Electrode cap dressing and welding method

Abstract

The application relates to an electrode cap grinding method and a welding method, wherein the electrode cap grinding method comprises the following steps: placing an electrode cap in a cutting grinding tool; cutting and grinding the electrode cap by adopting a first pressure value, and blowing air to the electrode cap; cutting and grinding the electrode cap by adopting a second pressure value, and blowing air to the electrode cap, wherein the second pressure value is smaller than the first pressure value; placing the electrode cap in a shaping grinding tool; shaping and grinding the electrode cap, and blowing air to the electrode cap. The application can improve the grinding problems caused by the poor copper chip removal effect, the insufficient air blowing timing coverage and the mechanical imbalance during the asymmetric electrode cap grinding in the prior art.

Description

Technical Field

[0001] This application relates to the field of grinding technology, and in particular to a method for grinding and welding electrode caps. Background Technology

[0002] In resistance welding, the electrode cap, as a core component that directly contacts the workpiece, directly determines the quality and appearance of the weld. During welding, the electrode cap undergoes high-temperature plastic deformation, copper alloy deposition, and oxide layer accumulation, leading to geometric misalignment of the end face. To ensure weld consistency, the flatness and contour accuracy of the electrode cap must be restored periodically through mechanical grinding. However, in the large-scale application of asymmetrical electrode cap structures (with a large end face on the visible side and a small end face on the non-visual side), traditional grinding processes still suffer from multiple systemic defects.

[0003] The existing grinding method adopts a series mode of "single cutting + direct shaping". Although the cutting stage can remove the main oxide layer, the single-stage pressure is not enough to completely decompose the copper chips, so the fine copper chips are not effectively broken. In the subsequent shaping process, the electrode surface is forcibly pressed in the state of the chips without removing them, which may embed the copper chips into the softened electrode copper layer and form permanent pits. Summary of the Invention

[0004] This application provides an electrode cap grinding method and a welding method, which aim to improve the grinding problems caused by poor copper shavings removal in the prior art.

[0005] This application first provides a method for grinding an electrode cap, comprising: placing the electrode cap in a cutting and grinding tool; grinding the electrode cap with a first pressure value and blowing air onto the electrode cap; grinding the electrode cap with a second pressure value and blowing air onto the electrode cap, wherein the second pressure value is less than the first pressure value; placing the electrode cap in a shaping and grinding tool; shaping and grinding the electrode cap and blowing air onto the electrode cap.

[0006] In the electrode cap grinding method of this application, the copper layer is quickly removed in the high-pressure cutting stage (coarse cutting at the first pressure value to remove the main material and fine cutting at the second pressure value to break up the chips) and air blowing is performed simultaneously. After the copper layer is removed in the high-pressure cutting stage, the copper chips are further broken in the low-pressure cutting stage, making the chips easier to be carried away by the airflow. At the same time, the air blowing and grinding processes are switched and coordinated to ensure that the copper chips are washed away from the contact surface by the airflow during and at the end of the cutting process, reducing the accumulation of copper chips that would cause the chips to be pressed into the electrode cap surface in the subsequent shaping stage. This can reduce the problem of copper chip residue caused by direct shaping after a single cutting in the traditional grinding method.

[0007] In some embodiments, shaping and grinding the electrode cap and blowing air onto the electrode cap includes: blowing air onto the electrode cap before shaping and grinding; blowing air onto the electrode cap during the shaping and grinding process; and blowing air onto the electrode cap after shaping and grinding.

[0008] In some embodiments, both the cutting and shaving tools and the shaping and shaving tools are provided with air guide grooves, and blowing air onto the electrode cap is done by injecting airflow through the air guide grooves to blow air onto the electrode cap.

[0009] In some embodiments, the grinding method further includes: removing the electrode cap from the cutting and grinding tool and placing it in a first preset position before placing the electrode cap in the shaping and grinding tool; and blowing air onto the electrode cap located in the first preset position.

[0010] In some embodiments, the grinding method further includes: after completing the shaping and grinding of the electrode cap, removing the electrode cap from the shaping and grinding tool and placing it in a second preset position; and blowing air onto the electrode cap located in the second preset position.

[0011] This application also provides a welding method, comprising: welding a workpiece to be welded using an electrode cap; after welding the workpiece to be welded, replacing it with the next workpiece to be welded; during the process of replacing the next workpiece to be welded, shaping and grinding the electrode cap, comprising: placing the electrode cap in a shaping and grinding tool; blowing air into the electrode cap before shaping and grinding the electrode cap; blowing air into the electrode cap during shaping and grinding the electrode cap; and blowing air into the electrode cap after shaping and grinding the electrode cap; and welding the next workpiece to be welded using the shaped and ground electrode cap.

