Terminal wire harness ultrasonic welding detection all-in-one machine and detection method

Abstract

The application discloses a terminal wire harness ultrasonic welding detection all-in-one machine, which comprises a terminal feeding device, a welding device, a moving device and a detection device; two groups of ultrasonic welders are adopted in the scheme, and two welding stations are matched, terminal feeding devices and moving devices are arranged on the front and back sides respectively for terminal feeding and wire harness feeding, specifically, welding of a first wire harness and a terminal is carried out on a first welding table, then welding of a second wire harness and the terminal is carried out on a second welding table, at this time, the first welding table is idle for cooling, when the welding on the second welding table is completed, the moving device transports the welded two wire harness terminals to the detection device, then retreats to the initial position for the next round of welding, meanwhile, the detection device carries out appearance detection and peeling test on the welding area, the whole process is more efficient, meanwhile, the peeling test carries out radial strength test on the welding area, and it is ensured that the welding strength meets the requirements.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic welding technology, specifically to an integrated machine and method for testing ultrasonic welding of terminal wire harnesses. Background Technology

[0002] Ultrasonic welding technology is a mature application in terminal and wire harness connections. It works by vibrating stranded wires together at a frequency of 15-40kHz, thereby forming a strong metallurgical bond between individual conductors. This vibrational energy causes surface oxides to wear away on the individual conductors, resulting in a highly conductive metallurgical bond. Ultrasonic welded terminals are widely used due to their high production efficiency, reliable welding performance, and reduced voltage, and represent a trend in the automotive wire harness industry.

[0003] During ultrasonic welding, a large amount of heat is generated in the welding area, welding head, and welding table. After welding is completed, it needs to cool for a period of time before the next welding can be carried out, otherwise the welding equipment will be damaged. This results in relatively low welding efficiency. In addition, the current wire harness welding strength test is mostly a pull-out test, and there is a lack of radial strength test, as well as a lack of suitable radial testing equipment. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides an integrated ultrasonic welding inspection machine and inspection method for terminal wire harnesses.

[0005] The specific technical solution is as follows: a terminal wire harness ultrasonic welding and testing integrated machine, including a terminal feeding device, a welding device, a transfer device and a testing device;

[0006] The terminal feeding device is located on one side of the welding device, and the terminal feeding device includes a terminal clamp and a first slide group for driving the terminal clamp to move.

[0007] The welding device includes a liftable ultrasonic welding machine, with a welding table set below the ultrasonic welding machine.

[0008] The transfer device includes a clamping mechanism for holding the wire harness and a second slide group for driving the clamping mechanism to move.

[0009] The detection device includes a detection platform, a first detection camera is arranged above the detection platform, a sliding platform is arranged on the side of the detection platform, and a peel test device and a second detection camera are arranged on the platform.

[0010] The testing station includes a support block and a support block. The support block is fixedly connected above the support block. The upper part of the support block has a recess corresponding to the welding area, and the depth of the recess is the same as the thickness of the terminal. The peel test device includes a push block and a driving device for driving the push block to move. The push block is located on the side of the support block. When the terminal part of the welding area is located in the recess of the support block, the head of the push block is at the same height as the wire harness part of the welding area.

[0011] Furthermore, there are two ultrasonic welding machines, each with a welding table at its lower part. There are also two testing tables, each with a first testing camera at its upper part. The peeling test device and the second testing camera are correspondingly provided on both sides of the two testing tables.

[0012] Furthermore, the terminal clamp includes a jaw and a clamping block. The clamping block is L-shaped, and two clamping blocks are arranged facing each other and connected to the jaw portion of the jaw. The first slide group includes a first linear slide, a linear guide rail, a platform, a second linear slide, a lifting platform, and a telescopic mechanism. The first linear slide is arranged parallel to the linear guide rail. The lower part of the platform is connected to the slider of the linear guide rail and the slide base of the first linear slide. There are two second linear slides arranged parallel to each other on the platform. The sliding direction of the second linear slide is perpendicular to the sliding direction of the first linear slide. The lifting platform is provided on the slide base of each of the two second linear slides. The upper part of each of the two lifting platforms is also provided with a telescopic mechanism. The telescopic mechanism is a slide cylinder, and the terminal clamp is provided at the head end of each of the two slide cylinders. The lifting platform includes a square frame. Two vertically upward slide cylinders are provided on the square frame. The upper part of the two vertically upward slide cylinders is connected to a base plate. The telescopic mechanism is arranged on the base plate. The telescopic direction of the telescopic mechanism is parallel to the sliding direction of the second linear slide.

[0013] Furthermore, the welding device includes a frame, on which a drive mechanism is provided to drive the ultrasonic welding machine to move up and down. The drive mechanism includes a cylinder, an adapter block, and a connecting seat. The cylinder is located on the upper part of the frame and faces downward. The head end of the cylinder is connected to the adapter block through a floating joint. The lower part of the adapter block is connected to the connecting seat. The connecting seat is fixedly connected to the ultrasonic welding machine.

[0014] Furthermore, a vertical platform is connected to the adapter block. The back of the platform is connected to the frame via a linear guide rail. A limiting block is also provided on the back of the platform, and the limiting block has a U-shaped groove. The frame is also provided with a limiting mechanism, which includes a motor, a lead screw, and a lead screw slider. The frame has a vertical hollow groove, and the lead screw is set in the hollow groove. The upper part of the lead screw is connected to the output end of the motor via a bevel gear. The lead screw slider is sleeved on the lead screw and is engaged in the hollow groove. The lead screw is engaged in the U-shaped groove of the limiting block, and the limiting block is located above the lead screw slider.

