An adaptive clamping device for wiring harness terminal welding

Abstract

The application discloses a kind of self-adapting clamping devices for wiring harness terminal welding, belong to wiring harness welding technical field, including mould base, cylinder, wedge drive assembly, guide frame and sliding clamping assembly;Mould base is box type structure, and lower end is fixedly connected to the end of cylinder, and the telescopic rod of cylinder is fixedly connected with wedge drive assembly by passing through the bottom wall of mould base;Guide frame is fixed in mould base, and guide frame is provided with sliding slot, and wedge drive assembly is slidingly connected in sliding slot;Sliding clamping assembly includes guide rod, clamping arm, compression spring and gyro wheel, one end of guide rod is fixed on clamping arm, the other end of guide rod is articulated gyro wheel, and compression spring is sleeved on guide rod and is in pre-compressed state;Gyro wheel and the inclined surface of wedge-shaped slider of wedge drive assembly are rolling fit, and constitute pure mechanical type elastic floating compensation mechanism.

Description

Technical Field

[0001] This invention relates to the field of wire harness welding technology, and more specifically to an adaptive clamping device for welding wire harness terminals. Background Technology

[0002] In the control systems of new energy vehicles, energy storage, and high-power motors, the use of large-section wire harnesses (typically referring to copper / aluminum wires with a cross-sectional area of ​​16mm² to 100mm² or larger) is becoming increasingly widespread. These wire harnesses are usually connected to terminals via ultrasonic welding to achieve extremely low contact resistance and excellent durability.

[0003] Compared with conventional small-section terminals, large-square terminals have the following significant unique characteristics:

[0004] Large size and heavy weight: The terminals themselves have great inertia, and if they are not firmly fixed under high-frequency vibration, they are prone to displacement or jumping.

[0005] Material hardness differences: To ensure conductivity, T2 pure copper or oxygen-free copper is usually used. The material is relatively soft, and the surface is very easy to produce indentations or plastic deformation due to uneven clamping force, which affects the appearance and subsequent assembly.

[0006] Cumulative dimensional tolerances: Due to the large volume, small angular deviations or length tolerances during the processing are magnified in absolute value, which places extremely high demands on the error tolerance of the mold.

[0007] Currently, the industry typically uses two clamping methods: one is rigid clamping, which can provide sufficient clamping force, but it is very easy to damage the terminal surface and cannot adapt to the rapid switching of different terminal specifications; the other is active servo adjustment clamping, which adjusts the position in real time through sensor feedback. Although it has high precision, it has a complex structure, its response speed is difficult to match the high speed of ultrasonic welding, and it is also expensive. Summary of the Invention

[0008] The present invention aims to solve the technical problems mentioned in the background section above, and provides an adaptive clamping device for welding wire harness terminals, which can protect the terminal surface, adapt to the size fluctuations of large square terminals, and has a rapid response and controllable cost.

[0009] Based on the above-mentioned objectives, the technical solution provided by the present invention is as follows: an adaptive clamping device for welding wire harness terminals, comprising a mold base, a cylinder, a wedge-shaped drive assembly, a guide frame, and a sliding clamping assembly;

[0010] The lower end of the mold base is fixedly connected to the end of the cylinder, and the telescopic rod of the cylinder passes through the bottom wall of the mold base and is fixedly connected to the wedge-shaped drive assembly.

[0011] The guide frame is fixed inside the mold base, and a groove is provided on the guide frame. The wedge-shaped drive assembly is slidably connected inside the groove.

[0012] The sliding clamping assembly is fixedly connected to the upper end of the guide frame and includes a guide rod, a clamping arm, a compression spring, and a roller. One end of the guide rod is fixed to the clamping arm, and the other end of the guide rod is hinged to the roller. The compression spring is sleeved on the guide rod and is in a pre-compressed state. The roller and the wedge-shaped slider of the wedge-shaped drive assembly roll in cooperation, and together with the compression spring, they form a purely mechanical elastic floating compensation mechanism.