[0012] In the welding method of this application, shaping and grinding (including three-stage air blowing) is embedded in the gap between welding parts. Electrode restoration is completed by utilizing the inherent cycle time window of the production line. Pre-blowing before shaping and grinding can remove historical residual copper chips and reduce their interference with the initial contact of shaping. Continuous air blowing during shaping can lift the flat copper chips generated during the shaping process and remove them from the cutting edge by impacting the gap between the tool and the electrode. After shaping, supplementary air blowing can remove the final debris. The three-stage air blowing forms a closed-loop sweep, covering the entire path of chip generation, adhesion and residue during the shaping process, reducing the risk of copper chip adhesion in the fine shaping stage. Thus, shaping is performed once for each part to be welded, so that the electrode cap can maintain the same surface condition and geometric accuracy before and after each welding, reducing the electrode deformation difference accumulated in batch welding, and improving the consistency of the weld joint morphology of the parts to be welded.

[0013] In some embodiments, the welding method further includes: when the number of welding operations on the electrode cap reaches a first preset number, cutting and grinding the electrode cap, including: placing the electrode cap in a cutting and grinding tool, cutting and grinding the electrode cap with a first pressure value and blowing air onto the electrode cap, and cutting and grinding the electrode cap with a second pressure value and blowing air onto the electrode cap, wherein the second pressure value is less than the first pressure value.

[0014] In some embodiments, the welding method further includes replacing the electrode cap when the number of welding operations reaches a second preset number, wherein the first preset number is less than the second preset number. Attached Figure Description

[0015] Figure 1 This is a flowchart of the electrode cap grinding method according to an embodiment of this application.

[0016] Figure 2 This is a sub-flowchart of step S500 in an embodiment of this application.

[0017] Figure 3 A flowchart of an electrode cap grinding method according to another embodiment of this application.

[0018] Figure 4 The flowchart of another embodiment of the electrode cap grinding method of this application is shown.

[0019] Figure 5 This is a flowchart of a welding method according to an embodiment of this application.

[0020] Figure 6 This is a flowchart of a welding method according to another embodiment of this application.

[0021] Figure 7 This is a schematic diagram of the structure of the grinding tool according to an embodiment of this application.

[0022] Figure 8 This application Figure 7 A schematic diagram of the upper and lower bottom surfaces of the grinding tool in the embodiment.

[0023] Figure 9 This application Figure 7 A schematic diagram illustrating the scenario where the regrinding blade of the regrinding tool in the embodiment contacts the welding electrode cap.

[0024] Figure 10 This is a schematic diagram of the structure of a shaving tool according to another embodiment of this application.

[0025] Figure 11 This application Figure 10 A schematic diagram of the upper and lower bottom surfaces of the grinding tool in the embodiment.

[0026] Figure 12 This application Figure 10 A schematic diagram illustrating the scenario where the regrinding blade of the regrinding tool in the embodiment contacts the welding electrode cap.

[0027] Figure 13 This is a partial structural schematic diagram of the grinding equipment according to an embodiment of this application.

[0028] The following detailed description, in conjunction with the accompanying drawings, will further illustrate this application. Detailed Implementation

[0029] To make the technical problems, technical solutions, and beneficial effects solved by this application clearer, the following detailed description is provided in conjunction with embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0030] This application provides an electrode cap grinding method, welding method, grinding tool, and grinding equipment, aiming to improve the grinding problems caused by poor copper shaving removal in existing technologies. Some embodiments will be described below with reference to the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0031] In this application, cutting grinding refers to rough machining that removes deep material from the welding electrode cap to correct its macroscopic shape, while shaping grinding refers to performing micro-finishing on the basis of cutting grinding to achieve a precise final machining of the surface. Both are essentially tool grinding, but the difference is that the former focuses on eliminating the severe wear layer of the electrode cap (such as mushroom head deformation), while the latter focuses on removing the oxide film and optimizing the microstructure. The fundamental difference lies in the amount of material removed and the level of precision.

[0032] In this application, an asymmetric electrode cap refers to an electrode cap with differentiated two-end structure electrodes in resistance welding: one side is an electrode cap with a large end face for forming the weld point on the appearance side, and the other side is an electrode cap with a small end face for welding on the non-appearance side.

[0033] Figure 1 This is a flowchart of the electrode cap grinding method according to an embodiment of this application.

[0034] This application first provides a method for grinding electrode caps, which will be referred to as the "grinding method" below for ease of description. Figure 1 As shown, grinding methods may include: Step S100: Place the electrode cap in the cutting and grinding tool.

[0035] The electrode cap can be a single electrode cap, a symmetrical electrode cap structure, or an asymmetrical electrode cap structure. "Placing the electrode cap in the cutting and grinding tool" specifically refers to moving the electrode cap to be ground to the grinding equipment and placing the welded end of the electrode cap in the cutting and grinding groove of the grinding tool, and stabilizing it (such as by clamping and fixing it with the fixture of the grinding equipment) for subsequent cutting and grinding.

[0036] Step S200: The electrode cap is cut and ground using the first pressure value, and the electrode cap is blown with air.