[0015] Furthermore, the welding table includes a welding seat, with a sliding groove formed on each side of the welding seat by limiting plates. A cylinder is located at the bottom of the sliding groove, and a slider seat is connected to the cylinder. Above the slider seat is a slidable pressure block and a driving assembly for driving the pressure block to slide. The driving assembly includes a channel plate with a cover plate. The channel plate and the top surface of the slider seat form a lower channel, within which a slidable slider is located. The channel plate and the cover plate form an upper channel, within which a slidable pressure block is located. The upper and lower channels are connected by a straight slot. A transmission pin is inserted and fixed to the lower part of the pressure block. The slider is provided with a… A slanted groove is provided, with the lower part of the transmission pin inserted into the slanted groove through a straight groove opening. A cylinder that drives the slider is connected to the slider. The upper part of the channel plate and the cover plate also form a limiting channel. A lead screw is provided in the limiting channel, with the direction of the lead screw parallel to the upper channel. A limiting block is provided in the limiting channel, with a threaded hole on the limiting block that cooperates with the lead screw. One end of the limiting block has a T-shaped protrusion. The channel plate has a T-shaped guide groove corresponding to the protrusion. The lead screw extends to the outside of the channel plate and has a knob. The side of the pressure block has a limiting pin that cooperates with the limiting block. Air nozzles are provided on both sides of the welding seat, and wire harness clamps are also provided on the side of the welding seat.

[0016] Furthermore, the second slide group of the transfer device includes a first linear slide and a second linear slide. The second linear slide is mounted on the slide base of the first linear slide via a platform. The direction of the second linear slide is perpendicular to the direction of the first linear slide. There are two second linear slides. Vertically upward slide cylinders are fixedly connected to the slide bases of the two second linear slides. Lifting platforms are connected to the two slide cylinders. The clamping mechanism is mounted on the lifting platform and consists of multiple wire harness clamps.

[0017] Furthermore, auxiliary clamps are provided on the front and rear sides of the testing platform. The auxiliary clamps include mechanical clamps and clamping blocks. The clamping blocks are fixed on the jaws of the mechanical clamps. The clamping blocks are square. A rotary pressing cylinder is also provided on the side of the testing platform. A pressing block is provided at the head end of the rotary pressing cylinder.

[0018] The platform is connected to a linear slide table that drives the platform to slide via a connecting rod.

[0019] The push block is disposed inside the lifting seat. The lower part of the lifting seat is provided with a linear guide rail. The lifting seat includes a seat body, a guide block, a locking block, a lead screw, and a knob. The linear guide rail is disposed at the lower part of the seat body. The guide block is disposed on the seat body. The guide block is provided with a guide groove. The rear end of the push block is disposed in the guide groove and the shape of the rear end corresponds to the guide groove. The rear end of the push block is provided with a vertical screw hole. The lead screw is disposed in the screw hole. The upper part of the lead screw is connected to the knob. The locking block is disposed on the upper part of the guide block. The locking block is provided with a through hole with an opening on one side. The lead screw passes through the through hole. A locking bolt is provided at the position of the through hole.

[0020] The driving device includes an electric cylinder and a slide block. The slide block has two interconnected cross-shaped upper and lower channels formed by a cover plate inside and above it. An upper slider and a lower slider are respectively provided in the upper and lower channels. The lower part of the upper slider is provided with an inclined groove, and the upper part of the lower slider is provided with a transmission pin. The transmission pin is inserted into the inclined groove. The lower slider is connected to the output end of the electric cylinder, which drives the lower slider to slide in the lower channel. One end of the upper slider is connected to the base.

[0021] Furthermore, the testing device also includes a test piece loading device, which includes a mounting frame, a three-axis slide, and a loading clamp. The mounting frame is disposed above the testing table, the three-axis slide is disposed on the mounting frame, and the loading clamp is disposed on the three-axis slide and moves freely under the drive of the three-axis slide. The loading clamp includes a horizontally disposed mounting plate, and a plurality of wire harness clamps are provided on the bottom surface of the mounting plate. The mounting plate is also provided with a cylinder, and the cylinder head is provided with a push plate for pushing the wire harness out of the wire harness clamp.

[0022] Based on the same concept, the present invention also proposes a method for ultrasonic welding inspection of terminal wire harnesses. This method is applicable to the aforementioned integrated ultrasonic welding inspection machine for terminal wire harnesses, and includes the following steps:

[0023] Step 1: Place the two terminals to be soldered on the terminal clamp, and place the two wire harnesses to be soldered on the clamping mechanism;

[0024] Step 2: The terminal feeding device moves one of the terminals and places it on the welding table. Then, the transfer device moves the clamping mechanism and moves the wire harness above the terminal on the welding table for welding.

[0025] Step 3: The terminal feeding device moves another terminal and places it on another welding table. Then, the transfer device moves the clamping mechanism and moves another wire harness above the terminal on the other welding table for welding.

[0026] Step 4: The transfer device moves the two welded wire harnesses to the front of the detection device and places them on the detection table by manual or mechanical means, so that the welding area is stuck in the recess on the support block. The table slides and moves the second detection camera to the side of the detection table. The first and second detection cameras perform visual inspection of the welding area.

[0027] Step 5: The sliding plate aligns the peel test device with the side of the welding area. Driven by the drive device, the pusher applies a radial force to the welding area to perform the peel test. At the same time, the terminal feeding device and the transfer device return to their initial positions.

[0028] Compared with existing technologies, this solution uses two sets of ultrasonic welders, adapted to two welding stations. Terminal feeding devices and transfer devices are set on the front and rear sides respectively for terminal feeding and wire harness feeding. Specifically, the first wire harness is welded to the terminal on the first welding station, and then the second wire harness is welded to the terminal on the second welding station. At this time, the first welding station is idle and cooling. After the second welding station is completed, the transfer device transports the two welded wire harness terminals to the inspection device, and then returns to the initial position for the next round of welding. At the same time, the inspection device performs visual inspection and peel test on the welding area. The whole process is more efficient. The peel test also performs radial strength test on the welding area to ensure that the welding strength meets the requirements. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of the structure of the present invention.

