A controller copper bar bonding fixing welding jig

Abstract

The present application relates to the technical field of welding fixture, and discloses a controller copper bar bonding fixing welding fixture, which comprises a base fixed on a designated ground, a jig plate rotationally connected to the middle part of the top end of the base, and a telescopic part rotationally connected in the base and used for lifting the jig plate to rotate, wherein an end welding fixing assembly is adjusted in position by a screw rod structure, a height adjusting cylinder is used to adjust the height of a lifting plate, a rotating cylinder drives a swing lever to press the copper bar from the side, a middle cylinder drives a pressing plate with a welding hole to press the copper bar from above, and the close bonding and fixing and annular welding of the upper and lower copper bars are realized in the extremely narrow space of only 9mm between the controller body and the copper bar. The tail welding fixing assembly is provided with a nitrogen connecting pipe and a protective cover, nitrogen is introduced during welding to prevent the copper bar from being oxidized. The present application solves the technical problem of copper bar bonding and fixing in a narrow space, has high welding quality, and is suitable for the copper bar welding of new energy automobile motor controllers and other products.

Description

Technical Field

[0001] This invention relates to the field of welding fixture technology, specifically to a welding fixture for bonding and fixing copper busbars of a controller. Background Technology

[0002] In the manufacturing process of controllers (such as motor controllers and power controllers for new energy vehicles), the electrical connection of the internal copper busbars is one of the core processes. Typically, two copper busbars need to be attached and fixed together, and then welded along a circular or ring-shaped path using a welding torch. The welding quality directly affects the conductivity and reliability of the controller.

[0003] The welding fixture of this invention is used to electrically weld two copper busbars in a controller. Specifically, the upper and lower copper busbars are first attached and fixed together, and then welded using a welding torch. The welding path is circular or annular. The challenge of this invention lies in the fact that the space between the right side of copper busbar A and the controller body is only 9mm, leaving extremely little room for the welding fixture to operate. How to achieve a tight fit and fixation of the upper and lower copper busbars within such a confined space is the core technical problem that needs to be solved.

[0004] In addition, the complex shape of the controller housing, the need for the copper busbar to extend from the rear, the need to protect the welding area during welding (such as nitrogen protection to prevent oxidation), and the need for the versatility of the fixture (to adapt to controllers of different sizes) all pose challenges to the design of the welding fixture. Summary of the Invention

[0005] To achieve the above objectives, the present invention provides the following technical solution: a welding fixture for bonding and fixing copper busbars of a controller, comprising: The base is fixed to the designated ground surface; The fixture plate is rotatably connected to the middle of the top end of the base; The telescopic component is rotatably connected inside the base and lifts the fixture plate for rotation. The clamping cylinders are distributed around the jig plate and are used to fix the edge of the outer shell; Positioning pins, distributed on the fixture plate, are used to position the housing and to cooperate with the clamping cylinder; The tail welding fixing component cooperates with the clamping cylinder to press into the outer shell, and the tail of the copper busbar passes through the tail welding fixing component; An end welding fixing component is provided on the base to fix the end of the copper busbar and to weld it. The end welding fixing component is located near the controller body.

[0006] Furthermore, the end welding fixing assembly includes a sliding plate disposed on the base, and: A lead screw structure fixed between the top of the base and the bottom of the slide plate; Support plates are vertically fixed to both sides of the top of the skateboard; A height-adjusting cylinder is vertically fixed to the outside of the support plate; The lifting plate is fixed to the end of the height adjustment cylinder and moves up and down between the support plates as the height adjustment cylinder moves. Rotary rod connected to the top of the lifting plate; A swing arm fixed to the end of the rotating rod; A rotating structure installed on the lifting plate to drive the swing arm to rotate; An intermediate cylinder is vertically fixed between the support plates; The pressure plate is connected to the output end of the intermediate cylinder.

[0007] Furthermore, the rotating structure includes a rotating cylinder vertically fixed to the bottom end of the lifting plate, and: A rack that is slidably connected to the surface of the lifting plate and connected to the output end of the rotating cylinder; A gear fixed to the outside of the rotating rod and meshing with the rack.

[0008] Furthermore, the pressure plate includes a pressure drop plate connected to the output end of the intermediate cylinder, and: The pressure block is fixed with bolts at a position below the pressure drop plate; Welding holes at corresponding positions in the vertical direction of the pressure drop plate and the pressure block.

[0009] Furthermore, the lead screw structure includes a nut fixed to the bottom end of the slide plate, and: A lead screw is fixed to the top of the base, and the lead screw is threadedly connected to a nut; A drive component connected to the end of a lead screw.