[0037] Among them, the "first pressure value" refers to the higher axial clamping force applied to the electrode cap during the cutting and grinding stage, which is mainly used to quickly peel off the oxide layer and welding slag on the surface of the electrode cap, so as to achieve efficient material removal.

[0038] Step S300: The electrode cap is cut and ground using the second pressure value, and the electrode cap is blown with air.

[0039] The "second pressure value" refers to the lower axial clamping force used during the cutting and grinding stage; that is, the second pressure value is less than the first pressure value. By reducing the clamping degree, excessive copper chips are avoided, making it easier for residual chips to be rolled away from the electrode surface by the airflow, thus achieving the purpose of refined chip removal and surface finishing.

[0040] Step S400: Place the electrode cap in the shaping and grinding tool.

[0041] Specifically, "placing the electrode cap in the shaping and grinding tool" means that after the electrode cap to be ground is cut, it is moved from the cutting and grinding groove to the shaping and grinding groove of the grinding equipment, and the welded end of the electrode cap is placed in the shaping and grinding groove of the grinding tool and stabilized (such as by clamping and fixing it with the fixture of the grinding equipment) for subsequent shaping and grinding.

[0042] Step S500: Shape and grind the electrode cap, and blow air into the electrode cap.

[0043] In steps S100 to S500 of this application, through staged cutting and grinding (coarse cutting at the first pressure value to remove the main material, and fine cutting at the second pressure value to refine and break the chips) and simultaneous air blowing, after the copper layer is quickly removed in the high-pressure cutting stage, the copper chips are further broken in the low-pressure cutting stage, making the chips easier to be carried away by the airflow. At the same time, the air blowing and grinding processes are switched and coordinated to ensure that the copper chips are washed away from the contact surface by the airflow during and at the end of the cutting process, reducing the accumulation of copper chips that would cause the chips to be pressed into the electrode cap surface in the subsequent shaping stage. This can reduce the problem of copper chip residue caused by direct shaping after a single cutting in the traditional grinding method.

[0044] Figure 2 This is a sub-flowchart of step S500 in an embodiment of this application.

[0045] In some embodiments, such as Figure 2 As shown, the electrode cap is shaped and ground, and then air is blown onto the electrode cap. That is, step S500 may include: Sub-step S501: Before shaping and grinding the electrode cap, blow air into the electrode cap.

[0046] Sub-step S502: During the shaping and grinding process of the electrode cap, the electrode cap is blown with air.

[0047] Sub-step S503: After shaping and grinding the electrode cap, blow air into the electrode cap.

[0048] Through sub-steps S501 to S503, pre-blowing before shaping and grinding removes residual copper chips from the electrode cap body and the shaping and grinding groove after cutting, reducing their interference with the initial contact during shaping. Continuous blowing during shaping uses airflow to impact the gap between the tool and the electrode, lifting flat copper chips off the cutting edge and removing them. Post-shaping supplementary blowing removes final debris by continuing to blow air onto the electrode cap before it leaves the shaping and grinding groove. This three-stage blowing creates a closed-loop sweep, covering the entire path of chip generation, adhesion, and residue during the shaping process, reducing the risk of copper chip adhesion during the fine shaping stage.

[0049] In the embodiments of this application, both the cutting and shaping tools are equipped with air guide grooves. Air is injected into the electrode cap through these grooves to blow air onto the cap. In this case, the air guide groove design of the cutting and shaping tools allows the airflow to be directly directed to the contact surface between the electrode and the tool, accelerating the airflow penetration rate in the cutting edge area. That is, the high-speed airflow, after being introduced through the air guide grooves, flows closely along the electrode surface, enhancing the entrainment and dragging effect on fine copper chips. Compared to external blowing, this reduces energy loss of the airflow in complex structures and improves chip removal efficiency.

[0050] Furthermore, in the electrode cap grinding method described in this application, the cutting and grinding of the electrode cap can also include length compensation. Specifically, during the secondary cutting and grinding stage (the process of switching between the first and second pressure values), the current wear length of the electrode cap can be simultaneously collected, and a compensation mechanism is triggered based on a preset wear threshold. Based on this compensation mechanism, the grinding equipment drives the axial telescopic device supporting the electrode cap to advance the electrode cap along the grinding direction to compensate for the length, thus filling the thickness of the electrode material removed by cutting. The compensation amount can be dynamically calculated based on the electrode material removal rate and the target welding pressure model to ensure that the total length of the electrode cap after compensation is consistent with the original design value. This process is completed in conjunction with low-speed feed during the low-pressure precision cutting stage, which can reduce positioning deviations caused by high-speed cutting. Through length compensation, the effective working size of the electrode cap can be maintained after multiple grindings, reducing the problem of the electrode cap being too short and the welding pressure being insufficient due to repeated grindings, and ensuring the stability of pressure parameters during the welding process.

[0051] Figure 3 A flowchart of an electrode cap grinding method according to another embodiment of this application.