[0031] Figure 2 This is a top view of the present invention.

[0032] Figure 3 This is a schematic diagram of the terminal feeding device.

[0033] Figure 4 This is a schematic diagram of the welding device.

[0034] Figure 5This is a schematic diagram of the back structure of the welding device.

[0035] Figure 6 This is an exploded view of the welding station.

[0036] Figure 7 This is a schematic diagram of the transfer device.

[0037] Figure 8 This is a schematic diagram of the detection device.

[0038] Figure 9 This is a schematic diagram of the testing station structure.

[0039] Figure 10 This is a schematic diagram of the peeling test device.

[0040] Figure 11 This is a schematic diagram of the device for feeding the part to be tested.

[0041] Figure 12 This is a schematic diagram of the alignment device. Detailed Implementation

[0042] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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 invention.

[0043] To address the problems existing in the relevant prior art, this invention proposes an integrated ultrasonic welding inspection machine and inspection method for terminal wire harnesses. The principle and structure of this invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0044] Please see Figures 1 to 12 A terminal wire harness ultrasonic welding and testing integrated machine includes a terminal feeding device 1, a welding device 2, a transfer device 3, and a testing device 4.

[0045] Specifically, the terminal feeding device 1 is located on the back of the welding device 2 and is used to transport and place the terminals onto the welding device 2. The transfer device 3 is located on the front of the welding device 2. The wire harness to be welded is first placed on the transfer device and then transported to the welding device. After welding is completed, the transfer device transports the welded wire harness to the testing device for testing. In this embodiment, the operator stands on the side closest to the transfer device, which is the front, and the corresponding side is the back. The operator faces the equipment. The left and right direction is defined as the x-axis, the front and back direction as the y-axis, and the up and down direction as the z-axis. The following descriptions will all use this direction.

[0046] The terminal feeding device 1 is located on one side of the welding device. Specifically, the terminal feeding device 1 is located on the back of the welding device 2. It transports the terminals from the back of the welding device to the welding device 2. The terminal feeding device 1 includes a terminal clamp 1a and a first slide group 1b for driving the terminal clamp to move. The terminal clamp 1a is used to clamp and fix the terminal to be welded, and the first slide group 1b is used to drive the terminal clamp to move freely. In practice, the terminal feeding can be done manually or with the help of a robotic arm to place the terminal onto the terminal clamp.

[0047] The welding device 2 includes an ultrasonic welding machine 2a that can be raised and lowered, and a welding table 2b is set below the ultrasonic welding machine 2a. The ultrasonic welding machine 2a is a commonly used device in the field of ultrasonic welding, including a welding head 2aa, an amplitude transformer 2ab, a transducer 2ac, an ultrasonic generator, and other necessary equipment components. The welding table 2b is specifically set below the welding head 2aa. The welding process is carried out on the welding table 2b. The terminal feeding device places the terminal onto the welding table 2b, and then the transfer device moves the end of the wire harness that needs to be welded to the top of the terminal. The welding head 2aa then descends to perform welding.

[0048] The transfer device 3 includes a clamping mechanism 3a for clamping the wire harness and a second slide group 3b for driving the clamping mechanism 3a to move; the detection device 4 includes a detection table 4a, a first detection camera 4j is arranged above the detection table 4a, a sliding platform 4b is arranged on the side of the detection table 4a, and a peel test device 4c and a second detection camera 4d are arranged on the platform 4b. Specifically, the detection device is arranged on the right side of the welding device 2, and the transfer device is arranged along the left and right direction. In actual use, the transfer device 3 can move the wire harness to be welded to the front of the welding device 2 for wire harness loading. After welding is completed, the transfer device moves the welded wire harness to the detection device for detection. The first detection camera 4j and the second detection camera 4d respectively perform visual inspection of the welding area from above and the side to determine whether the width and thickness of the welded area meet the requirements.

[0049] The testing platform 4a includes a support block 4aa and a support block 4ab. The support block 4ab is fixedly connected above the support block 4aa. The upper part of the support block 4ab has a recess corresponding to the welding area. The welding area refers to the area where the terminal and wire harness are welded and fixed during welding. Specifically, in this embodiment, the shape of the recess above the support block is the same as that of the terminal in the welding area, and the depth of the recess is the same as the thickness of the terminal in the welding area. During testing, the terminal part of the welding area is stuck in the recess. The peel test device 4c includes a push block 4ca and a driving device 4cb that drives the push block to move. Block 4ca is located on the side of support block 4ab. When the terminal part of the welding area is located in the recess of support block 4ab, the head of push block 4ca is at the same height as the wire harness part of the welding area. Specifically, push block 4ca is located on the left or right side of support block 4ab. The peel test is performed by driving device 4cb to move push block 4ca toward the welding area and contact the side of the wire harness part of the welding area. An external force is applied to the welding area from the side. If the terminal part and the wire harness part of the welding area do not deform or slide relative to each other under a certain external force, it indicates that the weld is qualified and there is no cold solder joint.

[0050] To address the issue of efficiency issues caused by the need for cooling after welding, this embodiment employs two ultrasonic welding machines 2a, each with a welding platform 2b at its lower part and two inspection platforms 4a. Each inspection platform 4a has a first inspection camera 4j on its upper part, and a peel test device 4c and a second inspection camera 4d are correspondingly located on both sides of the two inspection platforms 4a. The terminal feeding device 1 and the transfer device 3 can simultaneously feed the two welding platforms 2b. Specifically, the feeding device 1 and the transfer device 3 first feed the first welding platform 2b. After welding is completed, the feeding device 1 and the transfer device 3 feed the second welding platform. At this time, the first welding platform can be cooled. After welding is completed on the second welding platform, the welded wire harness is moved by the transfer device to the inspection device 4 for inspection. This process is then repeated, eliminating the need for waiting and allowing the two welding platforms to cool alternately, effectively improving work efficiency.

