Busbar welding machine

Abstract

The application relates to a busbar welding machine and belongs to the technical field of welding equipment. The busbar welding machine comprises a welding mechanism, a positioning mechanism and a supporting mechanism. The welding mechanism is used for welding welding positions of a main busbar and branch busbars; the positioning mechanism comprises a positioning table, a fixing tool and a turnover assembly. The positioning table is provided with a through working opening. The fixing tool fixes the main busbar and the branch busbars on the positioning table, and the projections of all the welding positions fall into the working opening. The turnover assembly drives the positioning table to rotate, so that the front surface and the back surface of the main busbar are sequentially oriented towards the welding mechanism. The supporting mechanism is arranged below the positioning table and comprises a movable assembly, a supporting table and a plurality of cushion blocks arranged on the upper surface of the supporting table. The movable assembly drives the supporting table to move, so that the cushion blocks are aligned with the working opening and then are lifted. The welding positions of the main busbar and the branch busbars are supported by the cushion blocks. The busbar welding machine provided by the application can weld thick busbars with welding seam depth and welding seam quality.

Description

Technical Field

[0001] This application relates to the field of welding equipment technology, and more specifically, to a busbar welding machine. Background Technology

[0002] Busbars, as key components in power transmission and distribution, are responsible for collecting and transmitting large currents in energy storage power stations. To meet high current-carrying capacity requirements, the busbars used in energy storage power stations are typically welded together from a thick main busbar and multiple branch busbars, with a busbar thickness much greater than that of busbars in conventional distribution cabinets or control cabinets. The welded joints of these thick busbars not only need sufficient mechanical connection strength but also require the welds to have sufficient depth and density to provide a long-term stable, low-resistance current conduction path.

[0003] Conventional welding machines are mostly designed for thin-plate busbars, and the welding method is mainly single-sided welding. The weld depth formed by single-sided welding is limited and it is difficult to penetrate the entire connection surface. Incomplete penetration areas are often left inside the joint, reducing the effective conductive cross-sectional area and resulting in high contact resistance. When a large current passes through for a long time, the local resistance heats up severely, aggravating the joint temperature rise. This not only causes energy loss but also easily leads to joint oxidation, loosening, or even melting, failing to meet the requirements for reliable operation of energy storage systems.

[0004] In summary, conventional welding machines cannot effectively ensure the penetration depth when welding thick busbars, resulting in insufficient weld depth, inadequate connection stability, and difficulty in meeting weld quality standards, thus failing to meet the high current carrying capacity requirements of busbars in energy storage power stations. Summary of the Invention

[0005] The purpose of this application is to provide a busbar welding machine that addresses the above-mentioned problems by welding thick busbars with both weld depth and weld quality, thereby improving the aforementioned issues.

[0006] This application is achieved through the following technical solution: This application provides a busbar welding machine, which includes a welding mechanism, a positioning mechanism, and a support mechanism. The welding mechanism is used to weld the main busbar and branch busbar at the weld joints. The positioning mechanism includes a positioning table, a fixing fixture, and a flipping component. The positioning table has a through working opening. The fixing fixture fixes the main busbar and branch busbar to the positioning table, and the projections of all weld joints fall into the working opening. The flipping component drives the positioning table to rotate, so that the front and back of the main busbar face the welding mechanism in sequence. The support mechanism is located below the positioning table and includes a movable component, a support table, and multiple pads on the upper surface of the support table. The pads are divided into a front support group and a back support group. The distribution of the pads in the front support group corresponds to the position of each weld joint when the main busbar faces the welding mechanism, and the distribution of the pads in the back support group corresponds to the position of each weld joint when the main busbar faces away from the welding mechanism. The movable component drives the support table to move, so that the front support group or the back support group aligns with the working opening and rises, with the corresponding pads supporting the weld joints of the main busbar and branch busbar.

[0007] In the technical solution of this application embodiment, the main busbar's front and back sides are sequentially faced with the welding mechanism and welded separately by flipping the component, transforming conventional single-sided welding into double-sided welding. The two welding processes melt the base material from two directions, with overlapping weld depths, penetrating the entire thick busbar connection surface. This eliminates the problem of incomplete penetration and unpenetrated areas left by conventional single-sided welding. After full-thickness penetration, the connection interface between the main busbar and the branch busbar is completely filled by the weld metal, and the effective conductive cross-sectional area is essentially equal to the busbar overlap area. This avoids high local resistance due to incomplete penetration, ensuring a stable and low-resistance current path, meeting the high-current carrying capacity requirements of energy storage power stations. The front and back support groups of the support mechanism accurately support the welding points from below during the front and back welding processes, respectively. The pad directly offsets the welding pressure and thermal stress, preventing the busbar from collapsing or warping due to high temperature and gravity. The weld is uniform and dense, with high mechanical connection strength. When a large current passes through for a long time, the joint temperature rise is small, and oxidation, loosening or burning failures are not likely to occur. This ensures the long-term stable operation of the busbar of the energy storage power station and reduces power loss and maintenance costs.

[0008] In some embodiments, the fixing fixture includes a central clamp and branch clamps. The central clamp is used to position the main busbar, and the branch clamps are used to position the branch busbars. The surface of the positioning table is provided with a recessed area, and at least some of the branch clamps are located in the recessed area, such that the branch busbars fixed by these branch clamps are centered with the main busbar and have a thickness greater than or less than that of the main busbar.