[0010] Furthermore, the end welding fixing assembly also includes a proximity switch fixed to the front of the slide plate.

[0011] Furthermore, the tail welding fixing assembly includes a connecting plate fixed inside the housing, and: A vertically fixed, deep-set cylinder at the top of the connecting plate; A protective cover is vertically connected to the bottom of the connecting plate; Nitrogen gas connection pipe connected to one side of the protective cover.

[0012] Furthermore, the protective cover A through hole is provided on the outer side.

[0013] Furthermore, the clamping cylinder includes a cylinder and a clamping plate vertically fixed to the end of the cylinder.

[0014] Furthermore, the positioning pin includes a fixing post, a positioning rod is vertically fixed to the top of the fixing post, and a protective pad is laid on the top of the positioning rod.

[0015] Compared with the prior art, the present invention provides a welding fixture for bonding and fixing the copper busbar of a controller, which has the following beneficial effects: 1. By setting up end welding fixing components and using a combination of height adjustment cylinder, rotating cylinder driven swing rod and intermediate cylinder driven pressure plate, the clamping and welding operations can be completed in an extremely narrow space of only 9mm between the controller body and the copper busbar, solving the technical problem of copper busbar fitting and fixing in a narrow space. 2. The pressure plate in the end welding fixing assembly has welding holes, and the welding gun can directly perform circumferential welding on the copper busbar through the welding holes without additional adjustment of the welding gun position, and the welding path is precise and controllable; 3. The tail welding fixing component is equipped with a protective cover and a nitrogen connection pipe. During the welding process, nitrogen can be supplied to the welding area for protection to prevent the copper busbar from oxidizing during high-temperature welding and to ensure welding quality. 4. The fixture plate can tilt and rotate under the drive of the telescopic component, which makes it easy for operators to place and remove the controller housing, and also facilitates post-weld inspection; 5. The clamping cylinder works in conjunction with the positioning pin to fix the housing from both the edge and the positioning hole, ensuring that the housing does not shift during the welding process; the protective pad at the top of the positioning pin can prevent scratches on the surface of the housing. Attached Figure Description

[0016] Figure 1 This is a perspective view of a welding fixture for bonding and fixing copper busbars of a controller, as proposed in this invention. Figure 2 This is a schematic diagram of the structure of a welding fixture for bonding and fixing the copper busbar of a controller, as proposed in this invention, after removing the outer shell and the controller body; Figure 3 This is a schematic diagram of the structure of a welding fixture for bonding and fixing the copper busbar of a controller, as proposed in this invention, to remove the base. Figure 4 This is a schematic diagram of the end welding and fixing assembly of a welding fixture for bonding and fixing copper busbars of a controller, as proposed in this invention. Figure 5 This invention provides a welding fixture for bonding and fixing copper busbars in a controller. Figure 4 Another three-dimensional structural diagram; Figure 6 This invention provides a welding fixture for bonding and fixing copper busbars in a controller. Figure 4 Rear view; Figure 7 This is a schematic diagram of the installation structure of a welding fixture pressure plate for bonding and fixing the copper busbar of a controller, as proposed in this invention. Figure 8 This invention provides a welding fixture for bonding and fixing copper busbars in a controller. Figure 7 Rear view; Figure 9 This is a schematic diagram of the tail welding and fixing assembly of a welding fixture for bonding and fixing copper busbars of a controller, as proposed in this invention. Figure 10 This is a schematic diagram of the installation structure of a protective cover for a welding fixture used for bonding and fixing copper busbars of a controller, as proposed in this invention. Figure 11 This is a schematic diagram of the connection structure between the lifting plate and the rotating rod of a welding fixture for bonding and fixing the copper busbar of a controller, as proposed in this invention. Figure 12 This is a schematic diagram of the installation structure of the copper busbar in the tail welding and fixing assembly of a welding fixture for bonding and fixing the copper busbar of a controller, as proposed in this invention.