[0051] Terminal clamp 1a includes a jaw 1aa and a clamping block 1ab. The jaw 1aa can be a commercially available pneumatic jaw. The clamping block 1ab is set on the jaw portion. The clamping block 1ab is L-shaped and is set facing each other on the jaw portion of the jaw 1aa, thus forming a recess above the two clamping blocks 1ab to hold the terminal. The first slide group 1b includes a first linear slide 1ba, a linear guide rail 1bb, a platform 1bc, a second linear slide 1bd, a lifting platform 1be, and a telescopic mechanism 1bf. The first linear slide 1ba and the linear guide rail 1bb are arranged parallel to each other along the x-axis, and the first linear slide is equipped with the necessary servo drive system. The lower part of the platform 1bc is connected to the slider of the linear guide rail 1bb and the slide base of the first linear slide 1ba. Driven by the first linear slide, the platform 1bc can reciprocate along the x-axis. The sliding mechanism comprises two second linear slides 1bd, which are arranged parallel to each other on the platform 1bc. The sliding direction of the second linear slides 1bd is perpendicular to the sliding direction of the first linear slide 1ba, that is, the second linear slides are arranged along the y-axis. Each of the two second linear slides 1bd has a lifting platform 1be on its slide base, and each of the two lifting platforms 1be has a telescopic mechanism 1bf on its upper part. The telescopic mechanism 1bf is a slide cylinder, and the head end of the two slide cylinders is provided with a terminal clamp 1a. The lifting platform 1be includes a square frame 1bea, on which two vertically upward slide cylinders 1bec are provided. The upper part of the two vertically upward slide cylinders 1bec is connected to a base plate 1bed. The telescopic mechanism is set on the base plate, and the telescopic direction of the telescopic mechanism 1bf is parallel to the sliding direction of the second linear slides 1bd.

[0052] In this embodiment, a position is set as the loading position within the stroke range of the first linear slide and the second linear slide. The terminal is placed on the terminal clamp 1a by manual or robotic arm loading. Then, the terminal is placed on the welding table with the cooperation of the first linear slide, the second linear slide, the lifting platform 1be and the telescopic mechanism 1bf.

[0053] The welding device 2 includes a frame 2c, on which a drive mechanism 2d is provided to drive the ultrasonic welding machine 2a to rise and fall. The drive mechanism 2d includes a cylinder 2da, an adapter block 2db, and a connecting seat 2dc. The cylinder 2da is located on the upper part of the frame 2c and faces downward. The head of the cylinder 2da is connected to the adapter block 2db through a floating joint. The lower part of the adapter block 2db is connected to the connecting seat 2dc. The connecting seat 2dc is fixedly connected to the ultrasonic welding machine 2a. Specifically, the connecting seat 2dc is fixedly connected to the welding head 2aa of the ultrasonic welding machine 2a. Thus, the extension and retraction of the cylinder 2da drives the ultrasonic welding machine 2a to rise or fall. When the welding head falls to the terminal and wire harness position, the ultrasonic welding machine is started to perform welding work. After welding is completed, the ultrasonic welding machine rises to cool down. After cooling is completed, the welding work can be repeated.

[0054] To ensure accuracy during the lifting process, a vertical platform 2dd is connected to the adapter block 2db. The back of the platform 2dd is connected to the frame 2c via a linear guide rail 2de. A limiting block 2df is also provided on the back of the platform, with a U-shaped groove. The frame 2c is also equipped with a limiting mechanism 2e, which includes a motor 2ea, a lead screw 2eb, and a lead screw slider 2ec. The frame 2c has a vertical slot, and the lead screw 2eb is placed in the slot. The upper part of the lead screw 2eb is connected to the output end of the motor 2ea via a bevel gear. The lead screw slider 2ec is sleeved on the lead screw 2eb and engaged with it. Inside the hollowed-out groove, the lead screw 2eb is engaged in the U-shaped slot of the limiting block 2df. The limiting block 2df is located above the lead screw slider 2ec. It is raised and lowered synchronously with the platform 2dd and the adapter block. The back of the platform 2dd is equipped with a vertical linear guide rail, which ensures that the ultrasonic welding machine will not be misaligned in the horizontal direction when it is raised and lowered. At the same time, the limiting block 2df is raised and lowered synchronously with the ultrasonic welding machine. When the limiting block descends, it will contact the lead screw slider. This is the extreme position of descent. The height of the lead screw slider is adjusted by the motor 2ea to set the extreme position of the ultrasonic welding machine's descent, which can effectively prevent the welding head from making hard contact with the welding table.