[0009] In the technical solution of this application embodiment, branch busbars of varying thicknesses are aligned with the main busbar in the thickness direction through a recessed area, so that the thickness center planes of the main busbar and the branch busbars coincide. During double-sided welding, the penetration depth of the front and back welds from the center outwards is symmetrical and balanced, and the welds intersect at the thickness center, avoiding problems such as false welds or excessive penetration on one side and insufficient penetration on the other due to offset, ensuring consistent weld penetration quality across the entire thickness. After alignment, regardless of the thickness of the branch busbar, the position of the back of the weld supported by the pad is always near the thickness center. The supporting force of the pad acts on the neutral layer of the welding area, providing stable support. The busbar is less prone to deflection or tilting under welding heat and pressure, resulting in a more uniform and dense weld formation.

[0010] In some embodiments, the branch clamp includes a pair of clamping members that can be driven to move toward or away from each other to clamp or release the branch busbar.

[0011] In the technical solution of this application embodiment, the paired clamping members move synchronously towards each other from both sides, pushing the branch busbar towards the center. The branch busbar is positioned at the center of the fixture the instant the clamping is completed. This center position is consistent with the centering reference of the main busbar. No matter how the width dimension of the branch busbar changes within the tolerance range, it can automatically center itself, ensuring that the weld coincides with the preset position and the welding accuracy is high.

[0012] In some embodiments, the opposing surfaces of the paired clamping members are provided with V-shaped or U-shaped positioning grooves, which are used to engage with the arc-shaped side of the branch busbar to clamp the branch busbar.

[0013] In the technical solution of this application embodiment, when the arc-shaped side enters the V-shaped or U-shaped positioning groove, a guiding effect towards the center of the groove bottom is generated. Even if the branch busbar is initially offset, as long as the arc surface contacts the groove surface, it will be guided to the center of the clamping member. Compared with plane-to-plane clamping, this mating method has stronger automatic alignment capability and improved positioning accuracy, making it suitable for high-current busbars that are sensitive to welding position deviations. The side of the branch busbar is arc-shaped. If it is clamped directly with a flat clamping surface, line contact or point contact will be formed, which can easily cause surface indentations, scratches, or even micro-cracks when the clamping force is large. The inclined or arc surface of the V-shaped or U-shaped positioning groove can fit against the arc-shaped side, increasing the contact area, distributing the clamping force evenly, protecting the busbar surface from damage, and avoiding stress concentration at the contact point, making welding and energizing safer.

[0014] In some embodiments, the surface of the pad facing the positioning table has at least two protrusions; when the pad supports the welded joint of the main busbar and the branch busbar, the branch busbar is located between at least two protrusions.

[0015] In some embodiments, the pad of the back support assembly has a clearance opening on the surface facing the support platform; when the back support assembly rises and the pad supports the main busbar and branch busbar of the welding mechanism with its back facing the back, the protruding weld structure between the main busbar and the branch busbar can extend into the clearance opening, so that the pad is in contact with the main busbar and / or the branch busbar.

[0016] In the technical solution of this application embodiment, after the clearance opening accommodates the protruding weld structure, the supporting surface of the pad can fit against the lower surface of the main busbar and / or branch busbar over a large area, so that the welding area obtains uniform and solid back support, avoiding welding spatter, unstable molten pool and poor weld formation caused by false support. The clearance opening prevents the protruding front weld from bearing the pressure of the pad, protecting the geometry and mechanical properties of the front weld, and ensuring that the quality of both welds after double-sided welding is intact.

[0017] In some embodiments, the pad of the back support assembly includes a contact portion and a temperature control portion, an clearance opening is provided through the contact portion, and a heat-conducting element is sandwiched between the contact portion and the temperature control portion. The heat-conducting element blocks the opening of the clearance opening away from the positioning stage and has both elasticity and thermal conductivity.

[0018] In the technical solution of this application embodiment, after the weld extends into the clearance opening, its end is buffered by a soft heat-conducting component. When the welding pressure is transmitted through the main body of the pad, the weld is not damaged by compression, and the geometry and strength of the front weld bead are preserved. The heat-conducting component efficiently transfers the welding heat to the pad, allowing the heat at the weld to dissipate quickly, reducing the peak temperature of the weld and the heat-affected zone. Appropriate accelerated cooling is beneficial for refining the grains of the weld metal, improving its density and mechanical strength, while reducing oxidation and deformation of the busbar caused by prolonged high temperatures, resulting in more stable electrical conductivity of the joint.

[0019] In some embodiments, the temperature control unit has a flow channel for fluid flow, which extends to the area directly opposite the clearance opening; the fluid in the flow channel can push the heat-conducting component to deform toward the positioning platform and extend into the clearance opening, and flow into the space formed after the heat-conducting component is deformed.

[0020] In the technical solution of this application embodiment, fluid pressure drives the heat-conducting component to undergo controllable elastic deformation, enabling it to actively adapt to the actual protrusion height and surface contour of the weld within the clearance opening, forming a conformal fit. Even if the weld reinforcement is inconsistent or there are minor unevennesses in the busbar, the heat-conducting component can fully fill the gap under fluid pressure, ensuring uniform support for the weld. The flow channel extends below the clearance opening, and after the fluid enters the deformation space of the heat-conducting component, it forms an extremely short heat conduction path with the heat-conducting component and the weld area closely adjacent to the contact portion through the heat-conducting component. The welding heat is rapidly and directionally removed, accelerating the cooling rate of the weld and heat-affected zone, refining the grains, and improving the strength and density of the weld metal. At the same time, rapid cooling effectively suppresses post-weld deformation of the busbar, ensuring the overall flatness after double-sided welding.