[0013] In some embodiments, the wedge drive assembly includes a wedge slider and a base plate. There are two wedge sliders, which are vertically fixed to both ends of the base plate. The base plate is slidably connected to the groove of the guide frame. The wedge sliders are in clearance fit with the inner sidewall of the mold base and move vertically up and down along the groove of the guide frame under the drive of the cylinder. The inclined surface of the wedge sliders pushes the rollers and clamping arms to move horizontally.

[0014] In some embodiments, the elastic floating compensation mechanism operates as follows: when the cylinder drives the wedge slider to rise, the inclined surface of the wedge slider pushes the clamping arm to close towards the center; when it encounters a terminal with a larger size, the clamping arm on that side is blocked and stops moving forward, and the compression spring behind it is further compressed to generate a yielding displacement; the clamping arm on the other side continues to move forward under the continuous drive of the wedge slider until it fits the terminal, thereby realizing automatic compensation for the thickness tolerance of the workpiece.

[0015] In some embodiments, the end of the guide rod near the clamping arm is fixedly connected to the clamping arm, and the end of the guide rod away from the clamping arm is provided with an external thread and connected to a limiting plate. One end of the compression spring abuts against the limiting plate, and the other end abuts against the back of the clamping arm. The pre-compression amount of the compression spring is adjusted by the limiting plate.

[0016] In some embodiments, the guide frame consists of two symmetrical, vertically fixed plates, each with a vertical groove, and the base plate is slidably connected within the two grooves; the upper end of the guide frame has a through hole, and the guide rod passes through the through hole.

[0017] In some embodiments, the guide frame is provided with a limiting block I, and the base plate is provided with a limiting block II. The limiting block I and the limiting block II cooperate to limit the rising position of the base plate and the wedge slider, so as to prevent the wedge slider from coming off the mold base.

[0018] In some embodiments, a composite flexible pad is detachably mounted on the front side of the clamping arm. The composite flexible pad includes a base layer and a surface layer. The base layer is a silicone sponge layer bonded to the back of the surface layer, used to absorb micro-vibrations during ultrasonic welding and compensate for the micro-dimensional tolerances of the terminals. The surface layer is a polyurethane rubber layer with a high coefficient of friction, used to provide gripping force and prevent damage to the terminal surface.

[0019] In some embodiments, the silicone sponge layer of the base layer has a Shore A hardness of 45°±5°, the polyurethane rubber layer of the surface layer has a Shore A hardness of 90°±5°, and the surface layer is pressed with a fine mesh anti-slip texture.

[0020] In some embodiments, the composite flexible pad is detachably installed on the front of the clamping arm, with the base layer located between the surface layer and the clamping arm, forming a double-layer composite structure with a hard, non-slip outer layer and a soft, cushioning inner layer.

[0021] In some embodiments, the roller is hinged to the end of the guide rod by a pin, and the roller and the inclined surface of the wedge slider are in rolling friction fit; when the clamping arm produces adaptive retraction under the action of the compression spring, the roller rolls along the inclined surface of the wedge slider, reducing transmission resistance and avoiding jamming.

[0022] The advantages of this invention compared to the prior art are:

[0023] 1. A spring is fitted on the guide rod, and a flexible interface with gradient hardness is constructed on the surface of the clamping arm, combining "spring floating buffer" and "double-layer padding material buffer" to avoid rigid contact impact on the workpiece; the inner silicone sponge can effectively protect the surface of the soft copper terminal from being scratched or crushed, while the anti-slip texture of the outer polyurethane rubber ensures that the workpiece will not slip under welding vibration.

[0024] 2. Springs are fitted onto the guide rod to achieve adaptive and uniform clamping, avoiding excessive force on one side; dimensional errors are automatically compensated by the elastic compression and release of the springs.