[0055] The welding table 2b includes a welding seat 2ba. A sliding groove is formed on each side of the welding seat 2ba by limiting plates 2bb. A cylinder 2bc is located at the bottom of the groove, and a slider seat 2bd is connected to the cylinder 2bc. A slidable pressure block 2bf and a driving assembly 2bg are located above the slider seat 2bd. Specifically, in this embodiment, by setting limiting plates 2bb in the front-back, left-right, and right directions of the welding seat 2ba, and providing protrusions on the inner side of the limiting plates, a sliding track is formed for the slider seat 2bd to slide. A cylinder is located at the bottom of the track to drive the slider seat 2bd to slide within the track, ultimately achieving the purpose of adjusting the height of the pressure block set on the slider seat 2bd. The driving assembly 2bg includes a channel plate 2bga, on which a cover plate 2bgb is provided. The channel plate 2bga and the top surface of the slider seat 2bd form a lower channel, in which a slidable slider 2bgc is located. The channel plate 2bga and the cover plate 2bgb form an upper channel, in which a slidable... The pressure block 2bf is connected to the upper and lower channels via a straight slot. A transmission pin 2bgd is inserted and fixed to the lower part of the pressure block 2bf. The slider 2bgc has a slanted groove, and the lower part of the transmission pin 2bgd passes through the straight slot and is inserted into the slanted groove. A cylinder 2bge is connected to the slider 2bgc to drive its sliding motion. The upper part of the channel plate 2bga and the cover plate also form a limiting channel. A lead screw 2bgf is installed in the limiting channel. The direction of the lead screw 2bgf is parallel to the upper channel. A limiting block 2bgg is provided, which has a threaded hole that cooperates with the lead screw 2bgf. One end of the limiting block 2bgg has a T-shaped protrusion. The channel plate 2bga has a T-shaped guide groove corresponding to the protrusion. The lead screw 2bgf extends to the outside of the channel plate 2bga and has a knob 2bgh. The side of the pressure block 2bf has a limiting pin 2bgi that cooperates with the limiting block 2bgg. The welding seat 2ba has air nozzles 2bh on both sides. The side of the welding seat 2ba also has a wire harness clamp 2bi.

[0056] Specifically, in this embodiment, cylinder 2bge pushes slider 2bgc to slide in the lower channel. Since the transmission pin 2bgd is inserted into the inclined groove of slider 2bgc, it can push pressure block 2bf to slide in the upper channel. In this way, pressure block 2bf can be driven to move back and forth. Specifically, pressure block 2bf and drive assembly 2bg are provided on both sides of welding seat 2ba. When the terminal is placed on welding seat 2ba, cylinders 2bc on both sides first drive their respective connected pressure blocks to rise, and then move towards each other under the drive of cylinder 2bge, so that... The pressure block head is positioned above the terminal. Then, cylinder 2bc drives the pressure block to descend, thus pressing the terminal onto the welding seat 2ba through the two pressure blocks. The two pressure blocks 2bf have diamonds embedded at their heads, forming a square area. During welding, the wire harness is located within this square area, and the welding head also performs welding within this area. The wire harness is pressed by the welding head and welded to the upper surface of the terminal by high-frequency vibration. After welding, cylinders 2bc and 2bge move in opposite directions to release the welded terminal and wire harness.

[0057] During the sliding of the pressure block 2bf in the upper channel, the side limiting pin 2bgi will move synchronously. During this process, the limiting pin 2bgi will contact the side of the limiting block 2bgg. This is the limit position of the pressure block 2bf moving towards the welding seat 2ba. By rotating the knob 2bgh, the limiting block 2bgg can be slid in the direction of the screw, and this limit position can be adjusted. With the above settings, the two pressure blocks can be prevented from colliding, which can effectively protect the head end of the pressure block 2bf. For easy observation, a position display is also provided on the screw 2bgf to determine the position of the limiting block 2bgg in the limiting channel.

[0058] The wire harness clamp 2bi is a commonly used device in this field. Specifically, it can be a thin pneumatic gripper connected to two opposing claw plates with V-grooves. The thin pneumatic gripper drives the claw plates to move towards or relative to each other to complete the gripping and releasing of the wire harness.

[0059] Taking the clamping of two wire harnesses at a time as an example, the second slide group 3b of the transfer device 3 includes a first linear slide 3ba and a second linear slide 3bb. The first linear slide is set along the x-axis, and the second linear slide 3bb is mounted on the slide of the first linear slide 3ba via a platform 3bc. The direction of the second linear slide 3bb is perpendicular to the direction of the first linear slide 3ba, that is, the second linear slide is set along the y-axis. There are two second linear slides 3bb, and each of the slides of the two second linear slides 3bb is fixedly connected to a vertically upward... The slide cylinder 3bd has two lifting platforms 3be connected to it. The lifting platform is a slide cylinder. The clamping mechanism 3a is installed on the lifting platform 3be. The clamping mechanism 3a consists of multiple wire harness clamps. The first linear slide, the second linear slide and the lifting platform 3be work together to drive the clamping mechanism 3a to move freely. The wire harness clamps used are the same as the wire harness clamp 2bi in structure. Each lifting platform is equipped with two wire harness clamps. During transportation, the two wire harness clamps clamp synchronously to effectively ensure the stability of the clamping and prevent shaking.

[0060] In practical use, to ensure the consistency of the wire harness placement position each time, an alignment device 5 is also set up. The alignment device 5 includes a slide cylinder 5a arranged along the y-axis. Two push plates 5b are fixedly connected to the head end of the slide cylinder 5a. The push plates 5b are provided with slots 5c for placing one end of the wire harness. The distance between the slots 5c on the two push plates is the same as the distance between the wire harness clamps between the two lifting platforms 3be. In practical use, the alignment device is set within the stroke range of the first linear slide. When the wire harness clamp is driven to the first linear slide, the second linear slide and the lifting platform to the same height as the slots on the push plates and aligned in the y-axis direction, the operator places the wire harness in the wire harness clamp, so that the end of the wire harness to be welded is located in the slot. At this time, the slide cylinder 5a pushes to make the two wire harnesses slide in the wire harness clamp. Then the wire harness clamp clamps and moves to feed the material. At this time, the alignment device plays the role of position calibration. Each feeding is aligned by the alignment device to achieve the same feeding position each time.

[0061] In some other embodiments, the two lifting platforms 3be are connected by a synchronous plate 3c, so that the two clamping mechanisms 3a move synchronously. In this way, each time two wire harnesses are fed onto the two clamping mechanisms 3a, one clamping mechanism is aligned with a welding device under the action of the first linear slide 3ba. At this time, the second linear slide is used to feed the wire harness and complete the welding. After the welding is completed, the second linear slide retracts and, under the action of the first linear slide, aligns the other clamping mechanism with the other welding device. At this time, the second linear slide extends to feed the wire harness and complete the welding of the other wire harness. After the welding is completed, the second linear slide repeats the retraction operation and moves to the front end of the detection device 4 under the action of the first linear slide. The two wire harnesses that have been welded are placed on the detection device for detection by manual or mechanical means.

