Ultrasonic composite welding gun

Abstract

The utility model discloses an ultrasonic composite welding gun which comprises a connecting unit, a push-pull wire unit, a welding gun body and an ultrasonic transduction unit, and the connecting unit is fixedly connected to a motion execution structure during working; the wire pushing and drawing unit is arranged on the connecting unit and used for pushing welding wires; the welding gun body is arranged on one side of the wire pushing and drawing unit, and a welding wire penetrates through the welding gun body to reach a working area. A hollow wire penetrating part is formed in the ultrasonic transduction unit, the ultrasonic transduction unit is coaxially arranged between the wire pushing and drawing unit and the welding gun body, and during working, vibration acts on a welding wire. The novel ultrasonic composite welding gun mechanism is provided, the welding wire is subjected to ultrasonic vibration in a molten pool, crystal grains in condensed metal are improved, and the mechanical property is improved.

Description

Technical Field

[0001] The utility model relates to the field of welding, in particular to an ultrasonic composite welding gun. Background Art

[0002] Ultrasonic hybrid welding is a new welding technology that introduces ultrasonic waves into traditional welding methods. It can effectively improve welding quality and efficiency, reduce welding costs and environmental pollution. Ultrasonic hybrid welding technology has been widely used in arc welding, brazing, stir friction welding and other welding methods, and has achieved remarkable results.

[0003] For ultrasonic arc additive welding, some equipment connects the ultrasonic frequency to the substrate to make the entire substrate vibrate, thereby trying to improve the grain inside the molten pool. However, as the welding object increases in size and moves away from the ultrasonic source of the substrate, the ultrasonic wave cannot act well on the welding molten pool due to the change in distance, resulting in failure of the improvement purpose. The ultrasonic source added to the substrate is larger in size and wastes more production costs. There are also methods that use ultrasonic waves to vibrate the welding molten pool in the air, but this method can only change the surface of the molten pool and cannot make changes deep inside the molten pool. There are also technical solutions that use a TIG welding gun to connect the tungsten needle to the ultrasonic wave to vibrate the molten pool. This method is mostly used for side wire feeding, and because the structure is not compact, the additive posture is subject to certain restrictions, and more complex products cannot be printed.

[0004] In short, ultrasonic hybrid welding technology is still facing some technical difficulties, such as the optimization of ultrasonic introduction method, frequency, amplitude, phase and other parameters, the coordination between ultrasonic device and welding device, the influence mechanism of ultrasonic wave on welding molten pool, etc., which need further research and exploration. Utility Model Content

[0005] The purpose of the utility model is to provide an ultrasonic composite welding gun and a welding method, so as to at least solve some of the problems existing in the prior art.

[0006] Technical solution, according to one aspect of the present application, an ultrasonic composite welding gun comprises:

[0007] A connecting unit, which is connected and fixed to the motion execution structure during operation;

[0008] A wire pushing and pulling unit is arranged on the connecting unit and is used for pushing the welding wire;

[0009] A welding gun is arranged on one side of the push-pull wire unit, and the welding wire passes through the welding gun to reach the working area;

[0010] The ultrasonic transducer unit is formed with a hollow wire-threading portion. The ultrasonic transducer unit is coaxially arranged between the wire-pushing and pulling unit and the welding gun. When working, the ultrasonic transducer unit applies vibration to the welding wire.

[0011] According to one aspect of the present application, the push-wire unit, ultrasonic transducer unit and welding gun are coaxially fixed on the connecting unit. At least when working, the welding wire passes through the push-wire unit, ultrasonic transducer unit and welding gun along a straight or nearly straight moving path.

[0012] According to one aspect of the present application, a welding wire holder is detachably connected to one side of the ultrasonic transducer unit, and vibration is applied to the welding wire through the welding wire holder.

[0013] According to one aspect of the present application, the connecting unit includes:

[0014] The welding gun bracket is used to support and fix the push-pull wire unit and the ultrasonic transducer unit.

[0015] A gun head fixing frame, used to form a connection part of the welding gun;

[0016] Connecting block, used for detachable connection with motion actuator.

[0017] According to one aspect of the present application, the ultrasonic transducer unit comprises:

[0018] A hollow tube body, with an insulating sleeve on the inner wall and threads on the outer wall;

[0019] An upper end cover is screwed to one end of the hollow tube body;

[0020] A lower end cover is screwed to the other end of the hollow tube body;

[0021] The working piece, including piezoelectric ceramics and pole pieces, is sleeved on the hollow tube body and located between the upper end cover and the lower end cover, and an insulating tube is arranged between the working piece and the hollow tube body;

[0022] The welding wire clamp is coaxially fixed on the lower end cover.

[0023] According to one aspect of the present application, a conductive clamp, a water, electricity and gas separation block, a cooling water joint and a shielding gas joint are provided on one side of the push-pull unit; a water, electricity and gas access block is provided on the welding gun, and the water, electricity and gas access block is detachably connected to the welding gun.