[0021] In some embodiments, the portion of the heat-conducting element extending into the clearance opening is provided with a plurality of heat-conducting sheets, which are arranged in an array within the clearance opening and do not extend beyond the clearance opening; the heat-conducting sheets are made of a metal material with good thermal conductivity.

[0022] In the technical solution of this application embodiment, the heat of the weld is rapidly transferred to the fluid through the low thermal resistance path of the heat-conducting plate, achieving a rapid cooling effect. This accelerates the solidification rate of the weld metal, refines the grains, and further improves its strength and conductivity. Multiple heat-conducting plates arranged in an array contact the weld from multiple locations, avoiding localized overcooling or cooling dead zones that may result from single-point contact. The cooling rate of the weld tends to be consistent along its length and width, reducing residual stress, minimizing post-weld deformation, and resulting in a more uniform hardness distribution in the heat-affected zone.

[0023] In some embodiments, one end of the heat-conducting sheet is inserted into the heat-conducting component, and the other end is bent; the heat-conducting sheet can deform under the push of the weld structure extending into the relief opening.

[0024] In the technical solution of this application embodiment, the bent heat-conducting sheet deforms under the push of the weld structure, and covers the raised contour and root arc of the weld under the push of the protruding weld structure. This conformal fitting changes the contact between the heat-conducting sheet and the weld from a single point or single line to a multi-point, multi-faceted surface contact, increasing the effective heat conduction area and significantly improving the heat extraction efficiency.

[0025] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the overall structure of a busbar welding machine provided in some embodiments of this application; Figure 2 This is a partial structural schematic diagram of a busbar welding machine provided in some embodiments of this application; Figure 3 This is a structural schematic diagram of the welded joint of the front support assembly provided in some embodiments of this application; Figure 4 This is a structural schematic diagram of the welded joint of the back support assembly provided in some embodiments of this application; Figure 5Schematic diagrams of the positioning mechanism provided in some embodiments of this application; Figure 6 for Figure 5 Enlarged view of point A in the middle; Figure 7 This is a schematic diagram of the structure of the pad block of the back support assembly provided in some embodiments of this application; Figure 8 A side view of the pad block of the back support assembly provided in some embodiments of this application; Figure 9 for Figure 8 Sectional view at point BB; Figure 10 An exploded view of the pad of the back support assembly provided in some embodiments of this application.

[0028] Icons: 10-Main busbar; 11-Branch busbar; 2-Welding mechanism; 3-Positioning mechanism; 30-Positioning table; 300-Working port; 301-Recessed area; 31-Fixed fixture; 310-Center clamp; 311-Branch clamp; 3110-Clamping component; 31100-Positioning groove; 32-Flipping assembly; 4-Supporting mechanism; 40-Moving component; 41-Supporting table; 42-Padded block; 420-Protrusion; 421-Allowing port; 422-Contact part; 423-Temperature control part; 4230-Flow channel; 424-Heat-conducting component; 4240-Heat-conducting plate. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0030] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used in the description of this application is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms "comprising" and "having," and any variations thereof, in the description, claims, and accompanying drawings of this application are intended to cover non-exclusive inclusion. The terms "first," "second," etc., in the description, claims, or accompanying drawings of this application are used to distinguish different objects, not to describe a specific order or hierarchy.

[0031] In this application, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this application can be combined with other embodiments.

[0032] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "attachment" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0033] In this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, in this application, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0034] In this application, "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0035] According to some embodiments of this application, optionally, such as Figures 1-4As shown, this application provides a busbar welding machine, which includes a welding mechanism 2, a positioning mechanism 3, and a support mechanism 4. The welding mechanism 2 is used to weld the main busbar 10 and the branch busbar 11. The positioning mechanism 3 includes a positioning table 30, a fixing fixture 31, and a flipping assembly 32. The positioning table 30 has a through working opening 300. The fixing fixture 31 fixes the main busbar 10 and the branch busbar 11 to the positioning table 30, and the projections of all welding points fall within the working opening 300. The flipping assembly 32 drives the positioning table 30 to rotate, so that the front and back of the main busbar 10 face the welding mechanism 2 in sequence. The support mechanism 4... Mechanism 4 is located below positioning platform 30 and includes movable component 40, support platform 41 and multiple pads 42 on the upper surface of support platform 41. The pads 42 are divided into front support group and back support group. The pads 42 of the front support group are distributed to correspond to the positions of each welding point when the main busbar 10 is facing the welding mechanism 2, and the pads 42 of the back support group are distributed to correspond to the positions of each welding point when the main busbar 10 is facing away from the welding mechanism 2. The movable component 40 drives the support platform 41 to move, so that the front support group or the back support group is aligned with the working port 300 and rises, and the corresponding pads 42 support the welding points of the main busbar 10 and the branch busbar 11.

[0036] Main busbar 10 is the main conductor in the busbar system, serving as the primary path for current transmission. It is typically a long, integral conductor. Branch conductors branching off from main busbar 10 are used to divert current from main busbar 10 to various branch loads.

[0037] The welding method used in the welding machine provided in this application is preferably TIG welding, and the material of the solder is copper.

[0038] The term "mother row" as used in this application may refer to either the main mother row 10 or the branch mother row 11, or both.

