A soldering jig and soldering method

Abstract

A kind of welding jig and welding method, welding jig includes support seat, reset support mechanism and actuating rod, support seat is divided into first, second support mechanism, can be positioned first hard copper bar, soft copper bar and second hard copper bar simultaneously;Reset support mechanism is composed of guide column, guide sleeve, guide rod, spring, support block, support block is flush with the top surface of second support plate in normal state, lift soft copper bar suspended end to ensure lap positioning accuracy;Actuating rod is fixed in welding station, after jig moves to position, support block can be pushed to compress spring to give way, to spot welding electrode give out operating space;When welding, upper and lower electrode respectively adhere to the bottom of soft copper bar, hard copper bar top surface to complete fusion, after jig moves out station, spring automatically drives support block to reset;This scheme solves the problem that traditional jig fixed support blocks electrode, copper bar suspended end easy to warp offset, welding virtual welding, suitable for automated assembly line operation, effectively improve welding yield and production efficiency, tool structure is simple, smooth, can be recycled continuous operation.

Description

Technical Field

[0001] This invention relates to copper bar welding fixture technology, and is particularly applicable to resistance spot welding of soft copper bars and hard copper bars at both ends in power battery busbars. Background Technology

[0002] Power battery modules typically use flexible copper busbars to connect two hard copper busbars on either side for conductive bonding. During production, resistance spot welding is required to fuse the two ends of the flexible copper busbars to their corresponding hard copper busbars. Existing welding fixtures have the following core defects:

[0003] The suspended end supports the interference electrode, resulting in poor welding fusion. One end of the soft copper bar overlaps with the first hard copper bar to form a suspended welding position. Traditional fixtures use a fixed support block to hold the suspended end of the soft copper bar for positioning. During spot welding, the lower electrode needs to be inserted into the bottom of the soft copper bar to apply pressure. The fixed support block will prevent the electrode post from entering the welding area, so the installation height of the soft copper bar must be raised to avoid the electrode. This results in a large gap between the overlapping surfaces of the soft and hard copper bars, insufficient spot welding pressure, and problems such as incomplete welds, small weld nuggets, and substandard conductivity.

[0004] Manually avoiding the support blocks results in poor positioning accuracy and low efficiency. If the support blocks are removed for positioning, the unsupported end of the soft copper busbar is prone to warping and displacement, and manual correction of the overlap position is time-consuming; frequent manual adjustment of the copper busbar position will cause poor consistency of overlap dimensions in batch products and low welding yield.

[0005] The tooling has poor versatility and the clamping process is cumbersome. Existing fixtures can only support a single copper busbar of a single specification and cannot simultaneously complete the limiting and positioning of soft copper bars and hard copper bars at both ends. During clamping, each copper busbar needs to be fixed step by step, which increases the cycle time and is not conducive to continuous operation of automated production lines.

[0006] In summary, the existing tooling cannot simultaneously achieve precise positioning of the copper busbar and interference-free electrode welding, resulting in technical pain points such as poor welding quality, low production efficiency, and excessive manual intervention, which urgently need to be improved. Summary of the Invention

[0007] To address the shortcomings of existing soft copper busbar welding fixtures, such as interference between the support structure and spot welding electrodes, low copper busbar positioning accuracy, poor welding yield, and low clamping efficiency, this invention provides a welding fixture and a matching welding method. Through a retractable reset support mechanism, it achieves automatic switching between positioning the suspended end of the soft copper busbar and electrode avoidance, simultaneously completing precise positioning of the three copper busbars, eliminating the obstruction of the electrodes by the support structure, improving spot welding fit accuracy and welding quality, and simplifying the clamping process for automated production.

[0008] To achieve the above and other related objectives, the technical solution provided by the present invention is: a welding fixture for welding soft copper bars to a first hard copper bar and a second hard copper bar, comprising:

[0009] The support base includes a first support mechanism and a second support mechanism. The first support mechanism is used to support and position the first hard copper bar, and the second support mechanism is used to support and position the soft copper bar and the second hard copper bar. The welding end of the first hard copper bar overlaps with one end of the soft copper bar that is suspended in the air, and the welding end of the second hard copper bar overlaps with the other end of the soft copper bar.