[0025] 3. The use of a central wedge slider in conjunction with a linear guide rail and low-friction transmission from rollers makes the entire mold base structure very compact and space-saving. At the same time, the wedge-shaped force-enhancing structure optimizes the force distribution, improves the smoothness and accuracy of transmission, and ensures rapid response of clamping actions.

[0026] 4. Flexible clamping and adaptive positioning reduce workpiece scrap caused by hard collisions or overpressure, and also reduce rigid wear of the clamps themselves. Under long-term operation, it can significantly reduce maintenance costs and improve the overall production efficiency and yield of automated production lines.

[0027] Additional aspects and advantages of the invention 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 the invention. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the adaptive clamping device for wire harness terminals according to an embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram of the clamping arm portion of the adaptive clamping device for wire harness terminals according to an embodiment of the present invention;

[0030] Figure 3 This is a schematic diagram of the adaptive clamping device for wire harness terminals in use according to an embodiment of the present invention;

[0031] In the attached diagram: 1. Mold base; 2. Clamping arm; 3. Cylinder; 4. Wedge slider; 5. Roller; 6. Composite flexible pad; 7. Compression spring; 8. Guide frame; 9. Guide rod; 10. Limiting block I; 11. Limiting block II. Detailed Implementation

[0032] The present invention will now be described in further detail.

[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0034] like Figure 1 As shown, an adaptive clamping device for welding wire harness terminals has a box-shaped mold base 1 as its main body. The lower end of the mold base 1 is fixedly connected to the end of a cylinder 3. The telescopic rod of the cylinder 3 passes through the bottom wall of the mold base 1 and is fixed to the bottom plate of the wedge-shaped slider inside the mold base 1.

[0035] A vertical guide frame 8 is fixed inside the mold base 1. The guide frame 8 consists of two symmetrically fixed vertical plates. Each plate has the same vertical groove. A base plate is slidably connected in both grooves. Vertical wedge-shaped sliders are fixed at both ends of the base plate. The wedge-shaped sliders 4 and the base plate together constitute the wedge-shaped drive assembly of the clamping arm 2.

[0036] The wedge-shaped slider 4 is fitted with the inner sidewall of the mold base 1 with a clearance, and can move vertically up and down along the slide groove of the guide frame 8 under the drive of the cylinder 3.

[0037] Furthermore, the guide frame 8 is provided with a limiting block I 10 and the base plate is provided with a limiting block II 11, which are used to limit the rising position of the base plate and the wedge slider to prevent the wedge slider from coming off the mold base 1.

[0038] like Figure 1 As shown, the upper ends of the two guide frames 8 are also provided with through holes, and sliding clamping components are fixedly connected in the through holes.

[0039] Combination Figure 2 As shown, the sliding clamping assembly includes a guide rod 9, a clamping arm 2, a compression spring 7, and a roller 5;

[0040] One end of the guide rod 9 is fixed to the clamping arm 2, and the other end of the guide rod 9 is hinged to the roller 5. A compression spring 7 in a pre-compressed state is sleeved between the roller 5 and the clamping arm 2.

[0041] Specifically, the guide rod 9 has an internal threaded hole at one end near the clamping arm 2. The clamping arm 2 has a positioning hole and a countersunk through hole. The guide rod 9 is inserted into the positioning hole. The guide rod 9 is fixedly connected to the clamping arm 2 by bolts passing through the countersunk through hole from the front (clamping contact surface) of the clamping arm 2.

[0042] The guide rod 9 has an external thread at one end away from the clamping arm 2. A limiting plate with a spring is connected through the external thread. One end of the compression spring 7 abuts against the limiting plate, and the other end abuts against the back of the clamping arm 2. The pre-compression amount of the compression spring 7 can be adjusted through the limiting plate.

