the two copper busbars. The length direction of the seam is defined as the first direction.

2. The large bending angle copper busbar welding machine according to claim 1, characterized in that, The transmission component includes a first connecting part, a first elastic unit, a first guide rod, a second connecting part, a second elastic unit, and a second guide rod. The first connecting part is connected to the output end of the first driving component. The second connecting part has a guide groove extending in a horizontal direction and perpendicular to the first direction. The first guide rod is connected to the first connecting part and extends into the guide groove. The first elastic unit is disposed between the first connecting part and the second connecting part, and the first elastic unit is parallel to the extension direction of the guide groove. The second guide rod extends vertically and is connected to the pressure plate. The second connecting part has a through hole for the second guide rod to pass through. The second elastic unit is sleeved on the second guide rod and its two ends abut against the pressure plate and the second connecting part, respectively. The push-receiving surface is disposed on the second connecting portion; When the transmission component is compressed and contracts, the second connecting part moves along the second guide rod and squeezes the second elastic unit; when the pushing component pushes the pushed surface, the second connecting part moves toward the already compressed copper busbar and squeezes the first elastic unit.

3. The large bending degree copper busbar welding machine according to claim 2, characterized in that, The second connecting part is provided with a guide groove on each of its opposite sides along the first direction, and each groove cooperates with the corresponding first guide rod. The second connecting portion forms the push-receiving surface away from the surface of the compressed copper busbar in a horizontal direction that is perpendicular to the first direction; The second connecting part has a protrusion on the side away from the positioning plate. The protrusion is located on the push surface, and the surface of the protrusion is an inclined surface. The inclined surface gradually approaches the compressed copper busbar in the direction from top to bottom.

4. The large bending angle copper busbar welding machine according to claim 1, characterized in that, The frame base includes an installation section and a processing section, the operating table is located in the processing section, and the operating table is suspended in the air; The positioning plate is arranged along the boundary line between the installation section and the processing section, and the length direction of the positioning plate is perpendicular to the first direction; The welding mechanism includes a welding execution unit and a movable component. The movable component is installed on the mounting section and is used to drive the welding execution unit to move along the seam of the two copper busbars located on the operating table. The installation section and the processing section are distributed along the first direction; The orthographic projections of the first clamping component, the second clamping component, and the welding execution unit on the operating table do not exceed the edge of the operating table.

5. A large bending angle copper busbar welding machine according to claim 4, characterized in that, The surface of the operating table for placing copper busbars has an installation groove for mounting a forming tray, and a welding groove is provided at the center of the forming tray. A cooling groove is provided on the side of the forming pallet away from the welding groove. The cooling groove extends along the first direction and forms a main channel for containing fluid with the bottom wall of the mounting groove. The bottom wall of the mounting groove has at least two openings that communicate with the outside. The side wall of the mounting groove is also provided with an overflow port, which connects to the main channel and extends to the surface of the operating table facing the copper busbar.

6. A large bending angle copper busbar welding machine according to claim 1, characterized in that, The locking assembly includes a lead screw and a nut that engages with the lead screw. The axis of the lead screw is parallel to the first direction. The nut is movable along the lead screw to fit against the edge of the bent portion of the copper busbar placed on the operating table, thereby pressing the copper busbar against the positioning plate.

7. A large bending degree copper busbar welding machine according to claim 6, characterized in that, The locking assembly also includes an elastic compensation sleeve fitted onto the lead screw. The elastic compensation sleeve is located between the nut and the copper busbar, and has a sealed cavity filled with compressible gas inside.

8. A large bending degree copper busbar welding machine according to claim 6, characterized in that, The nut and / or the positioning plate are provided with an auxiliary flow channel for accommodating fluid, and the auxiliary flow channel in the nut is a ring structure coaxial with the lead screw.

9. A large bending angle copper busbar welding machine according to claim 5, characterized in that, Multiple turbulence-disrupting columns are fixed in the inner cavity of the cooling tank, and the turbulence-disrupting columns are arranged alternately along the first direction.

10. A large bending degree copper busbar welding machine according to claim 5, characterized in that, The weld pool has outward and downward inclined guide surfaces at both ends along its length.

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