L-shaped flexible connection welding positioning device

Abstract

The application relates to the technical field of electric connection welding, and discloses an L-shaped flexible connection welding positioning device which comprises upper and lower graphite blocks arranged correspondingly, a positioning groove adapted to the shape of the L-shaped flexible connection is arranged on the upper surface of the lower graphite block, two convex pressure welding surfaces are arranged on the lower surface of the upper graphite block, and the positions of the pressure welding surfaces correspond to the welding areas at the two ends of the L-shaped flexible connection one by one. When the mold is closed, only the pressure welding surfaces abut and press the welding areas, and the non-welding areas are in a suspended state, and only pressure and heat conduction are applied to the welding positions. The device has high positioning precision, can avoid workpiece deviation and non-welding area deformation, is integrally machined through wire cutting, has short preparation period and low cost, is suitable for molecular diffusion welding process, and effectively improves the welding quality and processing efficiency of the L-shaped flexible connection.

Description

Technical Field

[0001] This invention relates to the field of electrical connector welding technology, specifically to an L-shaped flexible connector welding positioning device. Background Technology

[0002] Flexible connectors are core components in electrical systems that enable flexible conductive connections, widely used in power transmission and distribution, new energy storage, rail transportation, industrial frequency conversion, and many other fields. Existing flexible connectors typically consist of a flexible conductive body and metal connection terminals at both ends. The flexible conductive body is often made of flexible conductive materials such as laminated copper foil, braided copper strip, or aluminum foil, possessing excellent bending and deformation capabilities. The connection terminals at both ends are mostly rigid metal conductors, which can be bonded to the flexible body through welding, crimping, or other methods. The terminals can be equipped with mounting holes to adapt to the wiring structure of the equipment. Flexible connectors can compensate for installation dimensional deviations, absorb vibrations and shocks generated during equipment operation, and accommodate relative displacements between components, avoiding stress damage caused by rigid connections. They can also carry high current transmission, ensuring the conductive stability and operational reliability of the electrical system. Products of different specifications and shapes can be customized according to specific scenarios to meet the flexible wiring needs of various electrical equipment.

[0003] For welding irregularly shaped conductive connectors such as L-shaped flexible connectors, existing welding positioning fixtures have several adaptability issues: First, general positioning structures are difficult to match the special contours of L-shaped flexible connectors with varying lengths on both sides, making manual positioning difficult. During welding heating, the workpiece is prone to shifting, leading to dimensional deviations after welding and compromising welding accuracy and subsequent assembly compatibility. Second, conventional pressing fixtures mostly perform planar pressing, applying pressure to the non-welded areas of the flexible connector simultaneously. This can easily cause deformation of the flexible connector strip, damaging its flexible structure and conductivity, failing to balance the fixing effect with the workpiece's performance. Third, customized positioning molds often rely on external procurement, resulting in long processing cycles and high manufacturing costs. This makes it difficult to quickly respond to the production adjustment needs of small-batch, multi-specification L-shaped flexible connectors, lacking flexibility and adaptability. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an L-shaped flexible connector welding positioning device, which solves the problems of easy displacement and poor welding dimensional stability during welding of L-shaped flexible connectors after wire cutting.

[0005] To achieve the above objectives, the present invention provides the following technical solution: The device includes an upper graphite block and a lower graphite block, which are arranged vertically corresponding to each other. A positioning groove is formed on the upper surface of the lower graphite block, the outline of which matches the outer contour of the L-shaped flexible connector to be welded. Two raised welding surfaces are provided on the lower surface of the upper graphite block, located at both ends of the lower surface, with their positions corresponding to the welding areas at both ends of the L-shaped flexible connector. In the mold-closed state, the end faces of the welding surfaces abut against the welding area surface of the L-shaped flexible connector, and a gap is left between the non-welded area of ​​the L-shaped flexible connector and the lower surface of the upper graphite block.

[0006] Preferably, the welding surface is a block-shaped protrusion structure protruding from the lower surface of the upper graphite block, the end face of the protrusion is a flat plane, the side of the protrusion and the lower surface of the upper graphite block are vertically transitioned, and the vertical height of the protrusion is 5mm.

[0007] Preferably, the planar contour shape of the pressure welding surface is consistent with the planar contour shape of the welding area of ​​the L-shaped flexible connector, and the length and width dimensions of the planar contour of the pressure welding surface are exactly the same as the length and width dimensions of the welding area of ​​the L-shaped flexible connector.