[0039] Before and after flipping, when the front and back sides of the main busbar 10 are facing upwards, the positions of each weld point relative to the working port 300 of the positioning table 30 will change mirrorwise. A front support group and a back support group are set up separately, with their respective pads 42 pre-distributed to correspond to the weld point positions before and after flipping. By switching between different support groups using the movable component 40, it is ensured that each weld point is precisely supported by the corresponding pad 42, regardless of whether the welding is done on the front or back.

[0040] In practical application, the main busbar 10 and branch busbar 11 to be welded are assembled according to design requirements and placed on the positioning table 30 of the positioning mechanism 3. The main busbar 10 and branch busbar 11 are clamped and fixed using the fixing fixture 31 to ensure accurate relative positions and tight weld joints. At this time, the vertical projection of all weld joints (i.e., the area where the main busbar 10 and branch busbar 11 need to be welded) falls within the working opening 300 in the center of the positioning table 30. The front of the main busbar 10 faces upwards, directly opposite the welding mechanism 2 above, while the back of the main busbar 10 faces downwards. Next, the support mechanism 4 located below the positioning table 30 begins to operate: the movable component 40 first moves the support table 41 horizontally, aligning multiple pads 42 in the front support group with the working opening 300, and then drives the support table 41 to rise vertically. The pads 42 of the front support group pass through the working opening 300 and directly press against the back positions corresponding to the front weld joints of the main busbar 10 and branch busbar 11, forming a solid support. Welding mechanism 2 performs welding on all weld joints on the front side of the main busbar 10. Because the back of the weld joint is tightly supported by the pad 42, the busbar will not vibrate or deform during the welding process, and the arc heat is more concentrated on melting the base material, allowing the weld to penetrate fully in the depth direction. After the front welding is completed, the movable component 40 drives the support platform 41 to descend, causing the pad 42 of the front support group to detach from the busbar and exit the working port 300. Subsequently, the flipping component 32 moves again, flipping the positioning platform 30 so that the back of the main busbar 10 faces upward and is directly opposite the welding mechanism 2. The movable component 40 of the support mechanism 4 moves horizontally again, aligning the back support group with the working port 300, and then rises, supporting the back weld joint that needs to be welded at this time. Welding mechanism 2 performs welding on the back side, ensuring that the weld from the back side also achieves sufficient penetration depth, connecting with or even overlapping the front weld. After the back welding is completed, the support platform 41 descends and resets, the fixing fixture 31 is released, and the busbar assembly with both sides welded can be removed.

[0041] By flipping component 32, the front and back sides of the main busbar 10 are sequentially aligned with the welding mechanism 2 for welding, transforming conventional single-sided welding into double-sided welding. The two welding processes melt the base material from two directions, resulting in overlapping weld depths that penetrate the entire thick busbar connection surface. This eliminates the problem of incomplete penetration and unpenetrated areas inherent in conventional single-sided welding. After full-thickness penetration, the connection interface between the main busbar 10 and the branch busbar 11 is completely filled with weld metal, and the effective conductive cross-sectional area is essentially equal to the busbar overlap area. This avoids high local resistance due to incomplete penetration, ensuring a stable and low-resistance current path that meets the high-current requirements of energy storage power stations. The front and back support groups of the support mechanism 4 accurately support the welding points from below during the welding of the front and back sides, respectively. The pad 42 directly offsets the welding pressure and thermal stress, preventing the busbar from collapsing or warping due to high temperature and gravity. The weld is uniform and dense, with high mechanical connection strength. When a large current passes through for a long time, the joint temperature rise is small, and oxidation, loosening or burning failures are not likely to occur. This ensures the long-term stable operation of the busbar of the energy storage power station and reduces power loss and maintenance costs.

[0042] In the specific implementation process, an independent fine-tuning structure can be added between each pad 42 and the support platform 41. For minor thickness deviations or local unevenness at the weld joints of different batches of busbars, the height of the pad 42 can be adjusted individually so that each weld joint can obtain uniform and close support force, thereby improving the uniformity of the weld.

[0043] According to some embodiments of this application, optionally, such as Figure 5 As shown, the fixing fixture 31 includes a central clamp 310 and a branch clamp 311. The central clamp 310 is used to position the main busbar 10, and the branch clamp 311 is used to position the branch busbar 11. The surface of the positioning table 30 is provided with a recessed area 301, and at least some of the branch clamps 311 are located in the recessed area 301, so that the branch busbar 11 fixed by these branch clamps 311 can be aligned with the main busbar 10 in the thickness direction, regardless of whether its thickness is greater than or less than that of the main busbar 10.

[0044] The essence of centering is to make the center planes of the thicknesses of the two busbars coincide. The main busbar 10 is fixed to the surface of the positioning table 30 by the center clamp 310, and the height of its center plane is equal to the height of the positioning table 30 surface plus half the thickness of the main busbar 10. If the branch busbar 11 has the same thickness as the main busbar 10, it will be naturally centered when placed on the same surface; if the thicknesses are different, placing the branch busbar 11 directly on the same surface will result in its center plane height being too high or too low. The recessed area 301 lowers or raises the installation reference of the branch busbar 11 through clamp compensation, adjusting the center plane of the thickness of the branch busbar 11 to the same height as the center plane of the thickness of the main busbar 10. Therefore, centering can be achieved through the recessed area 301 in both cases where the thickness is greater or less than the main busbar 10.