[0010] A reset support mechanism is provided on the support base. The reset support mechanism is configured to support one end of the soft copper bar that is suspended in the air under normal conditions, or to support the end of the soft copper bar that is suspended away from the soft copper bar under the action of external force.

[0011] An actuating rod is used to actuate the end of the reset support mechanism that is suspended away from the soft copper bar.

[0012] The preferred technical solution is as follows: the first support mechanism includes a base, a first support plate, a vertical plate and a limiting block. The first support plate and the vertical plate are fixed on the base. The limiting block is fixed on the top of the vertical plate on the side away from the first support plate. The first support plate is provided with a ramp, a first side stop and a second side stop. The first side stop and the second side stop are arranged perpendicular to each other. A quick clamp is fixed on the top side of the first side stop.

[0013] The preferred technical solution is as follows: the top side of the vertical plate is provided with a clearance groove, the top side of the limiting block is provided with a limiting groove, and the clearance groove and the limiting groove are provided correspondingly.

[0014] The preferred technical solution is as follows: the second support mechanism includes a second support plate, which is fixed to the top of the vertical plate on the side away from the first support plate, and the second support plate is provided with a groove and a third side stop.

[0015] A preferred technical solution is that the depth of the groove is the same as the sum of the thicknesses of the soft copper bar and the second hard copper bar.

[0016] A preferred technical solution is as follows: the reset support mechanism includes a guide post, a guide sleeve, a guide rod, a spring, and a support block. The guide sleeve is fixed to the vertical plate, the guide rod passes through the guide sleeve, the guide rod is fixed to the vertical plate and arranged parallel to the guide post at intervals, the support block is fixed to one end of the guide post, the support block has a through hole, the guide rod passes through the through hole, the spring is sleeved on the guide rod, one end of the spring abuts against the vertical plate, the other end of the spring abuts against the support block, and the support block is located between the limiting block and the second support plate.

[0017] A preferred technical solution is that the top side of the support block is flush with the top side of the second support plate.

[0018] A welding method based on the above-mentioned welding fixture includes the following steps:

[0019] Step 1: Position the first hard copper bar, the second hard copper bar, and the soft copper bar on the support base;

[0020] Step 2: Fix the actuator rod in the welding position;

[0021] Step 3: Control the support to move to the welding position, so that the reset support mechanism moves away from the suspended end of the soft copper bar under the action of the actuator rod. One electrode post is located on the bottom side of the suspended end of the soft copper bar, and the other electrode post is located on the top side of the welding end of the first hard copper bar.

[0022] Due to the application of the above technical solution, the beneficial effects of this invention are as follows:

[0023] Eliminating electrode interference significantly improves welding quality. Under normal conditions, the support block is flush with the second support plate, stably supporting the suspended end of the soft copper bar and preventing copper busbar warping and overlap misalignment. When the fixture moves into the welding station, the actuator rod automatically pushes the support block backward, completely clearing the bottom space of the soft copper bar. The lower electrode can directly contact the bottom surface of the soft copper bar, ensuring uniform pressure on the upper and lower electrodes during spot welding, no gaps at the overlap surface, full weld nugget formation, eliminating defects such as incomplete welds, detachment, and poor conductivity, and improving the welding yield.

[0024] Integrated synchronous positioning simplifies clamping and improves production efficiency. The support base has two sets of support mechanisms, which can simultaneously clamp the first hard copper bar, the soft copper bar, and the second hard copper bar at one time. The side stop, the limiting groove, and the groove provide multi-directional limiting, eliminating the need for repeated manual correction of the copper busbar overlap position. With quick clamps for rapid locking, the clamping time for a single piece is shortened, making it suitable for automated production line transfer operations and reducing manual intervention.

[0025] The elastic automatic reset ensures stable and reliable continuous operation. The support block automatically rebounds using a spring, immediately returning to its supporting state after the fixture leaves the welding station. No manual reset of the support structure is required, allowing for continuous cyclic loading and unloading welding. Guide pillars, guide sleeves, and guide rods work together to guide the support block without jamming, maintaining positioning accuracy over long-term use and extending the tooling's service life.