[0008] Preferably, the bottom surface of the positioning groove is a continuous and flat planar structure, the side wall of the positioning groove is vertically transitioned to the bottom surface, the depth of the positioning groove is the value obtained by subtracting 5mm from the thickness of the L-shaped flexible connection, and a 5mm equipment gap is formed between the groove and the workpiece.

[0009] Preferably, in the mold-closed state, the non-welded area of ​​the L-shaped flexible connector is located in the gap area between the upper graphite block and the lower graphite block, and a gap is left between the upper surface of the non-welded area of ​​the L-shaped flexible connector and the non-protruding lower surface of the upper graphite block, and a gap is left between the lower surface of the non-welded area of ​​the L-shaped flexible connector and the non-groove upper surface of the lower graphite block.

[0010] Preferably, the upper graphite block is an integral structure formed by wire cutting of a single piece of graphite material, and the lower graphite block is also an integral structure formed by wire cutting of a single piece of graphite material, with the processing equipment specifications of the two being matched.

[0011] Preferably, the positioning groove is an L-shaped contour groove, the overall direction of the groove is consistent with the overall direction of the L-shaped flexible connection, the inner sidewall contour of the positioning groove fits the outer sidewall contour of the L-shaped flexible connection, and the fitting gap between the inner wall of the groove and the outer wall of the workpiece is evenly distributed.

[0012] Preferably, in the mold-closed state, the upper graphite block only contacts the welding area of ​​the L-shaped flexible connector through the pressure welding surface, and the lower graphite block only contacts the welding area of ​​the L-shaped flexible connector through the bottom surface of the positioning groove. The non-welding area of ​​the L-shaped flexible connector has no physical contact with either the upper or lower graphite block.

[0013] Preferably, the two welding surfaces are respectively arranged on the lower surface of the upper graphite block at the positions corresponding to the two ends of the L-shaped flexible connector, and the end face of each welding surface completely covers the welding area surface of the corresponding side L-shaped flexible connector end.

[0014] Compared with the prior art, the present invention provides an L-shaped flexible connection welding positioning device, which has the following beneficial effects: 1. This L-shaped flexible joint welding positioning device utilizes an L-shaped contour positioning groove on the surface of a lower graphite block to accurately match the special contours of the L-shaped flexible joint with different lengths on both sides. The workpiece can be placed and positioned without additional adjustment. The groove fits and limits the workpiece's outer wall to prevent thermal displacement during welding heating, ensuring the accuracy and consistency of the welding dimensions and adapting to the dimensional requirements of subsequent assembly.

[0015] 2. This L-shaped flexible connector welding positioning device utilizes the raised pressure welding surface on the lower surface of the upper graphite block to apply pressure only to the welding area of ​​the flexible connector. The size of the pressure welding surface is perfectly matched with the welding area to ensure uniform pressure in the welding area. At the same time, the non-welding area is in a suspended and stress-free state, which will not damage the flexible structure and conductivity of the flexible connector strip, thus balancing the welding fixation effect and the performance of the flexible connector itself.

[0016] 3. This L-shaped flexible joint welding positioning device utilizes a graphite block wire cutting integrated processing setup, which can share the same wire cutting equipment with the workpiece to complete the processing. There is no need to purchase additional special molds. The processing cycle of a single tooling is short, and it can quickly respond to the tooling adjustment needs of L-shaped flexible joints of different specifications, reduce processing and external purchase costs, and is suitable for small-batch, multi-specification flexible joint welding production scenarios. Attached Figure Description

[0017] Figure 1 This is a front view schematic diagram of the graphite block structure on an L-shaped flexible connection welding positioning device proposed in this invention; Figure 2 This is a schematic diagram of the pressure welding surface structure of an L-shaped flexible connection welding positioning device proposed in this invention; Figure 3 This is a front view of the graphite block structure under the L-shaped flexible connection welding positioning device proposed in this invention; Figure 4 This is a side view of the graphite block structure of the L-shaped flexible connection welding positioning device proposed in this invention. Figure 5 This is a front view schematic diagram of the L-shaped flexible connection structure of the L-shaped flexible connection welding positioning device proposed in this invention.