[0045] In practical applications, each branch busbar 11 is placed in its corresponding welding position and fixed one by one with a branch clamp 311. For branch busbars 11 with the same thickness as the main busbar 10, their branch clamps 311 are directly installed on the flat surface of the positioning table 30; for branch busbars 11 with a thickness greater than or less than the main busbar 10, their corresponding branch clamps 311 are installed in the recessed area 301 on the surface of the positioning table 30.

[0046] Because the bottom surface of the recessed area 301 is lower than the surface of the positioning table 30, when the thicker branch busbar 11 is placed inside, the fixture mounting surface sinks, and the overall height of the branch busbar 11 decreases; when the thinner branch busbar 11 is placed inside, it can be raised by using a shim or by compensating for the height of the fixture itself. Regardless of whether the branch busbar 11 is thicker or thinner than the main busbar 10, the two are ultimately aligned in the thickness direction (i.e., centered), and the center surfaces of the branch busbar 11 and the main busbar 10 are on the same plane.

[0047] The branch busbars 11 with varying thicknesses are aligned with the main busbar 10 in the thickness direction through the recessed area 301, ensuring that the thickness center planes of the main busbar 10 and the branch busbars 11 coincide. During double-sided welding, the penetration depth of the front and back welds from the center outwards is symmetrical and balanced, and the welds converge at the thickness center, avoiding false welds or problems of excessive penetration on one side and insufficient penetration on the other due to offset, ensuring consistent weld penetration quality across the entire thickness. After alignment, regardless of the thickness of the branch busbar 11, the position of its weld joint supported by the pad 42 is always near the thickness center. The supporting force of the pad 42 acts on the neutral layer of the welding area, providing stable support. Under the action of welding heat and pressure, the busbars are less likely to deflect or tilt, resulting in a more uniform and dense weld formation.

[0048] According to some embodiments of this application, optionally, such as Figures 5-6 As shown, the branch clamp 311 includes a pair of clamping members 3110, which can be driven to move toward or away from each other to clamp or release the branch busbar 11.

[0049] The paired clamping elements 3110 move synchronously from both sides towards each other, pushing the branch busbar 11 towards the center. The branch busbar 11 is positioned at the center of the fixture the instant clamping is complete. This center position is consistent with the centering reference of the main busbar 10. Regardless of how the width of the branch busbar 11 varies within the tolerance range, it can automatically center itself, ensuring that the weld coincides with the preset position and achieving high welding accuracy. Applying force from one side can easily cause the branch busbar 11 to deflect or lift, disrupting its fit with the main busbar 10. The paired clamping elements 3110 apply balanced clamping forces from both sides, subjecting the branch busbar 11 to symmetrical compression without generating additional torque, allowing it to smoothly fit onto the main busbar 10, ensuring a stable and reliable initial welding state.

[0050] In practice, elastic preload elements can be set on the clamping surfaces of the paired clamping parts 3110. During clamping, the elastic body first contacts the busbar to apply flexible preload, and then rigidly locks it after the alignment adjustment is completed. This can eliminate slight unevenness on the surface of the busbar, protect the busbar plating or surface from being damaged by clamping, and further improve the alignment accuracy.

[0051] According to some embodiments of this application, optionally, such as Figures 5-6 As shown, the opposing surfaces of the pair of clamping members 3110 are provided with V-shaped or U-shaped positioning grooves 31100. The positioning grooves 31100 are used to engage with the arc-shaped side of the branch busbar 11 to clamp the branch busbar 11.

[0052] The side of the branch busbar 11 is arc-shaped, with a V-shaped or U-shaped groove. The groove surface is tangent to the arc surface, resulting in smooth contact and continuous and gentle guiding effect. The busbar will not jump or get stuck during the centering process. At the same time, the smooth transition of the arc surface avoids plating damage that may be caused by sharp corner clamping.

[0053] In practical applications, the clamping member 3110 has a V-shaped positioning groove 31100 (or a U-shaped positioning groove 31100) on its opposite surface. As the clamping member 3110 approaches, the inclined or arc-shaped surfaces of the positioning grooves 31100 on both sides first contact the arc-shaped side surface of the branch busbar 11. Since the contact between the arc-shaped surface and the V-shaped / U-shaped groove is a line contact or a small-area contact, as the clamping member 3110 continues to advance, the branch busbar 11 will be subjected to an automatic sliding force towards the center, sliding along the groove surface into the center position of the positioning groove 31100. When the clamping members 3110 on both sides move to the set position, the arc-shaped side surface of the branch busbar 11 is completely fitted into the V-shaped or U-shaped positioning groove 31100. The working surfaces on both sides of the groove form a symmetrical clamping around the arc-shaped side surface, and the branch busbar 11 is firmly positioned at the geometric center of the clamping member 3110. At the same time, the branch busbar 11 has been aligned with the main busbar 10 in the thickness direction through the recessed area 301, so the entire welding point of the branch busbar 11 and the main busbar 10 is completely aligned.