[0026] The structure is highly adaptable, reducing processing costs. The depth of the second support plate groove matches the thickness of the two layers of copper busbars. The limiting groove and avoidance groove restrict the multi-directional displacement of the copper busbars, eliminating the need for additional shims to adapt to standard copper busbar specifications. The overall structure is modular, making disassembly and maintenance convenient. Compared with multiple sets of traditional split fixtures, the equipment investment cost is lower. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the welding fixture structure involved in the present invention.

[0028] Figure 2 This is a schematic diagram of the welding method involved in the present invention. Detailed Implementation

[0029] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0030] Please see Figures 1-2 It should be noted that in the description of this invention, the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use. These terms are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance. The terms "horizontal," "vertical," and "suspended," etc., do not indicate that the component must be absolutely horizontal or suspended, but can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0031] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" 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 mechanical connection or an electrical 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 invention based on the specific circumstances.

[0032] Example:

[0033] like Figure 1 As shown, according to an overall technical concept of the present invention, a soft copper bar welding fixture is provided for resistance spot welding of the two ends of the soft copper bar 300 of the power battery busbar to the first hard copper bar 100 and the second hard copper bar 200, respectively.

[0034] The support base consists of a base 1, a vertical plate 2, a first support mechanism, and a second support mechanism. The base 1 is a flat load-bearing base, and the vertical plate 2 is vertically fixed to the middle of the base 1.

[0035] The first support mechanism is located on the left side of the base 1, including a first support plate 3, a first side stop 31 and a second side stop 32 that are perpendicular to each other on the top side of the first support plate 3, and a ramp 33. A limiting block 4 is installed on the upper part of the vertical plate 2. The limiting block 4 has a limiting groove 41, and the vertical plate 2 has a corresponding clearance groove 21. A quick clamp 5 is installed on the top side of the first side stop 31. The first hard copper bar 100 is pushed in along the ramp 33. The side stop restricts the displacement, and the quick clamp 5 presses the top surface of the first hard copper bar 100. The first hard copper bar 100 extends at least partially into the limiting groove 41 to achieve complete positioning.

[0036] The second support mechanism is located at the top of the vertical plate 3 and is the second support plate 6. The top side of the second support plate 6 has a groove 61 and a third side stop 62. The depth of the groove 61 is equal to the soft copper bar 300 + the thickness of the second hard copper bar 200. The two layers of copper bars are stacked and embedded in the groove 61. The third side stop 62 prevents the second hard copper bar 200 from shifting back and forth. One end of the soft copper bar 300 extends outward to form a suspended overlapping section, which overlaps above the limiting block 4. The welding end of the first hard copper bar 100 overlaps the top side of the suspended overlapping section of the soft copper bar 300.

[0037] The reset support mechanism 8 includes a guide post 81, a guide sleeve 82, a guide rod 83, a spring 84, and a support block 85. The guide sleeve 82 is fixed to the vertical plate 2, and the guide post 81 passes through the guide sleeve 82 to achieve horizontal sliding guidance. The guide rod 83 is fixed to the vertical plate 2 and parallel to the guide post 81. The support block 85 is fixed to the end of the guide post 81 and sleeved on the outside of the guide rod 83. The spring 84 is sleeved on the guide rod 83, with one end pressing against the vertical plate 2 and the other end pressing against the support block 85.

[0038] Under normal conditions, the spring 84 extends, pushing the support block 85 to extend outward. The top surface of the support block 85 is flush with the second support plate 6, supporting the suspended section of the soft copper bar 300, preventing the soft copper bar 300 from falling or warping, and ensuring accurate overlap dimensions.

[0039] The welding station is pre-installed with a fixed actuator rod (not shown). When the production line moves the support base towards the welding equipment, the front end of the actuator rod presses against the side of the support block. The support block is forced to slide inward along the guide rod to compress the spring and completely detach from the bottom of the suspended section of the soft copper bar. At this time, the lower electrode post can rise directly to fit against the bottom surface of the soft copper bar, and the upper electrode presses down on the top surface of the first hard copper bar. The upper and lower electrodes clamp the two layers of copper busbars and spot weld them without any structural obstruction.

[0040] After spot welding is completed, the production line moves the fixture out of the welding station, the actuating rod disengages from the support block, and the spring force pushes the support block to automatically reset outward, lifting the soft copper bar again, and the workpiece can then be removed.