[0018] In the diagram: 1. Upper graphite block; 2. Lower graphite block; 3. Welding surface; 4. Positioning groove; 5. L-shaped flexible connection; 6. Welding area. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Please see Figure 1 - Figure 5 As shown, it includes an upper graphite block 1 and a lower graphite block 2, which are arranged vertically correspondingly. The upper surface of the lower graphite block 2 is provided with a positioning groove 4, the outline of which matches the outer outline of the L-shaped flexible connection 5 to be welded. The lower surface of the upper graphite block 1 is provided with two protruding pressure welding surfaces 3, which are respectively arranged at both ends of the lower surface of the upper graphite block 1. The positions of the two pressure welding surfaces 3 correspond one-to-one with the welding areas 6 at both ends of the L-shaped flexible connection 5. In the mold-closed state, the end face of the pressure welding surface 3 abuts against the surface of the welding area 6 of the L-shaped flexible connection 5, and a gap is left between the non-welded area of ​​the L-shaped flexible connection 5 and the lower surface of the upper graphite block 1. During operation, the upper and lower graphite blocks open and close synchronously with the pressure welding equipment. The positioning groove 4 of the lower graphite block 2 is pre-supported by the L-shaped soft connection 5 to complete the initial placement. After the upper graphite block 1 moves down and closes the mold, only the pressure welding surface 3 contacts the workpiece welding area 6. The overall structure forms a local contact fit, which can concentrate the pressure of the equipment at the welding part and avoid the additional squeezing or scratching effect caused by the contact of the workpiece by the extra structure.

[0021] First, the welding surface 3 is a block-shaped protrusion extending from the lower surface of the upper graphite block 1. The end face of the protrusion is a flat plane, and the side of the protrusion transitions vertically to the lower surface of the upper graphite block 1. The vertical height of the protrusion is 5mm. The height difference of this protrusion structure naturally creates a gap between the non-protruding surface of the upper graphite block 1 and the workpiece surface. The flat end face ensures that the pressure is evenly distributed on the surface of the welding area 6. The vertical transition structure avoids stress concentration at the protrusion edge. The 5mm protrusion height is just right to match the gap requirements between the workpiece and the upper mold, ensuring the accuracy of the pressing stroke and preventing problems such as excessive pressing or insufficient pressure.

[0022] Secondly, the planar contour shape of the pressure welding surface 3 is consistent with the planar contour shape of the welding area 6 of the L-shaped flexible connector 5. The length and width dimensions of the planar contour of the pressure welding surface 3 are exactly the same as the length and width dimensions of the welding area 6 of the L-shaped flexible connector 5. The perfect match of size and shape ensures that the pressure welding surface 3 completely covers the welding area 6. During pressing, the pressure will not exceed the welding area and will not cause extrusion deformation to adjacent non-welding areas. At the same time, it can ensure that the pressure is uniform at all points in the welding area 6, ensuring the flatness and consistency of the weld formation.

[0023] Furthermore, the bottom surface of the positioning groove 4 is a continuous and flat planar structure, and the sidewall of the positioning groove 4 transitions vertically to the bottom surface. The depth of the positioning groove 4 is the value obtained by subtracting 5mm from the thickness of the L-shaped flexible connection 5, forming a 5mm equipment gap between the groove and the workpiece. The flat bottom surface can stably support the lower surface of the workpiece welding area 6, ensuring that the bottom of the welding part is flat and without depressions. The 5mm equipment gap allows the workpiece to be smoothly placed into the groove without precise alignment, while the groove depth limitation prevents the workpiece from moving up and down, balancing the convenience of material placement and the stability of positioning.

[0024] Furthermore, in the mold-closed state, the non-welded area of ​​the L-shaped flexible connector 5 is located within the gap between the upper graphite block 1 and the lower graphite block 2. A gap exists between the upper surface of the non-welded area of ​​the L-shaped flexible connector 5 and the non-protruding lower surface of the upper graphite block 1, and a gap also exists between the lower surface of the non-welded area of ​​the L-shaped flexible connector 5 and the non-groove upper surface of the lower graphite block 2. These gaps on both sides allow the flexible connector's strip portion to be suspended, preventing bending deformation due to pressure from the upper and lower molds and avoiding contact with heat conducted from the graphite blocks. This fully preserves the flexible structure and electrical conductivity of the flexible connector strip, avoiding any impact from the welding process on the original performance of the non-welded parts.