[0017] In the diagram: 100, base; 200, jig plate; 300, telescopic component; 400, clamping cylinder; 500, positioning pin; 600, tail welding fixing assembly; 601, connecting plate; 602, indentation cylinder; 603, nitrogen connection pipe; 604, protective cover; 700, end welding fixing assembly; 701, sliding plate; 702, lead screw structure; 703, proximity switch; 704, support plate; 705, height adjustment cylinder; 706, lifting plate; 707, rotating cylinder; 708, rack; 709, rotating rod; 7010, swing rod; 7011, gear; 7012, intermediate cylinder; 7013, pressure plate; 1, outer shell; 2, controller body; 3, copper busbar. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Please see Figures 1 to 3 A welding fixture for bonding and fixing copper busbars of a controller includes a base 100, a fixture plate 200, a telescopic component 300, a clamping cylinder 400, a positioning pin 500, a tail welding and fixing assembly 600, and an end welding and fixing assembly 700. Please see Figures 1 to 3 The base 100 is fixed on the designated ground and is made of cast iron or steel structure with sufficient rigidity and stability. A jig plate 200 is rotatably connected to the top center of the base 100. The jig plate 200 is used to support the controller housing 1 and internal components. The shape of the jig plate 200 matches the bottom contour of the controller housing 1.

[0020] The base 100 is rotatably connected to a telescopic component 300 (such as a cylinder or electric push rod). The output end of the telescopic component 300 lifts the jig plate 200, causing the jig plate 200 to rotate around its hinge point at a certain angle (usually 10°-30°). This tilting function facilitates the placement and removal of the outer casing 1 by the operator, and also facilitates post-weld inspection.

[0021] Multiple clamping cylinders 400 are distributed around the jig plate 200; each clamping cylinder 400 includes a cylinder body and a clamping plate vertically fixed at the end of the cylinder, which is used to press the edge of the outer shell 1 from above and fix the outer shell 1 on the jig plate 200.

[0022] The jig plate 200 has multiple positioning pins 500 distributed on it for positioning the positioning holes on the housing 1 and for use in conjunction with the clamping cylinder 400 to achieve precise positioning and reliable fixation of the housing 1. The positioning pin 500 includes a fixing post, and a positioning rod is vertically fixed at the top of the fixing post. The top of the positioning rod is covered with a protective pad (such as rubber or polyurethane) to prevent scratching the surface of the housing 1.

[0023] Please see Figure 1 , Figure 2 , Figure 9 , Figure 10 and Figure 12 The tail welding and fixing component 600 is located inside the housing 1 and is pressed into the housing 1 in cooperation with the clamping cylinder 400; the tail of the copper busbar 3 passes through the tail welding and fixing component 600. The tail welding and fixing assembly 600 includes a connecting plate 601, an inlet cylinder 602, a protective cover 604, and a nitrogen connection pipe 603; The connecting plate 601 is fixed inside the outer casing 1, serving as the mounting base for the tail welding fixing assembly 600; the insertion cylinder 602 is vertically fixed to the top of the connecting plate 601, and the tail of the copper busbar 3 passes through the insertion cylinder 602; the protective cover 604 is vertically connected to the bottom of the connecting plate 601, and covers the welding area of ​​the copper busbar 3; a nitrogen connecting pipe 603 is connected to one side of the protective cover 604, which is used to introduce nitrogen into the protective cover 604 to form a protective atmosphere during the welding process and prevent the copper busbar from oxidizing during high-temperature welding; a through hole is provided on the outside of the protective cover 604 to facilitate observation of the welding situation when the welding torch enters from the insertion cylinder 602.

[0024] Please see Figures 4 to 8 as well as Figure 11The end welding fixing component 700 is set on the base 100, near the controller body 2, and is used to fix the end of the copper busbar 3 and weld it; the end welding fixing component 700 includes a sliding plate 701, a lead screw structure 702, a proximity switch 703, a support plate 704, a height adjustment cylinder 705, a lifting plate 706, a rotating cylinder 707, a rack 708, a rotating rod 709, a swing rod 7010, a gear 7011, an intermediate cylinder 7012, and a pressure plate 7013.

[0025] The slide plate 701 is mounted on the base 100 and can move horizontally along the base 100. The lead screw structure 702 is connected between the top of the base 100 and the bottom of the slide plate 701 and is used to drive the slide plate 701 to move horizontally. The lead screw structure 702 includes a nut fixed to the bottom of the slide plate 701, a lead screw fixed to the top of the base 100, and a drive component (handwheel or motor) connected to the end of the lead screw. When the drive component is rotated, the lead screw rotates and drives the nut and the slide plate 701 to move along the lead screw axis, thereby adjusting the distance between the end welded fixing component 700 and the controller body 2 to accommodate controllers of different sizes. The proximity switch 703 is fixed in front of the slide plate 701 (towards the controller body 2) to detect whether the end welding fixing component 700 has reached the predetermined position, ensuring accurate welding position.