[0043] Furthermore, to protect the terminal surface from being pinched and damaged, a flexible adhesive layer is detachably installed on the front of the clamping arm 2. This flexible adhesive layer includes a base layer and a surface layer. The base layer is a silicone sponge layer bonded to the back of the surface layer, with a Shore A hardness of 45°±5°, used to absorb micro-vibrations during ultrasonic welding and compensate for the micro-dimensional tolerances of the terminals. The surface layer is a high-friction coefficient polyurethane rubber layer with a fine mesh anti-slip texture pressed onto its surface, with a Shore A hardness of 90°±5°, used to provide grip and prevent damage to the terminal surface.

[0044] Combination Figure 1 , Figure 2 , Figure 3 As shown, the compression spring 7 is directly fixed in the through hole of the guide frame 8. The compression spring 7 is in a pre-compressed state and always gives the clamping arm 2 an inward restoring force (that is, makes the clamping arms 2 on both sides tend to close), so that the clamping arm 2 has the freedom to float in the horizontal direction, forming an elastic floating compensation mechanism.

[0045] When cylinder 3 drives wedge slider 4 to rise, the inclined surface of wedge slider 4 pushes clamping arm 2 to close towards the center. At this time, if it encounters a terminal with a larger size (such as the left side), the clamping arm 2 on that side will be blocked and stop moving forward, and the compression spring 7 behind it will be further compressed to generate a yielding displacement; while the clamping arm 2 on the other side (right side) is unaffected and continues to move forward until it fits under the continuous drive of wedge slider 4; automatic compensation for workpiece thickness tolerance can be achieved using a purely mechanical structure, without the need for expensive sensors and servo motors, ensuring uniform clamping force on both sides and avoiding one-sided suspension or overpressure; the response speed is extremely fast and the economy is high.

[0046] During clamping, the surface layer of the composite flexible pad 6 is made of high-hardness polyurethane rubber (Shore hardness approximately 90A), with a fine mesh-like anti-slip texture pressed onto the surface. Its function is to provide a sufficient coefficient of friction to prevent terminal slippage during ultrasonic welding, while also providing wear resistance.

[0047] The base layer, made of low-hardness silicone foam (Shore hardness approximately 45A), is located between the outer layer and the metal clamping arm 2. Its function is to absorb high-frequency vibration energy and provide secondary cushioning, protecting the surface of the soft copper terminal from being damaged.

[0048] The guide rod 9 is hinged to the roller 5 via a pin hole and a pin shaft (the connection method of the roller 5 is a conventional connection method, such as...). Figure 2 As shown (not elaborated here), the roller 5 and the inclined surface of the wedge-shaped slider 4 experience rolling friction, which significantly reduces transmission resistance. This not only improves transmission efficiency but, more importantly, ensures that during the "adaptive yielding" process, the clamping arm 2 can respond sensitively to changes in the elastic force of the compression spring 7, avoiding jamming caused by excessive friction and ensuring smooth execution of the adaptive function.

[0049] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. An adaptive clamping device for welding wire harness terminals, characterized in that, It includes a mold base (1), a cylinder (3), a wedge drive assembly, a guide frame (8), and a sliding clamping assembly; The lower end of the mold base (1) is fixedly connected to the end of the cylinder (3), and the telescopic rod of the cylinder (3) passes through the bottom wall of the mold base (1) and is fixedly connected to the wedge-shaped drive assembly. The guide frame (8) is fixed inside the mold base (1), and the guide frame (8) is provided with a sliding groove, and the wedge-shaped drive assembly is slidably connected inside the sliding groove; The sliding clamping assembly is fixedly connected to the upper end of the guide frame (8) and includes a guide rod (9), a clamping arm (2), a compression spring (7) and a roller (5). One end of the guide rod (9) is fixed to the clamping arm (2), and the other end of the guide rod (9) is hinged to the roller (5). The compression spring (7) is sleeved on the guide rod (9) and is in a pre-compressed state. The roller (5) rolls with the wedge slider (4) of the wedge drive assembly on the inclined surface, and together with the compression spring (7), they form a purely mechanical elastic floating compensation mechanism.

