High-efficiency flexible ring transformer automatic welding equipment

Abstract

This invention provides a high-efficiency automatic welding equipment for flexible toroidal transformers, including a lead wire feeding and shearing mechanism, a first clamping mechanism, a solder pot, a transfer mechanism, a second clamping mechanism, a PCB loading mechanism, a welding mechanism, and a controller. The lead wire feeding and shearing mechanism includes a first Y-axis moving module, a lead wire slot, and a liftable shearing blade, with the shearing blade positioned above the lead wire slot. Both the first and second clamping mechanisms include XZ-axis moving modules and rotatable finger cylinders. The transfer mechanism includes an XY-axis moving module and a clamping plate assembly. The lead wire feeding and shearing mechanism, solder pot, and transfer mechanism are positioned on the X-axis moving path of the first clamping mechanism. The PCB loading mechanism includes a second Y-axis moving module and a PCB fixing slot. The welding mechanism includes a YZ-axis moving module and a soldering iron, with the soldering iron positioned above the PCB fixing slot. The transfer mechanism, PCB loading mechanism, and welding mechanism are positioned on the X-axis moving path of the second clamping mechanism. This invention automates the entire welding process, reducing the barrier to manual operation, improving welding efficiency and product quality consistency, optimizing the production process, and reducing enterprise manufacturing costs.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, and specifically to a high-efficiency automatic welding equipment for flexible toroidal transformers. Background Technology

[0002] Currently, the welding of flexible toroidal transformers for DC / DC power modules in the industry generally adopts the traditional welding process of manual operation with an electric soldering iron. The specific work process is as follows:

[0003] 1. Manual cutting: The twisted flexible toroidal transformer leads are manually cut to the required length according to the process specifications;

[0004] 2. Manual tin plating: The cut transformer leads are manually tin-plated to remove the varnish and expose the conductive parts;

[0005] 3. Manual trimming: Manually trim the length of the tin-plated part of the lead wire, and remove excess tin plating and wire ends;

[0006] 4. Manual soldering: The transformer leads are precisely soldered to the corresponding solder points on the PCB board using a soldering iron.

[0007] In summary, the complete welding process for traditional flexible toroidal transformers is as follows: manual wire cutting → manual tin plating → manual trimming of tin plating length → manual welding.

[0008] This traditional process has several technical drawbacks: First, the procedures are cumbersome and rely entirely on manual operation. The tin plating and soldering processes require highly skilled operators, resulting in long training cycles, difficulty in recruiting qualified operators, and high labor costs. Second, production efficiency is low, as the speed of manual operation is limited by factors such as proficiency and physical strength, making it impossible to achieve large-scale, efficient production. Third, product quality stability is poor, as the soldering quality depends entirely on the operator's technical level and work ethic. Differences in operation between different personnel and at different times can easily lead to poor product consistency, becoming a common technical bottleneck in the industry that restricts the increase in DC / DC power module production capacity. Summary of the Invention

[0009] To overcome the shortcomings of existing technologies, this invention provides a high-efficiency automatic welding equipment for flexible toroidal transformers. By replacing manual labor with automated equipment to complete the entire welding process, it lowers the threshold for manual operation, improves welding efficiency and product quality consistency, optimizes the production process, and reduces the production and manufacturing costs for enterprises.

[0010] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0011] A high-efficiency automatic welding equipment for flexible toroidal transformers includes a lead wire feeding and shearing mechanism, a first clamping mechanism, a solder pot, a transfer mechanism, a second clamping mechanism, a PCB feeding mechanism, a welding mechanism, and a controller.

[0012] The lead wire feeding and shearing mechanism includes a first Y-axis moving module, which has a lead wire slot and a liftable shearing blade, the shearing blade being positioned above the lead wire slot; the first clamping mechanism includes an XZ-axis moving module, which has a rotatable finger cylinder; the transfer mechanism includes an XY-axis moving module, which has an openable and closable clamping plate assembly; the lead wire feeding and shearing mechanism, the solder pot, and the transfer mechanism are all located on the X-axis moving path of the first clamping mechanism;

[0013] The structure of the second clamping mechanism is the same as that of the first clamping mechanism; the PCB loading mechanism includes a second Y-axis moving module, on which a PCB fixing groove is provided; the welding mechanism includes a YZ-axis moving module, on which a soldering iron is provided, and the soldering iron is located above the PCB fixing groove; the adapter mechanism, the PCB loading mechanism, and the welding mechanism are located on the X-axis moving path of the second clamping mechanism.