[0025] Furthermore, the upper graphite block 1 is a one-piece structure formed from a single piece of graphite material using wire cutting technology, and the lower graphite block 2 is also a one-piece structure formed from a single piece of graphite material using wire cutting technology. The processing equipment specifications for both are matched. The one-piece wire-cut structure has no splicing gaps, and the overall structural strength is uniform. Processing with the same equipment can ensure that the dimensional accuracy and fitting accuracy of the upper and lower molds are consistent. At the same time, it can share the wire cutting equipment with the L-shaped flexible connector 5 for production, eliminating the need to purchase additional special molds, thus shortening the tooling preparation cycle and reducing processing costs.

[0026] Furthermore, the positioning groove 4 is an L-shaped contoured groove, with its overall orientation consistent with that of the L-shaped flexible connector 5. The inner wall contour of the positioning groove 4 fits snugly against the outer wall contour of the L-shaped flexible connector 5, and the fit clearance between the inner wall of the groove and the outer wall of the workpiece is uniform. The contoured groove wall can restrict the horizontal displacement of the L-shaped flexible connector 5 from all sides, preventing the workpiece from shifting due to thermal expansion or equipment vibration during welding heating. The uniform fit clearance will neither hinder the placement or removal of the workpiece nor cause positioning deviation due to excessive clearance, ensuring the accuracy of the welding position.

[0027] Furthermore, in the mold-closed state, the upper graphite block 1 only contacts the welding area 6 of the L-shaped flexible connector 5 through the welding surface 3, and the lower graphite block 2 only contacts the welding area 6 of the L-shaped flexible connector 5 through the bottom surface of the positioning groove 4. The non-welding areas of the L-shaped flexible connector 5 have no physical contact with either the upper or lower graphite block 1. Only the welding area 6 forms physical contact with the upper and lower graphite blocks, and the welding heat is only directionally conducted to the welding area through the contacting graphite parts. The non-welding areas have no heat conduction path and are not affected by the welding heat, thus achieving directional heat transfer and reducing unnecessary heat loss and thermal damage to the flexible connector strip.

[0028] Finally, two welding surfaces 3 are respectively positioned on the lower surface of the upper graphite block 1 at the positions corresponding to the two ends of the L-shaped flexible connector 5. The end face of each welding surface 3 completely covers the welding area 6 surface of the corresponding side end of the L-shaped flexible connector 5. The welding surfaces 3 corresponding to the two ends can simultaneously press and conduct heat to the two welding ends of the L-shaped flexible connector 5. The synchronous welding operation of both ends can be completed in one mold closing, without the need to adjust the workpiece position in multiple steps, thus improving the efficiency of welding processing and the consistency of welding quality at both ends.

[0029] Working principle: First, the upper graphite block 1 and the lower graphite block 2 are fixedly installed on the upper and lower mold bases of the pressure welding equipment, respectively. The coaxiality and mold closing gap of the upper and lower molds are adjusted to ensure that the pressure welding surface 3 of the upper graphite block 1 and the positioning groove 4 of the lower graphite block 2 are precisely aligned, completing the alignment and debugging of the tooling. Then, the L-shaped flexible connector 5 to be processed is flattened to ensure that the strip is wrinkle-free and the ends are flush. It is then placed smoothly into the positioning groove 4 on the upper surface of the lower graphite block 2 and pushed into place along the groove, so that the outer wall of the workpiece is in contact with the inner wall of the positioning groove 4, and the welding areas 6 at both ends are completely within the support range of the bottom of the groove, corresponding to the two pressure welding surfaces 3 above. The pressure welding equipment is started to drive the upper mold to descend at a uniform speed. The upper graphite block 1 descends synchronously with the upper mold. The pressure welding surface 3 first contacts the upper surface of the welding area 6 of the L-shaped flexible connector 5. As the mold closing stroke advances, the pressure welding surface 3 applies the set welding pressure evenly to the weld. On the contact area 6, at this time, the non-welded strip part of the L-shaped flexible connection 5 neither contacts the lower plane of the upper graphite block 1 nor the upper plane of the lower graphite block 2, and is completely suspended, without being subjected to additional compressive force. Then, the molecular diffusion welding heating program is started, and the upper and lower graphite blocks are heated by electricity. The high thermal conductivity of graphite itself will evenly transfer heat to the contact welding area 6, so that the metal in the welding area 6 reaches the diffusion welding temperature. Under the combined action of pressure and heat, the two ends are synchronously welded together. Since there is no graphite contact in the non-welded area, no excess heat will be conducted, and the original flexibility and conductivity will be completely preserved. After the welding pressure and heat preservation stage is completed, the equipment stops heating, and the upper mold drives the upper graphite block 1 to move upward at a uniform speed to open the mold. The pressure welding surface 3 is completely separated from the workpiece surface, and the welded L-shaped flexible connection 5 can be taken out from the positioning groove 4 with tools and transferred to the subsequent shaping and inspection process.