2. The adaptive clamping device for welding wire harness terminals according to claim 1, characterized in that, The wedge drive assembly includes a wedge slider (4) and a base plate. There are two wedge sliders (4) and they are vertically fixed at both ends of the base plate. The base plate is slidably connected to the groove of the guide frame (8). The wedge slider (4) is in clearance fit with the inner side wall of the mold base (1). Under the drive of the cylinder (3), it moves vertically up and down along the groove of the guide frame (8). The inclined surface of the wedge slider (4) pushes the roller (5) and the clamping arm (2) to move horizontally.

3. The adaptive clamping device for welding wire harness terminals according to claim 1, characterized in that, The working method of the elastic floating compensation mechanism is as follows: when the cylinder (3) drives the wedge slider (4) to rise, the inclined surface of the wedge slider (4) pushes the clamping arm (2) to close towards the center; when it encounters the side of the terminal with a larger size, the clamping arm (2) on that side is blocked and stops moving forward, and the compression spring (7) behind it is further compressed to generate a yielding displacement; the clamping arm (2) on the other side continues to move forward under the continuous drive of the wedge slider (4) until it fits the terminal, thereby realizing automatic compensation for the thickness tolerance of the workpiece.

4. The adaptive clamping device for welding wire harness terminals according to claim 1, characterized in that, The guide rod (9) is fixedly connected to the clamping arm (2) at one end near the clamping arm (2), and the guide rod (9) away from the clamping arm (2) is provided with an external thread and connected to a limiting plate. One end of the compression spring (7) abuts against the limiting plate, and the other end abuts against the back of the clamping arm (2). The pre-compression amount of the compression spring (7) is adjusted by the limiting plate.

5. The adaptive clamping device for welding wire harness terminals according to claim 1, characterized in that, The guide frame (8) consists of two symmetrical, vertically fixed plates, each with a vertical groove, which together slides to connect the base plate. The upper end of the guide frame (8) has a through hole, through which the guide rod (9) passes.

6. The adaptive clamping device for welding wire harness terminals according to claim 2, characterized in that, The guide frame (8) is provided with a limiting block I (10) and the bottom plate is provided with a limiting block II (11). The limiting block I (10) and the limiting block II (11) cooperate to limit the rising position of the bottom plate and the wedge slider (4) to prevent the wedge slider (4) from coming out of the mold base (1).

7. The adaptive clamping device for welding wire harness terminals according to claim 1, characterized in that, The front of the clamping arm (2) is detachably fitted with a composite flexible pad (6), which includes a base layer and a surface layer. The base layer is a silicone sponge layer bonded to the back of the surface layer, used to absorb micro-vibrations during ultrasonic welding and compensate for the micro-dimensional tolerances of the terminals. The surface layer is a polyurethane rubber layer with a high coefficient of friction, used to provide gripping force and prevent damage to the terminal surface.

8. The adaptive clamping device for welding wire harness terminals according to claim 7, characterized in that, The silicone sponge layer of the base layer has a Shore A hardness of 45°±5°, the polyurethane rubber layer of the surface layer has a Shore A hardness of 90°±5°, and the surface layer is pressed with a fine mesh anti-slip texture.

9. The adaptive clamping device for welding wire harness terminals according to claim 7, characterized in that, The composite flexible pad (6) is detachably installed on the front of the clamping arm (2), with the base layer located between the surface layer and the clamping arm (2), forming a double-layer composite structure with an outer hard anti-slip layer and an inner soft cushioning layer.

10. The adaptive clamping device for welding wire harness terminals according to claim 1, characterized in that, The roller (5) is hinged to the end of the guide rod (9) by a pin. The roller (5) and the inclined surface of the wedge slider (4) are in rolling friction fit. When the clamping arm (2) produces adaptive yielding under the action of the compression spring (7), the roller (5) rolls along the inclined surface of the wedge slider (4), reducing transmission resistance and avoiding jamming.

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