[0014] Furthermore, the lead wire feeding and cutting mechanism also includes a lead wire tail recovery assembly, which includes a driving device, a slider, a scraper, and a junction box. The scraper is connected to the slider and its top side is in contact with the side of the lead wire slot. The junction box is connected to one side of the slider. The driving device drives the slider to reciprocate along the side of the lead wire slot.

[0015] Furthermore, the lead wire slot is composed of two card plates spaced a certain distance apart, and the top of the card plates is provided with multiple wire grooves. The cutting blade is located in the gap between the two card plates.

[0016] Furthermore, the shearing blade is provided with a cutting edge groove corresponding to the wire groove.

[0017] Furthermore, the top of the groove is provided with a V-shaped opening.

[0018] Furthermore, it also includes a solder scraping mechanism located next to the solder furnace. The solder scraping mechanism includes a telescopic cylinder and a solder scraper. The solder scraper is located inside the furnace trough of the solder furnace, and the telescopic cylinder drives the solder scraper to reciprocate within the furnace trough.

[0019] Furthermore, one finger of the finger cylinder is connected to a clamping plate, and the other finger is connected to a clamping rod. The contact surface between the clamping plate and the clamping rod is provided with multiple clamping grooves.

[0020] Furthermore, the clamping plate assembly includes a lifting cylinder, a lower clamping plate, and an upper clamping plate. The lifting cylinder is fixedly connected to one side of the lower clamping plate, and the output end of the lifting cylinder is connected to the upper clamping plate, driving the upper clamping plate to clamp or open with the lower clamping plate.

[0021] Compared with the prior art, the present invention has the following beneficial technical effects:

[0022] 1. Significantly lower the employment threshold: Eliminate the reliance on highly skilled operators; with only simple training, ordinary workers can quickly get started, covering various groups such as student workers and middle-aged and elderly workers, completely solving the problems of difficulty in recruiting and training skilled workers for enterprises, and effectively alleviating employment pressure.

[0023] 2. Significantly improves production efficiency: Manual welding efficiency is only 150 pieces / hour, while the automated welding efficiency of this equipment can reach 350 pieces / hour, and the welding efficiency of a single machine is 2.3 times that of manual welding; combined with process integration and optimization, the overall production efficiency of the equipment reaches 5.5 times that of manual welding, greatly increasing product capacity.

[0024] 3. Simplify the production process: The four separate processes of traditional manual wire cutting, tin plating, trimming and welding are integrated into an integrated automatic operation. The operator only needs to complete the loading and unloading and equipment start-up, reducing manual operation and reducing process connection errors.

[0025] 4. Effectively reduce labor costs: Through automated operations, multiple processes such as wire cutting, tin plating, and welding can save 4.5 people, reducing the company's labor input and lowering production and manufacturing costs.

[0026] 5. Improve product quality consistency: The equipment adopts standardized automated operation, and the welding parameters, tin plating length, and shearing dimensions are all precisely controllable, avoiding human operation errors, ensuring stable and consistent product welding quality, and improving the product qualification rate. Attached Figure Description

[0027] Figure 1 This is a structural diagram of an automatic welding device for a high-efficiency flexible toroidal transformer according to the present invention.

[0028] Figure 2 This is a partially enlarged view of the lead wire feeding and shearing mechanism and the transfer mechanism of the present invention.

[0029] Figure 3 This is a partial enlarged view of the lead slot of the present invention.

[0030] Figure 4 This is an enlarged view of the finger cylinder of the present invention.

[0031] The components include: 1. Lead wire feeding and shearing mechanism; 11. First Y-axis moving module; 12. Shearing blade; 13. Clamping plate; 131. Wire groove; 14. Wire tail recycling assembly; 141. Drive device; 142. Slider; 143. Wire scraper; 144. Junction box; 2. First clamping mechanism; 21. XZ-axis moving module; 22. Finger cylinder; 221. Clamping plate; 222. Clamping rod; 23. Stepper motor; 3. Solder pot; 4. Transfer mechanism; 41. XY moving module; 42. Lifting cylinder; 43. Lower clamping plate; 44. Upper clamping plate; 5. Second clamping mechanism; 6. PCB feeding mechanism; 61. Second Y-axis moving module; 62. PCB fixing groove; 7. Soldering mechanism; 71. YZ-axis moving module; 73. Soldering iron; 8. Solder scraping mechanism; 81. Telescopic cylinder; 82. Solder scraper. Detailed Implementation

[0032] Numerous specific details are set forth in the following description to provide a full understanding of the invention. However, the invention can be practiced in many other ways than those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0033] Example 1

[0034] like Figure 1-4 As shown, a high-efficiency flexible toroidal transformer automatic welding equipment is provided on the frame with a lead wire feeding and shearing mechanism 1, a first clamping mechanism 2, a solder pot 3, a transfer mechanism 4, a second clamping mechanism 5, a PCB feeding mechanism 6, a welding mechanism 7, and a controller.