[0026] Support plates 704 are vertically fixed on both sides of the top of the slide plate 701, and the two support plates 704 are arranged in parallel and opposite to each other; height adjustment cylinder 705 is vertically fixed on the outside of support plate 704, and its output end extends upward; lifting plate 706 is fixed on the end of height adjustment cylinder 705, and moves up and down between support plates 704 as height adjustment cylinder 705 extends and retracts; by adjusting the height of lifting plate 706, it can accommodate copper busbars 3 of different thicknesses.

[0027] The rotating rod 709 is rotatably connected to the top of the lifting plate 706 and can rotate freely around its axis; the swing rod 7010 is fixed to the end of the rotating rod 709 and is used to press or release the copper busbar 3. A rotating structure is mounted on the lifting plate 706 to drive the swing arm 7010 to rotate. The rotating structure includes a rotating cylinder 707, a rack 708, and a gear 7011. The rotating cylinder 707 is vertically fixed to the bottom end of the lifting plate 706, with its output end extending upward. The rack 708 is slidably connected to the surface of the lifting plate 706 and is connected to the output end of the rotating cylinder 707, sliding up and down as the rotating cylinder 707 extends and retracts. The gear 7011 is fixed to the outside of the rotating rod 709 and meshes with the rack 708. When the rotating cylinder 707 extends and retracts, the rack 708 moves up and down, driving the gear 7011 and the rotating rod 709 to rotate, thereby causing the swing arm 7010 to swing, thus achieving the pressing or releasing of the copper busbar 3.

[0028] The intermediate cylinder 7012 is vertically fixed between two support plates 704, with its output end facing the controller body 2; the pressure plate 7013 is connected to the output end of the intermediate cylinder 7012 and is used to press the copper busbar 3 from above.

[0029] The pressure plate 7013 includes a pressure plate and a pressure block; the pressure plate is connected to the output end of the intermediate cylinder 7012, and the pressure block is fixed to the lower position of the pressure plate by bolts; the pressure plate and the pressure block are provided with vertically corresponding welding holes, and the welding gun can perform annular or circular welding on the copper busbar 3 through the welding holes.

[0030] In use, the horizontal position of the slide plate 701 is adjusted by the lead screw structure 702, so that the end welded fixing component 700 is close to the controller body 2. The proximity switch 703 stops after detecting the position. The height adjustment cylinder 705 is activated to adjust the height of the lifting plate 706, so that the swing arm 7010 and the pressure plate 7013 are at a suitable height position with the copper busbar 3. The rotation cylinder 707 is activated, the rack 708 moves downward, driving the gear 7011 and the rotating rod 709 to rotate, and the swing arm 7010 swings accordingly, pressing the copper busbar 3 from the side. At the same time, the intermediate cylinder 7012 is activated to push the pressure plate 7013 to press from above. The copper busbar 3 is held in place; the swing arm 7010 and the pressure plate 7013 work together to ensure that the upper and lower copper busbars are tightly fitted and fixed; the welding torch extends into the welding hole on the pressure plate 7013 to perform ring or circular path welding on the copper busbar 3; during the welding process, the nitrogen gas connection pipe 603 of the tail welding fixing component 600 continuously introduces nitrogen gas into the protective cover 604 to protect the welding area from oxidation; after the welding is completed, the rotating cylinder 707 moves in the opposite direction, the swing arm 7010 swings back to release the copper busbar 3; the middle cylinder 7012 retracts, and the pressure plate 7013 is lifted; the end welding fixing component 700 retracts as a whole to make room for removing the workpiece. The tail welding fixing component 600 is fixed inside the outer shell 1, and the tail of the copper busbar 3 passes through the indenter 602. During welding, the protective cover 604 covers the welding area, and nitrogen gas is introduced into the nitrogen gas connection pipe 603 to form a positive pressure protective atmosphere inside the protective cover 604. This prevents the copper busbar from contacting oxygen in the air and generating an oxide layer during high-temperature welding, thus ensuring the welding quality. The through hole on the outside of the protective cover 604 can discharge some gas and facilitate observation of the welding process.

[0031] Working principle: Start the telescopic component 300, and the jig plate 200 tilts and lifts; place the controller housing 1 on the jig plate 200, and align the positioning hole of the housing 1 with the positioning pin 500; pass the tail of the copper busbar 3 through the indenter 602 of the tail welding fixing component 600, with the end of the copper busbar 3 facing outward. The jig plate 200 returns to a horizontal position; the clamping cylinder 400 is activated, and the clamping plate presses down on the edge of the outer shell 1 from above, fixing the outer shell 1 onto the jig plate 200; Adjust the position, height and angle of the end welding fixing component 700 so that the swing rod 7010 and the pressure plate 7013 press the copper busbar 3 from the side and the top respectively, so that the upper and lower copper busbars fit tightly together; Start the welding torch and perform circumferential welding on the copper busbar 3 through the welding holes on the pressure plate 7013; at the same time, nitrogen gas is introduced into the tail welding fixing component 600 for protection. After welding is completed, the end welding fixing component 700 is released and retracted, the clamping cylinder 400 is lifted, the telescopic component 300 lifts the fixture plate 200, and the welded controller is taken out.