[0054] When the arc-shaped side enters the V-shaped or U-shaped positioning groove 31100, it creates a guiding effect towards the center of the groove bottom. Even if the branch busbar 11 is initially misaligned, it will be guided to the center of the clamping member 3110 as long as the arc-shaped surface contacts the groove surface. Compared to plane-to-plane clamping, this mating method has stronger automatic alignment capability and improved positioning accuracy, making it suitable for high-current busbars that are sensitive to welding position deviations. The side of the branch busbar 11 is arc-shaped. If it is clamped directly with a flat clamping surface, line contact or point contact will be formed, which can easily cause surface indentations, scratches, or even micro-cracks when the clamping force is large. The inclined or arc surface of the V-shaped or U-shaped positioning groove 31100 can fit against the arc-shaped side, increasing the contact area, distributing the clamping force evenly, protecting the busbar surface from damage, and avoiding stress concentration at the contact point, making welding and energizing safer. The arc-shaped side and the V-shaped / U-shaped groove form a wedge-shaped wrapping effect. The paired clamping elements 3110 not only apply positive pressure from both sides, but the grooved structure also limits the branch busbar 11 in the vertical direction, making it less prone to moving up and down or deflecting during welding vibration or flipping. This multi-directional constraint clamping method keeps the branch busbar 11 stable throughout the entire double-sided welding process, ensuring the quality of the weld formation.

[0055] In the specific implementation process, the clamping part 3110 and the drive of the branch clamp 311 are detachably connected. For branch busbars 11 of different thicknesses, it is only necessary to replace the clamping part 3110 with the corresponding positioning groove 31100 height to meet the alignment requirements of the branch busbar 11 and the main busbar 10.

[0056] According to some embodiments of this application, optionally, such as Figures 3-4 , Figures 7-8 As shown, the surface of the pad 42 facing the positioning table 30 is provided with at least two protrusions 420; when the pad 42 supports the welding joint of the main busbar 10 and the branch busbar 11, the branch busbar 11 is located between at least two protrusions 420.

[0057] During the welding process, the arc force, shielding gas flow, and thermal expansion may cause lateral micro-movements in the branch busbar 11. The branch busbar 11 is confined between the two protrusions 420, and its lateral degree of freedom is constrained. The weld point will not deviate from the predetermined position, which is conducive to obtaining welds with precise dimensions and consistent penetration depth, and improving weld quality.

[0058] According to some embodiments of this application, optionally, such as Figure 7 and Figure 10As shown, the pad 42 of the back support assembly has a clearance opening 421 on the surface facing the support platform 41; when the back support assembly rises and the pad 42 supports the main busbar 10 and branch busbar 11 facing the welding mechanism 2, the protruding weld structure between the main busbar 10 and the branch busbar 11 can extend into the clearance opening 421, so that the pad 42 fits against the main busbar 10 and / or the branch busbar 11.

[0059] During front-side welding, the main busbar 10 and branch busbar 11 are not yet welded, and the joint surface is smooth with no protruding weld seams. Therefore, the pad 42 of the front-side support assembly does not require the clearance opening 421 and can directly adhere to the busbar surface. However, when welding the back side after flipping, a protruding weld seam already exists on the front side, and this weld seam is located below the busbar and faces the support platform 41. If the clearance opening 421 is not provided, it will cause interference. Therefore, the clearance opening 421 is asymmetrically designed according to the welding process direction and is only used for the back-side support assembly.

[0060] In practical applications, after front welding, one or more weld seam structures protruding from the front of the busbar are formed at the overlap of the main busbar 10 and the branch busbar 11. These weld seams have a certain excess height and protrude outwards. After the front welding is completed, the pad 42 of the front support group exits the working port 300. The flipping component 32 drives the positioning table 30 to rotate, so that the back of the main busbar 10 faces the welding mechanism 2. At this time, the front of the main busbar 10 faces downwards, and the protruding weld seam structure turns downwards accordingly. The moving component 40 drives the support table 41 to move, so that the back support group rises after aligning with the welding point. During the rising process, the surface of the pad 42 of the back support group facing the positioning table 30 first approaches the bottom of the main busbar 10 and the branch busbar 11. Since the surface of the pad 42 facing the support table 41 (i.e., the lower surface area of ​​the pad 42) is provided with a clearance opening 421, the clearance opening 421 forms an upward receiving space inside the pad 42. As the support platform 41 continues to rise, the downward-protruding weld structure between the main busbar 10 and the branch busbar 11 aligns precisely with the clearance opening 421 and gradually extends into it, unobstructed by the solid pad 42. When the support platform 41 rises to the predetermined height, the upper surface of the pad 42 (the side facing the positioning platform 30), except for the area of ​​the clearance opening 421, is tightly fitted with the lower surface of the main busbar 10 and / or the branch busbar 11, forming a stable support. The welding mechanism 2 performs welding on each weld joint on the back of the main busbar 10. Throughout the welding process, the pad 42 firmly supports the busbar, while the protruding weld is safely contained within the clearance opening 421 and does not participate in the load-bearing.

[0061] The protruding weld structure formed by the front welding is located below the busbar during the back welding. Without the clearance opening 421, the pad 42 would first hit these protrusions when it rises, preventing the pad 42 from contacting the flat area of ​​the busbar and forming point or line support. After the clearance opening 421 accommodates the protruding weld structure, the supporting surface of the pad 42 can fit against the lower surface of the main busbar 10 and / or branch busbar 11 over a large area, providing uniform and solid back support to the welding area and avoiding welding spatter, unstable molten pool, and poor weld formation caused by insufficient support. If the pad 42 directly presses on the protruding front weld, the supporting force and welding heat transfer will cause the weld to deform, crush, or even crack, destroying the previous welding results. The clearance opening 421 allows the weld to be in a free state, not bearing the pressure of the pad 42, protecting the geometry and mechanical properties of the front weld and ensuring the quality of both welds after double-sided welding. By eliminating weld interference through the avoidance opening 421, the support stiffness provided by the back support group is comparable to that of the front support group during front welding. The process conditions for the two welding operations are consistent, resulting in symmetrical weld penetration on both sides of the joint after welding, and more uniform mechanical and electrical properties.