[0030] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. An L-shaped flexible joint welding positioning device, characterized in that, The system includes an upper graphite block (1) and a lower graphite block (2), with the upper graphite block (1) and the lower graphite block (2) arranged vertically and vertically respectively. The upper surface of the lower graphite block (2) is provided with a positioning groove (4), the outline of which is adapted to the outer outline of the L-shaped flexible connector (5) to be welded. The lower surface of the upper graphite block (1) is provided with two protruding pressure welding surfaces (3), which are respectively arranged at both ends of the lower surface of the upper graphite block (1). The positions of the two pressure welding surfaces (3) correspond one-to-one with the welding areas (6) at both ends of the L-shaped flexible connector (5). In the mold-closed state, the end face of the pressure welding surface (3) abuts against the surface of the welding area (6) of the L-shaped flexible connector (5), and there is a gap between the non-welding area of ​​the L-shaped flexible connector (5) and the lower surface of the upper graphite block (1).

2. The L-shaped flexible joint welding positioning device according to claim 1, characterized in that, The pressure welding surface (3) is a block-shaped protrusion structure that protrudes from the lower surface of the upper graphite block (1). The end face of the protrusion is a flat plane, and the side of the protrusion is vertically transitioned to the lower surface of the upper graphite block (1). The vertical height of the protrusion is 5mm.

3. The L-shaped flexible joint welding positioning device according to claim 1, characterized in that, The planar contour shape of the pressure welding surface (3) is consistent with the planar contour shape of the welding area (6) of the L-shaped flexible connector (5), and the length and width dimensions of the planar contour of the pressure welding surface (3) are exactly the same as the length and width dimensions of the welding area (6) of the L-shaped flexible connector (5).

4. The L-shaped flexible joint welding positioning device according to claim 1, characterized in that, The bottom surface of the positioning groove (4) is a continuous and flat planar structure. The side wall of the positioning groove (4) and the bottom surface are vertically transitioned. The depth of the positioning groove (4) is the value obtained by subtracting 5mm from the thickness of the L-shaped flexible connection (5). A 5mm equipment gap is formed between the groove and the workpiece.

5. The L-shaped flexible joint welding positioning device according to claim 1, characterized in that, In the mold-closed state, the non-welded area of ​​the L-shaped soft connection (5) is located in the interval area between the upper graphite block (1) and the lower graphite block (2). There is a gap between the upper surface of the non-welded area of ​​the L-shaped soft connection (5) and the non-protruding lower surface of the upper graphite block (1), and a gap between the lower surface of the non-welded area of ​​the L-shaped soft connection (5) and the non-groove upper surface of the lower graphite block (2).

6. The L-shaped flexible joint welding positioning device according to claim 1, characterized in that, The upper graphite block (1) is an integral structure formed by wire cutting of a whole piece of graphite material, and the lower graphite block (2) is also an integral structure formed by wire cutting of a whole piece of graphite material. The processing equipment specifications of the two are matched.

7. The L-shaped flexible joint welding positioning device according to claim 1, characterized in that, The positioning groove (4) is an L-shaped contour groove. The overall direction of the groove is consistent with the overall direction of the L-shaped flexible connection (5). The inner wall contour of the positioning groove (4) fits the outer wall contour of the L-shaped flexible connection (5). The fitting gap between the inner wall of the groove and the outer wall of the workpiece is evenly distributed.

8. The L-shaped flexible joint welding positioning device according to claim 1, characterized in that, In the mold-closed state, the upper graphite block (1) only contacts the welding area (6) of the L-shaped flexible connector (5) through the pressure welding surface (3), and the lower graphite block (2) only contacts the welding area (6) of the L-shaped flexible connector (5) through the bottom surface of the positioning groove (4). The non-welding area of ​​the L-shaped flexible connector (5) has no physical contact with the upper graphite block (1) and the lower graphite block (2).

9. The L-shaped flexible joint welding positioning device according to claim 1, characterized in that, The two pressure welding surfaces (3) are respectively arranged on the lower surface of the upper graphite block (1) at the positions corresponding to the two ends of the L-shaped flexible connector (5), and the end face of each pressure welding surface (3) completely covers the welding area (6) surface of the corresponding side L-shaped flexible connector (5).

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