[0062] The front and rear sides of the testing table 4a are provided with auxiliary clamps 4e. The auxiliary clamps 4e include mechanical clamps 4ea and clamping blocks 4eb. The clamping blocks 4eb are fixed on the jaws of the mechanical clamps 4ea. The clamping blocks 4eb are square. The side of the testing table 4a is also provided with a rotary clamping cylinder 4f. The head end of the rotary clamping cylinder 4f is provided with a pressure block 4g. Specifically, when the soldered wire harness is placed on the testing table, the auxiliary clamps 4e on the front and rear sides clamp the front terminal part and the rear wire harness part to prevent shaking during the testing process. At the same time, during the peel test, the rotary clamping cylinder 4f drives the pressure block 4g to rotate and press the soldered area into the recess of the support block 4ab to prevent the soldered area from sliding out of the recess.

[0063] The platform 4b is connected to a linear slide 4h via a connecting rod, which drives the platform 4b to slide. Specifically, in this embodiment, when two wire harnesses need to be tested simultaneously, two testing platforms 4a are set up along the x-axis. A platform 4b is set on each of the left and right sides of the two testing platforms. A peel test device and a second testing camera are respectively set on the platform. At the same time, the back of the two platforms are connected to the same linear slide via a connecting rod. Thus, driven by the same linear slide 4h, the two platforms slide synchronously, so that the second testing camera and peel test device on the two platforms are aligned with the corresponding testing platforms for testing.

[0064] Push block 4ca is installed inside lifting seat 4cc. Linear guide rail 4cd is provided at the lower part of lifting seat 4cc. Lifting seat 4cc includes seat body 4cca, guide block 4ccb, locking block 4ccc, lead screw 4ccd, and knob 4cce. Linear guide rail 4cd is provided at the lower part of seat body 4cca. Guide block 4ccb is installed on seat body 4cca. Vertical guide groove is provided inside guide block 4ccb. The rear end of push block 4ca, i.e., the end of push block 4ca away from detection table 4a, is located in the guide groove, and the shape of the rear end is opposite to the guide groove. The push block 4ca has a vertical screw hole at its rear end, and the lead screw 4ccd is set in the screw hole. A knob is connected to the upper part of the lead screw 4ccd. The locking block 4ccc is set on the upper part of the guide block 4ccb. The locking block 4ccc has a through hole with an opening on one side. The lead screw 4ccd passes through the through hole. A locking bolt is set at the position of the through hole. By rotating the knob, the push block 4ca moves up and down in the guide block 4ccb and is locked by the locking block, so as to adjust the height of the push block and align the head of the push block 4ca with the wire harness part of the welding area.

[0065] The drive unit 4cb includes an electric cylinder 4cba and a slide block 4cbb. The slide block 4cbb has two interconnected cross-shaped upper and lower channels formed by a cover plate 4cbc inside and above it. An upper slider 4cbd and a lower slider 4cbe are respectively located in the upper and lower channels. The lower part of the upper slider 4cbd has a sloping groove, and the upper part of the lower slider 4cbe has a transmission pin 4cbf, which is inserted into the sloping groove. The lower slider 4cbe is connected to the output end of the electric cylinder 4cba, causing it to slide within the lower channel. One end of the upper slider 4cbd is connected to the base 4cca, and the electric cylinder 4cba drives the lower slider to slide back and forth within the lower channel. This movement is further driven by the transmission pin and the sloping groove on the lower slider, ultimately causing it to slide left and right. Simultaneously, the lifting base slides, allowing the push block 4ca to contact the welding area of ​​the wire harness and apply external force for peel testing or to move away from the welding table for loading and unloading.

[0066] The testing device 4 also includes a test piece loading device 4i, which includes a mounting frame 4ia, a three-axis slide 4ib, and a loading clamp 4ic. The mounting frame 4ia is positioned above the testing table 4a, the three-axis slide 4ib is positioned on the mounting frame 4ia, and the loading clamp 4ic is positioned on the three-axis slide 4ib and moves freely under the drive of the three-axis slide 4ib. The three-axis slide 4ib is a commonly used slide assembly in the field, specifically capable of driving the loading clamp 4ic to move freely on the xyz axes. The loading clamp 4ic includes a horizontally positioned mounting plate 4ica, and several wire harness clamps 4icb are provided on the bottom surface of the mounting plate 4ica. The mounting plate 4ica is also provided with a cylinder 4icc, and the cylinder head 4icc has a push plate 4icd for pushing the wire harness out of the wire harness clamps 4icb.

[0067] The specific testing steps are as follows: When the two welded wire harnesses are moved to the front end of the testing device 4 by the transfer device 3, the three-axis slide 4ib drives the loading clamp 4ic to move above the clamping mechanism and clamps the welded wire harnesses. Then, driven by the three-axis slide 4ib, it moves to the top of the testing table 4a, so that the welding area of ​​the two wire harnesses is aligned with the two testing tables. Then, the wire harness clamp 4icb is released and the wire harness is pushed out of the wire harness clamp by the push plate 4icd. The wire harness falls onto the testing table 4a. At this time, the auxiliary clamps on the front and rear sides clamp the wire harness and the terminals. Then, the linear slide 4h drives the table to slide, so that the second testing camera is located on the side of the testing table 4a. The first testing camera above the testing table and the second testing camera on the side simultaneously perform visual inspection on the welding area. The specific visual inspection is a common technical means in this field and is not specifically limited here. The length and width of the welding area are determined by visual inspection to see if they meet the requirements.