[0035] The lead wire feeding and shearing mechanism 1 includes a first Y-axis moving module 11, which has a lead wire slot and a liftable shearing blade 12 positioned above the lead wire slot. The lead wire slot consists of two spaced-apart plates 13, the distance between which is determined by the reserved length of the transformer lead wire. The top of each plate 13 has multiple slots 131 according to the number of transformer solder points and wire diameter specifications, with the spacing between the slots 131 determined by the spacing of the solder points on the PCB board. Each slot 131 has a V-shaped opening at its top for easy insertion of the transformer lead wire. The shearing blade 12 is located between the two plates 13 and has blade grooves corresponding to the slots 131. The shearing blade 12 is lifted and lowered by a cylinder.

[0036] The lead wire feeding and cutting mechanism 1 also includes a lead wire tail recovery assembly 14, which includes a drive device 141, a slider 142, a scraper 143, and a junction box 144. The slider 142 is slidably connected to the first Y-axis moving module 11, the scraper 143 is connected to the slider 142 and its top side is in contact with the side of the lead wire slot, and the junction box 144 is connected to one side of the slider 142. The drive device 141 drives the slider 142 to reciprocate along the side of the lead wire slot; the drive device 141 is preferably a cylinder.

[0037] The first gripping mechanism 2 includes an XZ-axis moving module 21, on which a rotatable finger cylinder 22 is mounted. The finger cylinder 22 achieves precise rotation via a stepper motor 23. One finger of the finger cylinder 22 is connected to a clamping plate 221, and the other finger is connected to a clamping rod 222. Multiple wire-clamping grooves are provided on the contact surface between the clamping plate 221 and the clamping rod 222; the wire is gripped by the clamping of the clamping plate 221 and the clamping rod 222.

[0038] The adapter mechanism 4 includes an XY moving module 41, which is equipped with an openable clamping plate assembly to realize the transfer and clamping of the lead wire. The clamping plate assembly includes a lifting cylinder 42, a lower clamping plate 43, and an upper clamping plate 44. The lifting cylinder 42 is fixedly connected to one side of the lower clamping plate 43, and the output end of the lifting cylinder 42 is connected to the upper clamping plate 44, driving the upper clamping plate 44 to clamp or open with the lower clamping plate 43.

[0039] The lead wire cutting mechanism 1, the solder pot 3, and the transfer mechanism 4 are located on the X-axis moving path of the first clamping mechanism 2. A solder scraping mechanism 8 is also provided next to the solder pot 3. The solder scraping mechanism 8 includes a telescopic cylinder 81 and a solder scraper 82. The solder scraper 82 is located inside the furnace tank of the solder pot 3, and the telescopic cylinder 81 drives the solder scraper 82 to reciprocate within the furnace tank.

[0040] The second clamping mechanism 5 has the same structure as the first clamping mechanism 2, and is used to transfer the leads on the adapter mechanism 4 to the PCB loading mechanism 6. The PCB loading mechanism 6 includes a second Y-axis moving module 61, which has a PCB fixing slot 62. The soldering mechanism 7 includes a YZ-axis moving module 71, which has a soldering iron 73 positioned above the PCB fixing slot 62. The adapter mechanism 4, the PCB loading mechanism 6, and the soldering mechanism 7 are located on the X-axis moving path of the second clamping mechanism 5.

[0041] The high-efficiency automatic welding equipment for flexible toroidal transformers of the present invention has the following working process:

[0042] 1. Lead wire feeding: Place the 6 leads of the flexible toroidal transformer into the wire slot 131 of the lead wire slot in sequence.

[0043] 2. PCB board loading: Place the PCB board to be soldered into the PCB fixing slot 62.

[0044] 3. Start the equipment: Press the main start button on the controller to put the equipment into automatic operation mode.

[0045] 4. Automatic wire cutting operation: The shearing blade 12 moves downward and cuts the lead wire in the lead wire slot according to the preset length; after the cutting is completed, the wire tail recovery component 14 is activated, and the scraper 143 moves along the side of the lead wire slot to scrape the cut wire tail into the junction box 144. After the operation is completed, it resets.