[0041] like Figure 2 As shown, this application also relates to a welding method for a welding fixture, comprising the following steps:

[0042] Material loading and positioning: Place the first hard copper bar on the first support plate, and fix it by locking the quick clamps with the first and second side stops as the limit; stack the soft copper bar and the second hard copper bar on the groove of the second support plate, with the end of the soft copper bar's suspended overlapping section resting on the support block, and the welding end of the first hard copper bar overlapping the top side of the soft copper bar's suspended overlapping section, thus completing the one-time positioning of the three copper bars;

[0043] Equipment pre-installation: Lock the actuator rod in the welding station of the spot welding equipment in advance, and match the extension length of the actuator rod with the retraction stroke of the support block;

[0044] Automatic retraction spot welding: The robot arm moves the support base to the welding station, the actuator pushes the support block backward, and the electrode extends under the soft copper bar to perform spot welding;

[0045] Reset and unloading: After welding is completed, the support seat exits the work station, the support block spring returns to its original position, the quick clamp is released, the welded copper busbar assembly is taken out, and the next round of processing begins.

[0046] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A soldering jig for soldering between a soft copper bar and a first hard copper bar and a second hard copper bar, characterized by, include: The support base includes a first support mechanism and a second support mechanism. The first support mechanism is used to support and position the first hard copper bar, and the second support mechanism is used to support and position the soft copper bar and the second hard copper bar. The welding end of the first hard copper bar overlaps with one end of the soft copper bar that is suspended in the air, and the welding end of the second hard copper bar overlaps with the other end of the soft copper bar. A reset support mechanism is provided on the support base. The reset support mechanism is configured to support one end of the soft copper bar that is suspended in the air under normal conditions, or to support the end of the soft copper bar that is suspended away from the soft copper bar under the action of external force. An actuating rod is used to actuate the end of the reset support mechanism that is suspended away from the soft copper bar.

2. The soldering fixture of claim 1, wherein: The first support mechanism includes a base, a first support plate, a vertical plate, and a limiting block. The first support plate and the vertical plate are fixed on the base, and the limiting block is fixed on the top of the vertical plate on the side away from the first support plate. The first support plate is provided with a ramp, a first side stop, and a second side stop. The first side stop and the second side stop are arranged perpendicular to each other, and a quick clamp is fixed on the top side of the first side stop.

3. The soldering fixture of claim 2, wherein: The top side of the vertical plate is provided with a clearance groove, and the top side of the limiting block is provided with a limiting groove. The clearance groove and the limiting groove are provided correspondingly.

4. The soldering fixture of claim 2, wherein: The second support mechanism includes a second support plate, which is fixed to the top of the vertical plate on the side away from the first support plate. The second support plate is provided with a groove and a third side stop.

5. The soldering fixture of claim 4, wherein: The depth of the groove is the same as the sum of the thicknesses of the soft copper bar and the second hard copper bar.

6. The soldering fixture of claim 4, wherein: The reset support mechanism includes a guide post, a guide sleeve, a guide rod, a spring, and a support block. The guide sleeve is fixed to the vertical plate, the guide rod passes through the guide sleeve, and the guide rod is fixed to the vertical plate and arranged parallel to the guide post at intervals. The support block is fixed to one end of the guide post, and the support block has a through hole. The guide rod passes through the through hole, the spring is sleeved on the guide rod, one end of the spring abuts against the vertical plate, and the other end of the spring abuts against the support block. The support block is located between the limiting block and the second support plate.

7. The soldering fixture of claim 6, wherein: The top side of the support block is flush with the top side of the second support plate.

8. A welding method based on the welding fixture according to any one of claims 1-6, characterized in that, Includes the following steps: Step 1: Position the first hard copper bar, the second hard copper bar, and the soft copper bar on the support base; Step 2: Fix the actuator rod in the welding position; Step 3: Control the support to move to the welding position, so that the reset support mechanism moves away from the suspended end of the soft copper bar under the action of the actuator rod. One electrode post is located on the bottom side of the suspended end of the soft copper bar, and the other electrode post is located on the top side of the welding end of the first hard copper bar.

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