[0068] After visual inspection is completed, the linear slide 4h drives the platform to slide, aligning the peel test device 4c with the side of the welding area. The rotating clamping cylinder drives the pressure block to press on the top of the welding area. Then, driven by the electric cylinder 4cba, the push block 4ca moves towards the welding area and contacts the side of the welding area. A rated external force is applied by the electric cylinder. If the welding area does not misalign or deform under the action of the external force, the welding is considered qualified; otherwise, the welding is considered unqualified. Whether misalignment or deformation occurs can be confirmed by taking pictures with the upper inspection camera.

[0069] Based on the same concept, the present invention also proposes a method for ultrasonic welding inspection of terminal wire harnesses. This method is applicable to the aforementioned integrated ultrasonic welding inspection machine for terminal wire harnesses, and includes the following steps:

[0070] Step 1: Place the two terminals to be soldered on the terminal clamp 1a, and place the two wire harnesses to be soldered on the clamping mechanism 3a;

[0071] Step 2: The terminal feeding device 1 moves one of the terminals and places it on the welding table 2b. Then, the transfer device 3 moves the clamping mechanism 3a and moves the wire harness above the terminal on the welding table 2b for welding.

[0072] Step 3: The terminal feeding device 1 moves another terminal and places it on another welding station 2b. Then, the transfer device 3 moves the clamping mechanism 3a and moves another wire harness above the terminal of the other welding station for welding.

[0073] Step 4: The transfer device 3 moves the two welded wire harnesses to the front of the inspection device and places them on the inspection table by manual or mechanical means, so that the welded area is stuck in the recess on the support block. The table slides and moves the second inspection camera to the side of the inspection table. The first inspection camera 4j and the second inspection camera 4d perform visual inspection on the welded area.

[0074] Step 5: The sliding plate drives the peel test device 4c to align with the side of the welding area. Under the drive of the drive device, the push block applies a radial external force to the welding area to perform the peel test. At the same time, the terminal feeding device 1 and the transfer device 3 return to their initial positions.

[0075] The above are merely preferred embodiments of the present invention and are not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A terminal wire harness ultrasonic welding inspection integrated machine, characterized in that: It includes a terminal feeding device, a welding device, a transfer device, and a testing device; The terminal feeding device is located on one side of the welding device, and the terminal feeding device includes a terminal clamp and a first slide group for driving the terminal clamp to move. The welding device includes a liftable ultrasonic welding machine, with a welding table set below the ultrasonic welding machine. The transfer device includes a clamping mechanism for holding the wire harness and a second slide group for driving the clamping mechanism to move. The detection device includes a detection platform, a first detection camera is arranged above the detection platform, a sliding platform is arranged on the side of the detection platform, and a peel test device and a second detection camera are arranged on the platform. The testing station includes a support block and a support block. The support block is fixedly connected above the support block. The upper part of the support block has a recess corresponding to the welding area, and the depth of the recess is the same as the thickness of the terminal. The peel test device includes a push block and a driving device for driving the push block to move. The push block is located on the side of the support block. When the terminal part of the welding area is located in the recess of the support block, the head of the push block is at the same height as the wire harness part of the welding area.

2. The terminal wire harness ultrasonic welding inspection integrated machine according to claim 1, characterized in that: There are two ultrasonic welding machines, each with a welding table at its lower part. There are also two testing tables, each with a first testing camera at its upper part. The peeling test device and the second testing camera are respectively provided on both sides of the two testing tables.

3. A terminal wire harness ultrasonic welding inspection integrated machine according to claim 1 or 2, characterized in that: The terminal clamp includes a jaw and a clamping block. The clamping block is L-shaped, and two clamping blocks are arranged facing each other and connected to the jaw portion of the jaw. The first slide group includes a first linear slide, a linear guide rail, a platform, a second linear slide, a lifting platform, and a telescopic mechanism. The first linear slide is arranged parallel to the linear guide rail. The lower part of the platform is connected to the slider of the linear guide rail and the slide base of the first linear slide. There are two second linear slides arranged parallel to each other on the platform. The sliding direction of the second linear slide is perpendicular to the sliding direction of the first linear slide. The lifting platform is provided on the slide base of each of the two second linear slides. The upper part of each of the two lifting platforms is also provided with a telescopic mechanism. The telescopic mechanism is a slide cylinder, and the terminal clamp is provided at the head end of each of the two slide cylinders. The lifting platform includes a square frame. Two vertically upward slide cylinders are provided on the square frame. The upper part of the two vertically upward slide cylinders is connected to a base plate. The telescopic mechanism is provided on the base plate. The telescopic direction of the telescopic mechanism is parallel to the sliding direction of the second linear slide.

4. A terminal wire harness ultrasonic welding inspection integrated machine according to claim 1 or 2, characterized in that: The welding device includes a frame, on which a drive mechanism is provided to drive the ultrasonic welding machine to move up and down. The drive mechanism includes a cylinder, an adapter block, and a connecting seat. The cylinder is located on the upper part of the frame and faces downward. The head end of the cylinder is connected to the adapter block through a floating joint. The lower part of the adapter block is connected to the connecting seat. The connecting seat is fixedly connected to the ultrasonic welding machine.

5. The terminal wire harness ultrasonic welding inspection integrated machine according to claim 4, characterized in that: The adapter block is also connected to a vertical platform. The back of the platform is connected to the frame via a linear guide rail. A limiting block is also provided on the back of the platform. The limiting block has a U-shaped groove. The frame is also provided with a limiting mechanism, which includes a motor, a lead screw, and a lead screw slider. The frame has a vertical hollow groove. The lead screw is set in the hollow groove. The upper part of the lead screw is connected to the output end of the motor via a bevel gear. The lead screw slider is sleeved on the lead screw and is engaged in the hollow groove. The lead screw is engaged in the U-shaped groove of the limiting block. The limiting block is located above the lead screw slider.