[0052] In some embodiments, such as Figure 3 As shown, before placing the electrode cap in the shaping and grinding tool (i.e., before step S400), the grinding method may further include: Step S310: Remove the electrode cap from the cutting and grinding tool and place it in the first preset position.

[0053] The first preset position can be any position outside the cutting and grinding groove.

[0054] Step S320: Blow air into the electrode cap located at the first preset position.

[0055] In steps S310 and S320, after cutting, the electrode cap is removed and placed in the first preset position for post-cutting air blowing. This can utilize the exposed space after the electrode is removed from the tool to expand the airflow coverage area, and perform directional flushing on the copper chips hidden at the bottom of the electrode during cutting, removing residual chips in the tool blind area, reducing the amount of copper chips carried into the shaping process, and ensuring the cleanliness of the subsequent shaping interface.

[0056] Figure 4 The flowchart of another embodiment of the electrode cap grinding method of this application is shown.

[0057] In some embodiments, such as Figure 4 As shown, after the electrode cap has been shaped and ground (i.e., after step S500), the grinding method may further include: Step S510: Remove the electrode cap from the shaping and grinding tool and place it in the second preset position.

[0058] The second preset position can be any position outside the shaping and grinding groove.

[0059] Step S520: Blow air into the electrode cap located at the second preset position.

[0060] In steps S510 and S520, after shaping, the electrode cap is removed and placed at the second preset position for post-shaping air blowing. This process deeply cleans the micro-grooves and edge areas on the surface of the shaped electrode cap. By extending the airflow time through a second stop, the extremely fine copper shavings squeezed and embedded during shaping can be deeply peeled off, reducing the problem of foreign matter residue on the surface of the electrode cap.

[0061] Understandable, based on Figure 3 and Figure 4 In the process design of the illustrated embodiment, the post-cutting pause air blowing in steps S310 and S320, and the post-shaping pause air blowing in steps S510 and S520 are optional execution steps (they can be implemented individually or in multiple groups, or they can all be omitted). For example, this embodiment may include only steps S310 and S320, or only steps S510 and S520, or it may include steps S310 and S320 as well as steps S510 and S520.

[0062] In some embodiments, the electrode cap grinding method involved in this application can be applied to the cutting and shaping grinding of new electrode caps. In addition, some or all of the steps in the electrode cap grinding method involved in this application can also be applied to the cutting, grinding and shaping grinding of electrode caps used in welding. For details, please refer to the following welding method.

[0063] Figure 5 This is a flowchart of a welding method according to an embodiment of this application. Grinding is a crucial step in many welding processes. In existing welding methods, air blowing is only activated during grinding, which can easily lead to a disconnect between the timing of air blowing and the removal of chips. Furthermore, the fact that air blowing is only activated during or after grinding (such as shaping grinding) can easily overlook the control of copper chips in three key stages: pre-grinding contamination, where residual copper chips carried by the electrode cap contaminate the contact surface upon entering a new process; adhesion during shaping, where the adsorption effect of the shaping blade on flat copper chips may exceed the airflow's removal capacity; and residual chips during the process gap, where copper chips fall into the fixture or tool holder's dead corners during workpiece transfer between cutting and shaping, resulting in incomplete chip removal. Therefore, as... Figure 5 As shown, this application also provides a welding method, which may include: Step S01: Use the electrode cap to weld the workpiece to be welded. After welding the workpiece to be welded, replace it with the next workpiece to be welded.

[0064] Step S02: During the process of changing to the next part to be welded, the electrode cap is shaped and ground.

[0065] The shaping and grinding process may include: placing the electrode cap in a shaping and grinding tool; blowing air into the electrode cap before shaping and grinding; blowing air into the electrode cap during shaping and grinding; and blowing air into the electrode cap after shaping and grinding. As mentioned above, the shaping and grinding process may also be related to steps S400, S500, S510, and S520 in the above grinding method; therefore, the relevant descriptions and technical effects can be found above.

[0066] Step S03: Use the shaped and ground electrode cap to weld the next part to be welded.

[0067] This application, through steps S01 to S03, embeds shaping and grinding (including three-stage air blowing) during the welding part changeover interval, utilizing the inherent cycle time window of the production line to complete electrode restoration. Specifically, pre-blowing before shaping and grinding removes historical residual copper chips, reducing their interference with the initial contact during shaping; continuous air blowing during shaping uses airflow to impact the gap between the tool and electrode, lifting flat copper chips generated during shaping and detaching them from the tool edge; and supplementary air blowing after shaping removes final debris. This three-stage air blowing forms a closed-loop sweep, covering the entire path of chip generation, adhesion, and residue during the shaping process, reducing the risk of copper chip adhesion during the fine shaping stage. Thus, shaping is performed after each welded part, ensuring the electrode cap maintains the same surface condition and geometric accuracy before and after each weld, reducing accumulated electrode deformation differences in batch welding, and improving the consistency of weld joint morphology.

[0068] Figure 6 This is a flowchart of a welding method according to another embodiment of this application.