[0032] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A welding fixture for bonding and fixing copper busbars of a controller, characterized in that: include: The base (100) is fixed to the designated ground surface; The fixture plate (200) is rotatably connected to the middle of the top of the base (100); The telescopic component (300) is rotatably connected inside the base (100) and lifts the jig plate (200) to rotate; A clamping cylinder (400) is distributed around the jig plate (200) to fix the edge of the housing (1); Positioning pins (500) are distributed on the fixture plate (200) and are used to position the housing (1) and cooperate with the clamping cylinder (400); The tail welding fixing assembly (600) cooperates with the clamping cylinder (400) and is pressed into the housing (1), and the tail of the copper busbar (3) passes through the tail welding fixing assembly (600). An end welding fixing component (700) is provided on the base (100) to fix the end of the copper busbar (3) and weld it. The end welding fixing component (700) is located near the controller body (2). The end welding fixing assembly (700) includes a sliding plate (701) disposed on the base (100), and: A screw structure (702) is fixed between the top of the base (100) and the bottom of the slide plate (701). Support plates (704) are vertically fixed on both sides of the top of the slide plate (701). A height-adjusting cylinder (705) is vertically fixed to the outside of the support plate (704); The lifting plate (706) is fixed at the end of the height adjusting cylinder (705) and moves up and down between the support plates (704) as the height adjusting cylinder (705) moves. Rotary rod (709) connected to the top of the lifting plate (706); The swing arm (7010) is fixed to the end of the rotating rod (709). A rotating structure is provided on the lifting plate (706) to drive the swing arm (7010) to rotate; An intermediate cylinder (7012) is vertically fixed between the support plates (704); A pressure plate (7013) is connected to the output end of the intermediate cylinder (7012).

2. The welding fixture for bonding and fixing the copper busbar of a controller according to claim 1, characterized in that: The rotating structure includes a rotating cylinder (707) vertically fixed to the bottom end of the lifting plate (706), and: A rack (708) is slidably connected to the surface of the lifting plate (706) and connected to the output end of the rotary cylinder (707); A gear (7011) fixed to the outside of the rotating rod (709) and meshing with the rack (708).

3. The welding fixture for bonding and fixing the copper busbar of a controller according to claim 1, characterized in that: The pressure plate (7013) includes a pressure drop plate connected to the output end of the intermediate cylinder (7012), and: The pressure block is fixed with bolts at a position below the pressure drop plate; Welding holes at corresponding positions in the vertical direction of the pressure drop plate and the pressure block.

4. The welding fixture for bonding and fixing the copper busbar of a controller according to claim 1, characterized in that: The lead screw structure (702) includes a nut fixed to the bottom end of the slide plate (701), and: A lead screw is fixed to the top of the base (100), and the lead screw is threadedly connected to a nut; A drive component connected to the end of a lead screw.

5. The welding fixture for bonding and fixing the copper busbar of a controller according to claim 1, characterized in that: The end welding fixing assembly (700) also includes a proximity switch (703) fixed in front of the slide plate (701).

6. The welding fixture for bonding and fixing the copper busbar of a controller according to claim 1, characterized in that: The tail welding fixing assembly (600) includes a connecting plate (601) fixed inside the housing (1), and: A vertically fixed indentation cylinder (602) at the top of the connecting plate (601); A protective cover (604) is vertically connected to the bottom of the connecting plate (601). Nitrogen connection pipe (603) connected to one side of the protective cover (604).

7. The welding fixture for bonding and fixing the copper busbar of a controller according to claim 6, characterized in that: The protective cover (604) has a through hole on its outer side.

8. The welding fixture for bonding and fixing the copper busbar of a controller according to claim 1, characterized in that: The clamping cylinder (400) includes a cylinder and a clamping plate that is vertically fixed at the end of the cylinder.

9. The welding fixture for bonding and fixing the copper busbar of a controller according to claim 1, characterized in that: The positioning pin (500) includes a fixing post, a positioning rod is vertically fixed at the top of the fixing post, and a protective pad is laid at the top of the positioning rod.

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