[0024] According to one aspect of the present application, a plurality of pipeline grooves or pipeline grooves are provided on the connection unit.

[0025] According to one aspect of the present application, the operating frequency of the ultrasonic transducer unit is 10KHz to 80KHz.

[0026] According to one aspect of the present application, the wire feeding end of the welding wire clamp is funnel-shaped, and the cross-section gradually decreases along the direction of movement of the welding wire.

[0027] Beneficial effect: through the coaxial structure design, the welding wire can directly obtain the ultrasonic frequency, allowing the welding wire to ultrasonically vibrate in the molten pool, improving the internal grains of the metal after solidification and improving the mechanical properties. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a structural schematic diagram of the ultrasonic composite welding gun of the present application.

[0029] Figure 2 It is a cross-sectional view of the ultrasonic transducer unit of the present application.

[0030] Figure 3 It is a schematic diagram of the welding gun of this application when working.

[0031] Figure 4 It is an overall schematic diagram of ultrasonic composite welding of this application.

[0032] In the figure, the various reference numerals are respectively: fixing flange 1, connecting block 2, welding gun bracket 3, push-pull wire motor 4, locking nut 5, conductive clamp 6, water, electricity and gas separation block 7, cooling water joint 8, shielding gas joint 9, welding wire 10, transducer fixing flange 11, ultrasonic transducer 12, welding wire chuck 13, gun head fixing bracket 14, gun head fixing block 15, insulating gasket 16, water, electricity and gas access block 17, insulating sleeve 18, gun head locking nut 19, short straight welding gun 20, pipeline 21, pipeline buckle 22, ultrasonic power supply 23, welding power supply 24, upper end cover 25, stud bolt 26, insulating bushing 27, piezoelectric ceramic 28, pole piece 29, insulating sleeve 30, transducer body 31. DETAILED DESCRIPTION

[0033] like Figure 1 As shown, an ultrasonic composite welding gun is provided, which mainly includes a connecting unit, a wire pushing and pulling unit, a welding gun body and an ultrasonic transducer unit.

[0034] The main function of the connecting unit is to fix the relevant working unit on the actuator, such as the robot operating arm. Therefore, when working, the connecting unit is connected and fixed to the motion execution structure; under the drive of the motion actuator, the welding operation is performed. It should be noted that the connecting unit can be a whole or a combination of multiple mechanisms. For example, after the push-pull wire unit, the welding gun body and the ultrasonic transducer unit are combined into a whole, they are connected to the ultrasonic composite welding gun through a fixed bracket or a fixed plate. Or first fix it on a fixed plate or a fixed bracket, and then fix it on the robot operating arm through an adapter plate. In the above-mentioned embodiments, a connecting unit can be formed. Of course, a grouped design can also be adopted, that is, the push-pull wire unit, the welding gun body and the ultrasonic transducer unit are respectively fixed on a bracket or a fixed plate, and then the fixed plate or bracket is installed on the robot operating arm through a calibration plate or a positioning plate. The above embodiments are only cases, and other types of connecting units can also be designed.

[0035] The push-pull wire unit is arranged on the connection unit and is used to push the welding wire. The connection method between the push-pull wire unit and the connection unit mainly adopts a detachable connection method such as snap-fitting and screw connection. In some embodiments, it can also be set to a connection method such as welding and riveting. The welding gun body is arranged on one side of the push-pull wire unit, and the welding wire passes through the welding gun body to reach the working area. The ultrasonic transducer unit is formed with a hollow wire-threading part. The ultrasonic transducer unit is coaxially arranged between the push-pull wire unit and the welding gun, and when working, the vibration acts on the welding wire.

[0036] Coaxial means here that the axis of the welding wire, or the wire threading holes (welding wire passing holes) on the wire push-pull unit, welding gun body and ultrasonic transducer unit are on the same or nearly the same straight line. Therefore, no matter how the structures of the wire push-pull unit, welding gun body and ultrasonic transducer unit are designed, whether symmetrical or asymmetrical, it is sufficient to ensure that the wire threading holes on them can be located on the same straight line.

[0037] During operation, the welding wire passes through the wire push-pull unit, passes through the ultrasonic transducer unit, and then enters the welding gun body. Therefore, the welding wire has the performance of high-frequency vibration. The welding wire with ultrasonic vibration can refine the grains during welding operations, so that the metal components finally welded have better mechanical properties.

[0038] According to one aspect of the present application, the push-pull wire unit, the ultrasonic transducer unit and the welding gun body are coaxially fixed on the connection unit, and at least when working, the welding wire passes through the push-pull wire unit, the ultrasonic transducer unit and the welding gun along a straight or nearly straight moving path. In a non-working state, the wire threading holes of the push-pull wire unit, the ultrasonic transducer unit and the welding gun body are located on the same axis.