[0069] In some embodiments, such as Figure 6 As shown, the welding method may also include: Step S04: When the number of welding cycles of the electrode cap reaches the first preset number, the electrode cap is cut and ground.

[0070] The cutting and grinding process includes: placing the electrode cap in a cutting and grinding tool, cutting and grinding the electrode cap using a first pressure value and blowing air onto the electrode cap, and cutting and grinding the electrode cap using a second pressure value and blowing air onto the electrode cap, wherein the second pressure value is less than the first pressure value. As mentioned above, the cutting and grinding process can also be related to steps S100, S200, S300, S310, and S320 in the above grinding method; therefore, the relevant descriptions and technical effects can be found above.

[0071] In some embodiments, such as Figure 6 As shown, the welding method may also include: Step S05: When the electrode cap has been welded a second preset number of times, replace the electrode cap.

[0072] The first preset number of times is less than the second preset number of times. Step S05 is as follows: when the number of welding times of the electrode cap reaches the preset life threshold (i.e., the second preset number of times), the forced replacement mechanism is triggered. That is, the effective contact length of the electrode cap end face is identified by the automatic detection system as to whether it has been reduced to the preset wear scale line. This scale line is determined based on the comprehensive calibration of the electrode material elongation limit and the welding heat conduction efficiency.

[0073] When the total length of the electrode cap falls below the graduation mark due to repeated grinding (typically corresponding to a consumption of 20%-30% of the original length), its effective conductive cross-sectional area and heat dissipation capacity will be lower than the critical value for reliable welding. At this point, even continued grinding cannot restore the safe contact area; instead, it will lead to uncontrolled welding heat accumulation, weld nugget deformation, or an exponential increase in the risk of incomplete welds. The replacement process can be performed by the robotic arm of the grinding equipment, thereby reducing parameter drift caused by manual disassembly and assembly. Furthermore, the grinding equipment can simultaneously reset the welding count counter and initialize the grinding cycle for the new electrode cap. This ensures welding quality while enabling predictive maintenance of the equipment, reducing production line downtime caused by excessive electrode wear.

[0074] Furthermore, in the grinding tools or equipment used in the aforementioned grinding or welding methods, for electrode caps with a large-end-small-end-face combination, traditional grinding tools typically employ a general-purpose symmetrical design. This can easily lead to the large-end-face having a large contact area but low unit pressure, resulting in insufficient cutting force constraint, while the small-end-face has a small area but high pressure. This mechanical imbalance easily causes grinding problems. Therefore, this application also provides a new grinding tool and equipment, with the following specific improvements: Figure 7 This is a schematic diagram of the structure of the grinding tool 1 according to an embodiment of this application. Figure 8 This application Figure 7 A schematic diagram of the upper and lower bottom surfaces of the grinding tool 1 in the embodiment. Figure 9 This application Figure 7 A schematic diagram of the scenario in which the grinding blade 12 of the grinding tool 1 in the embodiment contacts the welding electrode cap.

[0075] This application also provides a grinding tool 1 for grinding welding electrode caps, and the welding electrode caps can be ground using the grinding method or welding method involved in the above embodiments of this application. Specifically, in the embodiments of this application, the grinding tool 1 can be a cutting grinding tool, the welding electrode cap can be an asymmetric electrode cap, and the welding electrode cap can include a large end face electrode cap 3a and a small end face electrode cap 3b.

[0076] like Figure 7 As shown, the regrinding tool 1 may include a regrinding tool holder 11 and a regrinding tool 12, such as Figure 8 As shown, the grinding tool holder 11 includes an upper bottom surface, a lower bottom surface, an upper grinding groove 110a disposed on the upper bottom surface, and a lower grinding groove 110b disposed on the lower bottom surface. The grinding blade 12 includes an upper grinding blade 12a disposed on the upper grinding groove 110a and a lower grinding blade 12b disposed on the lower grinding groove 110b. The upper grinding blade 12a is used for grinding the large end face electrode cap 3a of the welding electrode cap, and the lower grinding blade 12b is used for grinding the small end face electrode cap 3b of the welding electrode cap.

[0077] In the embodiments of this application, such as Figure 9 As shown, the lateral height of the upper grinding insert 12a is greater than or equal to a preset height (H), and the grinding angle of the upper grinding insert 12 is a preset angle (θ). The preset height is the minimum height at which the static friction force (F) between the welding electrode cap and the upper grinding insert 12 is greater than the overturning moment caused by the asymmetry of the welding electrode cap. The preset angle is the grinding angle at which the static friction force between the welding electrode cap and the upper grinding insert 12 is greater than the overturning moment caused by the asymmetry of the welding electrode cap. In this case, by increasing the lateral height and optimizing the grinding angle of the upper grinding insert 12 (large end face side), the contact area can be expanded, thereby increasing the radial constraint force of the welding electrode cap during grinding. The high lateral friction area can generate a static friction torque opposite to the overturning moment, thus suppressing the shaking caused by the imbalance of cutting forces at the large and small ends of the asymmetric structure. The optimized angle can guide the direction of the cutting resultant force, enhancing the stability control of the grinding tool 1 on the large end face electrode and improving the flatness of the grinding surface.