[0062] According to some embodiments of this application, optionally, such as Figures 7-10 As shown, the pad 42 of the back support assembly includes a contact portion 422 and a temperature control portion 423. An clearance opening 421 is provided through the contact portion 422. A heat-conducting element 424 is sandwiched between the contact portion 422 and the temperature control portion 423. The heat-conducting element 424 blocks the opening of the clearance opening 421 away from the positioning platform 30 and has both elasticity and thermal conductivity.

[0063] The thermal conductive component 424 can be, but is not limited to, thermally conductive silicone, expanded graphite elastic sheet, porous foam copper, etc.

[0064] After the weld extends into the clearance opening 421, its end is buffered by the flexible heat-conducting element 424. When the welding pressure is transmitted through the main body of the pad 42, the weld is not damaged by compression, and the geometry and strength of the front weld bead are preserved. The heat-conducting element 424 efficiently transfers the welding heat to the pad 42, allowing the heat at the weld to dissipate quickly and reducing the peak temperature of the weld and heat-affected zone. Appropriate accelerated cooling is beneficial for refining the grains of the weld metal, improving density and mechanical strength, while reducing oxidation and deformation of the busbar caused by prolonged high temperatures, resulting in more stable electrical conductivity of the joint. The excess height of the front weld is not absolutely consistent due to process fluctuations. The elasticity of the heat-conducting element 424 allows the effective depth of the clearance opening 421 to adapt to the weld height. When the weld is high, the elastic compression is large, and when the weld is low, the compression is small, ensuring that the upper surface of the contact part 422 can fit tightly with the busbar. There is no need to repeatedly adjust the height of the pad 42, making it convenient to use and providing a good fit.

[0065] According to some embodiments of this application, optionally, such as Figures 8-10As shown, the temperature control unit 423 has a flow channel 4230 for fluid flow, which extends to the area directly opposite the relief opening 421. The fluid in the flow channel 4230 can push the heat-conducting component 424 to deform toward the positioning platform 30 and extend into the relief opening 421, and flow into the space formed after the heat-conducting component 424 is deformed.

[0066] The flow channel 4230 within the temperature control unit 423 faces the clearance port 421 area, and its opening is covered and sealed by the heat-conducting element 424. When fluid enters the flow channel 4230 and is pressurized, the pressure of the liquid or gas acts evenly on the lower surface of the heat-conducting element 424. Under this pressure, the heat-conducting element 424 elastically bulges upwards, i.e., inside the clearance port 421. At the moment of bulging, a thin cavity filled with fluid is formed between the heat-conducting element 424 and the temperature control unit 423. The fluid then fills this space and continues to flow through it, carrying away heat.

[0067] Fluid pressure drives the heat-conducting component 424 to undergo controllable elastic deformation, enabling it to actively adapt to the actual protrusion height and surface contour of the weld within the clearance opening 421, forming a conformal fit. Even if the weld reinforcement is inconsistent or there are minor unevennesses in the busbar, the heat-conducting component 424 can fully fill the gap under fluid pressure, ensuring uniform support for the weld. The flow channel 4230 extends below the clearance opening 421. After the fluid enters the deformation space of the heat-conducting component 424, it forms an extremely short heat conduction path with the heat-conducting component 424 and the weld area closely adjacent to the contact portion 422 through the heat-conducting component 424. Welding heat is rapidly and directionally removed, accelerating the cooling rate of the weld and heat-affected zone, refining the grains, and improving the strength and density of the weld metal. At the same time, rapid cooling effectively suppresses post-weld deformation of the busbar, ensuring the overall flatness after double-sided welding.

[0068] According to some embodiments of this application, optionally, such as Figure 7 , Figures 9-10 As shown, the portion of the heat-conducting component 424 that extends into the relief opening 421 is provided with a plurality of heat-conducting plates 4240. The plurality of heat-conducting plates 4240 are arranged in an array within the relief opening 421 and do not extend beyond the relief opening 421. The heat-conducting plates 4240 are made of a metal material with good thermal conductivity.

[0069] While the heat-conducting component 424 itself possesses thermal conductivity, it is an elastic material with a limited thermal conductivity coefficient. Now, an array of metal heat-conducting plates 4240 is incorporated into the portion extending into the clearance opening 421. The thermal conductivity of the metal is higher than that of the elastic matrix, thus overcoming the bottleneck in heat conduction. During welding, the heat from the weld is rapidly transferred to the fluid via the low thermal resistance path of the heat-conducting plates 4240, achieving a rapid cooling effect. This accelerates the solidification rate of the weld metal, refines the grain size, and further improves its strength and conductivity. The multiple heat-conducting plates 4240 arranged in an array contact the weld from multiple locations, avoiding localized overcooling or cooling dead zones that might occur with single-point contact. The cooling rate of the weld tends to be consistent along its length and width, reducing residual stress, resulting in less post-weld deformation and a more uniform hardness distribution in the heat-affected zone. The heat-conducting plates 4240 are arranged in an array within the clearance opening 421 and do not extend beyond it, being concealed within the clearance space. After the weld extends into the clearance opening 421, it can freely occupy space without being rigidly squeezed, and can also make large-area contact with the heat-conducting plate 4240; while the upper surface of the contact part 422 of the pad 42 still fully fits the flat area of ​​the busbar, forming a stable support.