6. The terminal wire harness ultrasonic welding inspection integrated machine according to claim 4, characterized in that: The welding station includes a welding seat, with a sliding groove formed on each side of the welding seat by limiting plates. A cylinder is located at the bottom of the sliding groove, and a slider seat is connected to the cylinder. Above the slider seat is a slidable pressure block and a driving assembly for driving the pressure block to slide. The driving assembly includes a channel plate with a cover plate. The channel plate and the top surface of the slider seat form a lower channel, within which a slidable slider is located. The channel plate and the cover plate form an upper channel, within which a slidable pressure block is located. The upper and lower channels are connected by a straight slot. A transmission pin is inserted and fixed to the lower part of the pressure block. The slider has an inclined groove. The lower part of the transmission pin passes through the straight slot and is inserted into the inclined slot. The slider is connected to a cylinder that drives the slider to slide. The upper part of the channel plate and the cover plate also form a limiting channel. A lead screw is provided in the limiting channel. The direction of the lead screw is parallel to the upper channel. A limiting block is provided in the limiting channel. The limiting block has a threaded hole that cooperates with the lead screw. One end of the limiting block has a T-shaped protrusion. The channel plate has a T-shaped guide groove corresponding to the protrusion. The lead screw extends to the outside of the channel plate and has a knob. The side of the pressure block has a limiting pin that cooperates with the limiting block. Air nozzles are provided on both sides of the welding seat. A wire harness clamp is also provided on the side of the welding seat.

7. A terminal wire harness ultrasonic welding inspection integrated machine according to claim 1 or 2, characterized in that: The second slide group of the transfer device includes a first linear slide and a second linear slide. The second linear slide is mounted on the slide base of the first linear slide via a platform. The direction of the second linear slide is perpendicular to the direction of the first linear slide. There are two second linear slides. Each of the two slide bases of the second linear slides is fixedly connected to a vertically upward slide cylinder. Each of the two slide cylinders is connected to a lifting platform. The clamping mechanism is mounted on the lifting platform and consists of multiple wire harness clamps.

8. A terminal wire harness ultrasonic welding inspection integrated machine according to claim 1 or 2, characterized in that: The testing platform is provided with auxiliary clamps on the front and rear sides. The auxiliary clamps include mechanical clamps and clamping blocks. The clamping blocks are fixed on the jaws of the mechanical clamps. The clamping blocks are square. The testing platform is also provided with a rotary pressing cylinder on the side. The head end of the rotary pressing cylinder is provided with a pressing block. The platform is connected to a linear slide table that drives the platform to slide via a connecting rod. The push block is disposed inside the lifting seat. The lower part of the lifting seat is provided with a linear guide rail. The lifting seat includes a seat body, a guide block, a locking block, a lead screw, and a knob. The linear guide rail is disposed at the lower part of the seat body. The guide block is disposed on the seat body. The guide block is provided with a guide groove. The rear end of the push block is disposed in the guide groove and the shape of the rear end corresponds to the guide groove. The rear end of the push block is provided with a vertical screw hole. The lead screw is disposed in the screw hole. The upper part of the lead screw is connected to the knob. The locking block is disposed on the upper part of the guide block. The locking block is provided with a through hole with an opening on one side. The lead screw passes through the through hole. A locking bolt is provided at the position of the through hole. The driving device includes an electric cylinder and a slide block. The slide block has two interconnected cross-shaped upper and lower channels formed by a cover plate inside and above it. An upper slider and a lower slider are respectively provided in the upper and lower channels. The lower part of the upper slider is provided with an inclined groove, and the upper part of the lower slider is provided with a transmission pin. The transmission pin is inserted into the inclined groove. The lower slider is connected to the output end of the electric cylinder, which drives the lower slider to slide in the lower channel. One end of the upper slider is connected to the base.

9. The terminal wire harness ultrasonic welding inspection integrated machine according to claim 8, characterized in that: The testing device also includes a test piece loading device, which includes a mounting frame, a three-axis slide, and a loading clamp. The mounting frame is positioned above the testing table, the three-axis slide is mounted on the mounting frame, and the loading clamp is mounted on the three-axis slide and moves freely under the drive of the three-axis slide. The loading clamp includes a horizontally positioned mounting plate, and several wire harness clamps are provided on the bottom surface of the mounting plate. The mounting plate is also equipped with a cylinder, and the cylinder head is provided with a push plate for pushing the wire harness out of the wire harness clamp.

10. A method for ultrasonic welding inspection of terminal wire harnesses, characterized in that: This method is applicable to the ultrasonic welding and testing integrated machine for terminal wire harnesses as described in any one of claims 2-9, and the method includes the following steps: Step 1: Place the two terminals to be soldered on the terminal clamp, and place the two wire harnesses to be soldered on the clamping mechanism; Step 2: The terminal feeding device moves one of the terminals and places it on the welding table. Then, the transfer device moves the clamping mechanism and moves the wire harness above the terminal on the welding table for welding. Step 3: The terminal feeding device moves another terminal and places it on another welding table. Then, the transfer device moves the clamping mechanism and moves another wire harness above the terminal on the other welding table for welding. Step 4: The transfer device moves the two welded wire harnesses to the front of the detection device and places them on the detection table by manual or mechanical means, so that the welding area is stuck in the recess on the support block. The table slides and moves the second detection camera to the side of the detection table. The first and second detection cameras perform visual inspection of the welding area. Step 5: The sliding plate aligns the peel test device with the side of the welding area. Driven by the drive device, the pusher applies a radial force to the welding area to perform the peel test. At the same time, the terminal feeding device and the transfer device return to their initial positions.

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