[0078] exist Figure 7 In some embodiments, the grinding tool holder 11 may further include at least one chip removal and venting through hole 1110 communicating with the grinding tool groove. The chip removal and venting through hole 1110 is disposed at the bottom of the upper grinding tool groove 110a and / or the lower grinding tool groove 110b. The upper grinding tool groove 110a and / or the lower grinding tool groove 110b are recessed away from the center of the tool groove to form at least one air guide groove 1101. In this case, the upper grinding groove 110a and / or the lower grinding groove 110b are recessed outward to form an air guide groove 1101. The air guide groove 1101 and the chip removal and exhaust hole 1110 at the bottom of the grinding groove form a directional airflow channel. When external gas is injected, the airflow directly washes the electrode cap surface and the upper grinding groove 110a, or washes the electrode cap surface and the lower grinding groove 110b along the air guide groove 1101. This forcefully lifts up the debris trapped on the electrode cap surface, the dead corners of the upper grinding groove 110a and the lower grinding groove 110b, and discharges it through the chip removal and exhaust hole 1110. This can reduce the problem of inadequate chip cleaning caused by airflow obstruction in traditional tool holders and can indirectly improve the quality of the weld joint.

[0079] In some embodiments, at least one air guide groove 1101 is located in the area where the welding electrode cap and the regrinding tool are in close proximity. In this case, the air guide groove 1101 is precisely positioned in the area where the welding electrode cap and the regrinding tool are in close proximity, which is a high-incidence area for chip adhesion. The local airflow vortex generated by the air guide groove 1101 here can enhance the peeling strength of flat copper chips and achieve chip breaking, reducing their re-adhesion due to surface tension, thereby improving the cleaning efficiency of such critical areas. In other words, the air guide groove 1101 on the inner wall of the upper regrinding groove 110a or the lower regrinding groove 110b (especially the recessed design in the electrode contact area) can form a directional airflow channel pointing towards the bottom of the electrode cap. The accelerated airflow in the groove bypasses the obstruction area and reaches the cutting edge directly, applying a precise impact to the adhered chips; and in conjunction with the chip removal and exhaust vent 1110 to create a negative pressure effect, it can improve the copper chip removal efficiency and reduce the dead zone residue formed by conventional air blowing in the obstruction area.

[0080] exist Figure 7 In some embodiments, the upper grinding blade 12a or the lower grinding blade 12b can be a single blade or a double-edged blade. The number of double-edged blades, i.e., the grinding blades, can be two, and the two grinding blades can be symmetrically arranged in the upper grinding groove 110a or the lower grinding groove 110b. In other embodiments, the number of upper grinding blades 12a or lower grinding blades 12b can be multiple, such as three, four, or more.

[0081] Figure 10 This is a schematic diagram of the structure of the grinding tool 2 according to another embodiment of this application. Figure 11 This application Figure 10 A schematic diagram of the upper and lower bottom surfaces of the grinding tool 2 in the embodiment. Figure 12 This application Figure 10 A schematic diagram of the scenario in which the grinding blade 22 of the grinding tool 2 in the embodiment contacts the welding electrode cap.

[0082] This application also provides another grinding tool 2 for grinding the welding electrode cap, and the welding electrode cap can be ground by the grinding method or welding method involved in the above embodiments of this application. Specifically, in the embodiments of this application, the grinding tool 2 can be a shaping grinding tool, the welding electrode cap can be an asymmetric electrode cap, and the welding electrode cap can include a large end face electrode cap 3a and a small end face electrode cap 3b.

[0083] Similarly, as Figure 10 As shown, the shaving tool 2 includes a shaving tool holder 21 and a shaving tool 22, as... Figure 11As shown, the grinding tool holder 21 includes an upper bottom surface, a lower bottom surface, an upper grinding groove 210a disposed on the upper bottom surface, and a lower grinding groove 210b disposed on the lower bottom surface. The grinding blade 22 includes an upper grinding blade 22a disposed on the upper grinding groove 210a and a lower grinding blade 22b disposed on the lower grinding groove 210b. The upper grinding blade 22a is used for grinding the large end face electrode cap 3a of the welding electrode cap, and the lower grinding blade 22b is used for grinding the small end face electrode cap 3b of the welding electrode cap. Figure 12 As shown, the bottom of the upper grinding blade 22a is provided with two symmetrical pre-set grooves 220. The pre-set grooves 220 are far from the bottom center of the upper grinding blade 22a and close to the side of the upper grinding blade 22a. The pre-set grooves 220 are used to reduce the axial force diameter of the large end face electrode cap 3a during grinding (i.e., Figure 12 As shown, R1 decreases to R).