[0070] According to some embodiments of this application, optionally, such as Figure 7 , Figures 9-10 As shown, one end of the heat-conducting plate 4240 is inserted into the heat-conducting component 424, and the other end is bent; the heat-conducting plate 4240 can deform under the push of the weld structure extending into the relief opening 421.

[0071] In practical applications, the upper surface of the contact portion 422 adheres to the lower surfaces of the main busbar 10 and the branch busbar 11, while the protruding weld structure formed by the front welding extends into the clearance opening 421. During the extension process, the weld end first contacts the bent end of the heat-conducting plate 4240. As the pad 42 continues to rise into place, the weld structure further pushes these bent heat-conducting plates 4240, forcing them to undergo elastic deformation. Under the push of the weld, the heat-conducting plates 4240 gradually bend inward, conforming to the contour of the weld, and enveloping the weld surface and both sides of the root in a multi-point manner.

[0072] The bent heat-conducting sheet 4240 deforms under the push of the weld structure, covering the raised contour and root arc of the weld. This conformal fit changes the contact between the heat-conducting sheet 4240 and the weld from a single point or single line to a multi-point, multi-faceted surface contact, increasing the effective heat conduction area and significantly improving heat extraction efficiency.

[0073] Although this application has been described with reference to preferred embodiments, various modifications can be made thereto and components can be replaced with equivalents without departing from the scope of this application. In particular, the technical features mentioned in the various embodiments can be combined in any manner, provided there is no structural conflict. This application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A busbar welding machine, characterized in that, include: Welding mechanism, used for welding the joints between the main busbar and the branch busbar; The positioning mechanism includes a positioning table, a fixing fixture, and a flipping component. The positioning table has a through working opening. The fixing fixture fixes the main busbar and the branch busbar to the positioning table, and the projections of all welding joints fall into the working opening. The flipping component drives the positioning table to rotate, so that the front and back of the main busbar face the welding mechanism in sequence. A support mechanism, located below the positioning platform, includes a movable component, a support platform, and multiple pads on the upper surface of the support platform. The movable component drives the support platform to move, causing the pads to align with the working port and rise, with the pads supporting the welding joints of the main busbar and the branch busbar.

2. The busbar welding machine according to claim 1, characterized in that, The multiple pads are divided into a front support group and a back support group. The distribution of the pads in the front support group corresponds to the position of each welding point when the main busbar faces the welding mechanism, and the distribution of the pads in the back support group corresponds to the position of each welding point when the main busbar faces away from the welding mechanism. The movable component drives the support platform to move, so that the front support group or the back support group is aligned with the working port and rises, and the welding joint of the main busbar and the branch busbar is supported by the corresponding pad block.

3. A busbar welding machine according to claim 2, characterized in that, The fixing fixture includes a central clamp and a branch clamp, the central clamp being used to position the main busbar and the branch clamp being used to position the branch busbar; The surface of the positioning platform is provided with a recessed area, and at least part of the branch clamps are provided in the recessed area, such that the thickness of the branch busbar fixed by these branch clamps is greater than or less than that of the main busbar and the branch busbar is centered with the main busbar.

4. A busbar welding machine according to claim 3, characterized in that, The branch clamp includes a pair of clamping members that can be driven to move toward or away from each other to clamp or release the branch busbar. The opposing surfaces of the pair of clamping members are provided with V-shaped or U-shaped positioning grooves, which are used to engage with the arc-shaped side of the branch busbar to clamp the branch busbar.

5. A busbar welding machine according to claim 1, characterized in that, The surface of the pad facing the positioning platform has at least two protrusions; When the pad supports the welded joint of the main busbar and the branch busbar, the branch busbar is located between at least two of the protrusions.

6. A busbar welding machine according to claim 2, characterized in that, The pad of the back support assembly has a clearance opening on the surface of the support platform facing the support. When the back support assembly rises and the back of the pad supports face the main busbar and the branch busbar of the welding mechanism, the protruding weld structure between the main busbar and the branch busbar can extend into the clearance opening, so that the pad is in contact with the main busbar and / or the branch busbar.

7. A busbar welding machine according to claim 6, characterized in that, The pad of the back support assembly includes a contact part and a temperature control part. The clearance opening is provided through the contact part. A heat-conducting element is sandwiched between the contact part and the temperature control part. The heat-conducting element blocks the opening of the clearance opening away from the positioning platform and has both elasticity and thermal conductivity.

8. A busbar welding machine according to claim 7, characterized in that, The temperature control unit has a flow channel for fluid flow, which extends to the area directly opposite the clearance opening; The fluid in the flow channel can push the heat-conducting component to deform toward the positioning platform and extend into the clearance opening, and flow into the space formed after the heat-conducting component is deformed.

9. A busbar welding machine according to claim 8, characterized in that, The portion of the heat-conducting component extending into the clearance opening is provided with multiple heat-conducting plates, which are arranged in an array within the clearance opening and do not extend beyond the clearance opening. The heat-conducting sheet is made of a metal material with good thermal conductivity.

10. A busbar welding machine according to claim 9, characterized in that, One end of the heat-conducting sheet is inserted into the heat-conducting component, and the other end is bent. The heat-conducting sheet can deform under the push of the weld structure extending into the clearance opening.

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