[0046] 5. Automatic tin plating operation: The first Y-axis moving module 11 drives the lead wire slot to move backward, the first clamping mechanism 2 moves to the left to clamp the transformer lead wire in the lead wire slot and transfer it to the top of the tin furnace 3. The tin scraper plate 82 of the tin scraper mechanism 8 scrapes away the impurities on the surface of the tin liquid. Then the first clamping mechanism 2 moves down to immerse the transformer lead wire in the tin liquid, completing the automatic tin plating of the lead wire.

[0047] 6. Transfer and positioning: After tin plating is completed, the first clamping mechanism 2 moves the transformer onto the transfer mechanism 4 to complete the temporary positioning.

[0048] 7. Circular tin plating operation: The first clamping mechanism 2 returns to one side of the lead slot and continues to clamp the next transformer lead to perform the tin plating process.

[0049] 8. Automatic welding operation: The second clamping mechanism 5 clamps the transformer lead on the transfer mechanism 4 and transfers it to the PCB loading mechanism 6. The welding mechanism 7 is started and, driven by the YZ axis moving module 71, completes the welding of each lead to the PCB board solder joint one by one.

[0050] 9. Batch processing: Repeat the above steps 9 times, and the equipment will automatically complete the transformer soldering operation of 10 PCB boards, and then automatically stop to wait for unloading.

[0051] 10. Manual unloading and restart: Manually remove the soldered PCB board, put the PCB board to be processed back in, press the board slot positioning button, start a new round of soldering operation, and cycle to complete batch production.

[0052] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. However, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-efficiency automatic welding equipment for flexible toroidal transformers, characterized in that: It includes a lead wire feeding and shearing mechanism, a first clamping mechanism, a solder pot, a transfer mechanism, a second clamping mechanism, a PCB feeding mechanism, a soldering mechanism, and a controller; The lead wire feeding and shearing mechanism includes a first Y-axis moving module, which has a lead wire slot and a liftable shearing blade, the shearing blade being positioned above the lead wire slot; the first clamping mechanism includes an XZ-axis moving module, which has a rotatable finger cylinder; the transfer mechanism includes an XY-axis moving module, which has an openable and closable clamping plate assembly; the lead wire feeding and shearing mechanism, the solder pot, and the transfer mechanism are all located on the X-axis moving path of the first clamping mechanism; The structure of the second clamping mechanism is the same as that of the first clamping mechanism; the PCB loading mechanism includes a second Y-axis moving module, on which a PCB fixing groove is provided; the welding mechanism includes a YZ-axis moving module, on which a soldering iron is provided, and the soldering iron is located above the PCB fixing groove; the adapter mechanism, the PCB loading mechanism, and the welding mechanism are located on the X-axis moving path of the second clamping mechanism.

2. The high-efficiency flexible toroidal transformer automatic welding equipment according to claim 1, characterized in that: The lead wire feeding and cutting mechanism also includes a lead wire tail recovery assembly, which includes a driving device, a slider, a scraper, and a junction box. The scraper is connected to the slider and its top side is in contact with the side of the lead wire slot. The junction box is connected to one side of the slider. The driving device drives the slider to reciprocate along the side of the lead wire slot.

3. The high-efficiency flexible toroidal transformer automatic welding equipment according to claim 2, characterized in that: The lead wire slot consists of two card plates spaced a certain distance apart. The top of each card plate has multiple wire grooves, and the shearing blade is located between the two card plates.

4. The high-efficiency flexible toroidal transformer automatic welding equipment according to claim 3, characterized in that: The shearing blade is provided with a cutting edge groove corresponding to the wire groove.

5. The high-efficiency flexible toroidal transformer automatic welding equipment according to claim 4, characterized in that: The top of the cable tray is provided with a V-shaped opening.

6. The high-efficiency flexible toroidal transformer automatic welding equipment according to any one of claims 1-5, characterized in that: It also includes a tin scraping mechanism located next to the tin furnace. The tin scraping mechanism includes a telescopic cylinder and a tin scraper. The tin scraper is located in the furnace trough of the tin furnace, and the telescopic cylinder drives the tin scraper to reciprocate within the furnace trough.

7. The high-efficiency flexible toroidal transformer automatic welding equipment according to claim 6, characterized in that: One finger of the finger cylinder is connected to a clamping plate, and the other finger is connected to a clamping rod. The contact surface between the clamping plate and the clamping rod is provided with multiple clamping grooves.

8. The high-efficiency flexible toroidal transformer automatic welding equipment according to claim 7, characterized in that: The clamping plate assembly includes a lifting cylinder, a lower clamping plate, and an upper clamping plate. The lifting cylinder is fixedly connected to one side of the lower clamping plate, and the output end of the lifting cylinder is connected to the upper clamping plate, driving the upper clamping plate to clamp or open with the lower clamping plate.

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