[0084] In the regrinding tool 2 of this application, the symmetrical groove design at the bottom of the upper regrinding blade 22a allows for selective reduction of the actual contact area between the large end face electrode cap 3a and the upper regrinding blade 22a, thereby balancing the pressure difference between the large and small end faces. The portion of the bottom of the upper regrinding blade 22a between the two grooves provides local support, reducing the effective regrinding area of ​​the large end face to the core functional area (covering the corrosion areas of both large and small end face electrodes, i.e., R > R2), while maintaining the natural contact area of ​​the small end face. Thus, by maintaining consistent shaping pressure on both upper and lower regrinding blades 22, simultaneous clean shaping of the large end face and edge protection of the small end face can be achieved, reducing uneven shaping problems caused by pressure imbalance.

[0085] Similarly, in Figure 10 In some embodiments, the grinding tool holder 21 may further include at least one chip removal and venting through hole 211 communicating with the grinding tool groove. The chip removal and venting through hole 211 is disposed at the bottom of the upper grinding tool groove 210a and / or the lower grinding tool groove 210b. The upper grinding tool groove 210a and / or the lower grinding tool groove 210b are recessed away from the center of the tool groove to form at least one air guide groove 2101. In this case, the upper grinding groove 210a and / or the lower grinding groove 210b are recessed outward to form an air guide groove 2101. The air guide groove 2101 forms a directional airflow channel by cooperating with the chip removal and exhaust vent 211 at the bottom of the grinding groove. When external gas is injected, the airflow directly washes the electrode cap surface and the upper grinding groove 210a, or washes the electrode cap surface and the lower grinding groove 210b along the air guide groove 2101, which powerfully lifts up the debris trapped on the electrode cap surface, the dead corners of the upper grinding groove 210a and the lower grinding groove 210b, and discharges it through the chip removal and exhaust vent 211. This can reduce the problem of inadequate chip cleaning caused by airflow obstruction in traditional tool holders and can indirectly improve the quality of the weld joint.

[0086] In some embodiments, at least one air guide groove 2101 is located in the area where the welding electrode cap and the grinding tool 2 are in close proximity. In this case, the air guide groove 2101 is precisely positioned in the area where the welding electrode cap and the grinding tool 2 are in close proximity, which is a high-incidence area for chip adhesion. The local airflow vortex generated by the air guide groove 2101 here can enhance the peeling strength of flat copper chips and achieve chip breaking, reducing their re-adhesion due to surface tension, thereby improving the cleaning efficiency of such critical areas. In other words, the air guide groove 2101 on the inner wall of the upper grinding groove 210a or the lower grinding groove 210b (especially the recessed design in the electrode contact area) can form a directional airflow channel pointing towards the bottom of the electrode cap. The accelerated airflow in the groove bypasses the obstruction area and reaches the cutting edge directly, applying a precise impact to the adhered chips; and in conjunction with the chip removal and exhaust vent 211 to create a negative pressure effect, it can improve the copper chip removal efficiency and reduce the dead zone residue formed by conventional air blowing in the obstruction area.

[0087] Similarly, in Figure 10 In some embodiments, the upper grinding blade 22a or the lower grinding blade 22b can be a single blade or a double-edged blade. The number of double-edged blades, i.e., the grinding blades 22, can be two, and the two grinding blades 22 can be symmetrically arranged in the upper grinding groove 210a or the lower grinding groove 210b. In other embodiments, the number of upper grinding blades 22a or lower grinding blades 22b can be multiple, such as three, four, or more.

[0088] Figure 13 This is a partial structural schematic diagram of the grinding equipment 100 according to an embodiment of this application.

[0089] This application also provides a grinding device 100, which includes grinding tools according to any of the above embodiments of this application. Specifically, the grinding device 100 includes a cutting grinding tool 1 and a shaping grinding tool 2 according to any of the above embodiments of this application. That is, the cutting grinding tool 1 and the shaping grinding tool 2 can be integrated into the grinding device 100 as a matching combination to jointly realize the staged processing of the electrode cap—the cutting grinding tool 1 completes the rough grinding, and the shaping grinding tool 2 is responsible for the surface fine processing. The two work together to ensure the removal of copper chips and the optimization of the shape during the grinding process. Figure 13 As shown, the regrinding equipment 100 also includes an air circuit system, which includes multiple gas circuits for blowing air onto the regrinding tools.

[0090] In the grinding equipment 100 of this application, the cutting grinding tool 1 and the shaping grinding tool 2 are integrated into the same equipment. The air circuit system coordinates the operation of multiple sets of gas circuits to blow air onto the cutting grinding tool 1 and the shaping grinding tool 2. The airflow is controlled by the air guide grooves of the two tools, which can remove the debris generated when the electrode cap is cut and ground and shaped by the cutting grinding tool 1 and the shaping grinding tool 2, thereby improving the welding quality.

[0091] In some embodiments, such as Figure 13 As shown, at least one gas circuit is disposed above and / or below the cutting and grinding tool 1 with the air blowing direction toward the cutting and grinding tool 1, such as air blowing path 101; at least one air blowing path is disposed above and / or below the cutting and grinding tool 1 with the air blowing direction away from the cutting and grinding tool 1, such as air blowing path 102; the upper air blowing path blowing toward the cutting and grinding tool 1 is used for air blowing during the cutting and grinding of the welding electrode cap, and the upper air blowing path away from the cutting and grinding tool 1 is used for air blowing after the cutting and grinding of the welding electrode cap. Figure 13 As shown, at least one air blowing path is provided above and / or below the shaping and grinding tool 2 and the air blowing direction is towards the shaping and grinding tool 2, such as air blowing path 103; at least one air blowing path is provided above and / or below the shaping and grinding tool 2 and the air blowing direction is away from the shaping and grinding tool 2, such as air blowing path 104; the upper air blowing path blowing towards the shaping and grinding tool 2 is used for air blowing during the shaping and grinding of the welding electrode cap, and the upper air blowing path away from the shaping and grinding tool 2 is used for air blowing after the shaping and grinding of the welding electrode cap.

[0092] In the embodiments of this application, the air blowing path during regrinding is used to actively remove chips from the tool cutting edge, and the air blowing path after regrinding is used to remove residual chips during the separation stage of the electrode cap and the tool. The spatiotemporal separation design of the two air blowing modes covers the entire cycle of the regrinding action. In particular, the post-air blowing mode completely prevents secondary adhesion by utilizing the exposed state of the electrode cap, achieving "one-time regrinding, zero residue".

[0093] In this application, "multiple" refers to two or more. Unless otherwise expressly defined, the term "connection" should be interpreted broadly, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0094] The terms "first," "second," "third," "fourth," etc. (if present) in this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. The term "and / or" in this application 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. Furthermore, the character " / " in this application generally indicates that the preceding and following related objects have an "or" relationship.

[0095] Unless otherwise specified, all steps in this application may be performed sequentially or randomly. For example, the method includes steps A and B, indicating that the method may include steps A and B performed sequentially, or steps B and A performed sequentially. For example, the method may also include step C, indicating that step C may be added to the method in any order. For example, the method may include steps A, B, and C, or steps A, C, and B, or steps C, A, and B, etc.

[0096] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A method for grinding electrode caps, characterized in that, include: Place the electrode cap in the cutting and grinding tool; The electrode cap is cut and ground using a first pressure value, and then air is blown onto the electrode cap. The electrode cap is cut and ground using a second pressure value, and the electrode cap is then blown with air, wherein the second pressure value is less than the first pressure value; Place the electrode cap in the shaping and grinding tool; The electrode cap is shaped and ground, and then air is blown into it.

2. The electrode cap grinding method according to claim 1, characterized in that, The process of shaping and grinding the electrode cap, and blowing air into the electrode cap, includes: Before shaping and grinding the electrode cap, the electrode cap is blown with air; During the shaping and grinding process of the electrode cap, air is blown onto the electrode cap; After the electrode cap is shaped and polished, it is blown with air.

3. The electrode cap grinding method according to claim 1 or 2, characterized in that, Both the cutting and grinding tool and the shaping and grinding tool are provided with air guide grooves. The air blowing on the electrode cap is performed by injecting airflow through the air guide grooves to blow air onto the electrode cap.

4. The electrode cap grinding method according to claim 1, characterized in that, Also includes: Before placing the electrode cap into the shaping and grinding tool, the electrode cap is removed from the cutting and grinding tool and placed in a first preset position; Air is blown onto the electrode cap located at the first preset position.

5. The electrode cap grinding method according to claim 1, characterized in that, Also includes: After the electrode cap has been shaped and ground, the electrode cap is removed from the shaping and grinding tool and placed in the second preset position. Air is blown onto the electrode cap located at the second preset position.

6. A welding method, characterized in that, include: The electrode cap is used to weld the workpiece to be welded. After the workpiece to be welded is completed, the next workpiece to be welded is replaced. During the process of replacing the next workpiece to be welded, the electrode cap is shaped and ground, including: placing the electrode cap in a shaping and grinding tool, blowing air into the electrode cap before shaping and grinding, blowing air into the electrode cap during shaping and grinding, and blowing air into the electrode cap after shaping and grinding. The next workpiece to be welded is then welded using the shaped and ground electrode cap.

7. The welding method according to claim 6, characterized in that, Also includes: When the number of welding operations on the electrode cap reaches a first preset number, the electrode cap is cut and ground, including: placing the electrode cap in a cutting and grinding tool, cutting and grinding the electrode cap with a first pressure value and blowing air onto the electrode cap, and cutting and grinding the electrode cap with a second pressure value and blowing air onto the electrode cap, wherein the second pressure value is less than the first pressure value.

8. The welding method according to claim 7, characterized in that, Also includes: When the electrode cap has been welded a second preset number of times, the electrode cap is replaced, wherein the first preset number of times is less than the second preset number of times.

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