[0039] According to one aspect of the present application, a welding wire holder is detachably connected to one side of the ultrasonic transducer unit, and vibration is applied to the welding wire through the welding wire clamp. The clamp can be screwed or clamped to one end of the ultrasonic transducer unit to form a coaxial design, and the vibration of the ultrasonic wave is transmitted to the welding wire through the clamp. The welding wire clamp (welding wire clamp) has multiple models and can be disassembled and replaced, so that the ultrasonic transducer unit can adapt to multiple models of welding wire.

[0040] According to one aspect of the present application, the ultrasonic transducer unit comprises:

[0041] A hollow tube body, with an insulating sleeve on the inner wall and threads on the outer wall;

[0042] An upper end cover is screwed to one end of the hollow tube body;

[0043] A lower end cover is screwed to the other end of the hollow tube body;

[0044] The working piece, including piezoelectric ceramics and pole pieces, is sleeved on the hollow tube body and located between the upper end cover and the lower end cover, and an insulating tube is provided between the working piece and the hollow tube body;

[0045] The welding wire clamp is coaxially fixed on the lower end cover.

[0046] According to one aspect of the present application, the connection unit includes: a welding gun bracket for supporting and fixing the push-pull wire unit and the ultrasonic transducer unit, a gun head fixing frame for forming a connection part of the welding gun body, and a connection block for detachably connecting with the motion actuator. The connection unit is provided with a plurality of pipeline grooves or pipeline grooves.

[0047] According to one aspect of the present application, a conductive clamp, a water, electricity and gas separation block, a cooling water joint and a shielding gas joint are provided on one side of the push-pull unit; a water, electricity and gas access block is provided on the welding gun, and the water, electricity and gas access block is detachably connected to the welding gun.

[0048] exist Figures 1 to 4 In the attached figure, a case is given, as follows: the fixed flange is usually fixed on the six-axis end of the robot or other motion execution components, and a connecting block is connected to it, which is used to obtain a better vertical welding gun posture during welding. The connecting block is connected to the welding gun bracket, and the push-pull wire motor is installed on the upper end of the welding gun bracket. The water, electricity and gas separation block is connected to the push-pull wire motor through a locking nut. The water, electricity and gas separation block is fixed with a conductive clamp and several cooling water joints and shielding gas joints. The transducer fixing flange is fixed at the lower end of the welding gun bracket, the welding wire clamp is tightened on the ultrasonic transducer, and the ultrasonic transducer is fixed on the transducer fixing flange. The gun head fixing frame is connected to the middle of the welding gun bracket, the gun head fixing block is fixed on the gun head fixing frame, the water, electricity and gas access block is connected to the gun head fixing block, and an insulating gasket is separated in the middle. The connecting bolts are all covered with insulating sleeves, and several cooling water joints and shielding gas joints are fixed on the water, electricity and gas access block.

[0049] The short straight welding gun is fixed on the water, electricity and gas access block through the gun head locking nut. The welding wire passes from the upper end to the lower end of the tool end.

[0050] In another embodiment of the present application, the push-pull wire motor is connected to the welding power source, and the connected gun cable contains a water, electricity and gas wire, which must pass through the ultrasonic transducer and be connected to the short straight welding gun. The welding wire must be guaranteed to pass straight from top to bottom, and the water, electricity and gas are drawn from the joint on the water, electricity and gas separation block and connected to the water, electricity and gas access block. In addition, during the welding process, hundreds of amperes of current pass through the welding wire. In order to prevent it from affecting the functional components in contact with it, insulation treatment is done on each component, such as insulating gaskets and insulating sleeves, as well as the transducer fixing flange that fixes the transducer and the insulating bushing inside the transducer.

[0051] In another embodiment of the present application, in order to replace different ultrasonic transducers and obtain different frequencies, such as 20KHz, 40KHz, 60KHz, etc., different transducers are fixed on the transducer fixing flange and connected to the welding gun bracket.

[0052] The ultrasonic power supply is powered on and communicates with the controller, and is the ultrasonic power source of the ultrasonic transducer. The welding power supply is powered on and communicates with the controller, and is the power source for melting the welding wire.

[0053] In another embodiment of the present application, a plurality of piezoelectric ceramics and pole pieces are stacked on each other, an insulating sleeve is placed in the middle, and finally a stud bolt is used to connect the end cover and the transducer body to compact the piezoelectric ceramics and the pole piece. A hollow insulating bushing is inserted into the stud bolt, and a welding wire clamp is screwed into the transducer body from the end.

[0054] In another embodiment of the present application, in order to ensure that the welding wire can pass through it and that the welding wire obtains ultrasonic waves of an accurate and specific frequency, the design uses a stud bolt as a starting point, which is characterized by a hollow new style and insulation in the middle to ensure that the current on the welding wire will not be transmitted to the ultrasonic transducer during welding.

[0055] In another embodiment of the present application, common welding wire diameters are φ1.0, φ1.2, φ1.6 and other different specifications. The design must take into account the commonality of welding wires of various specifications, that is, welding wires of different diameters can obtain better ultrasonic frequencies when passing through the transducer. The design adopts the form of replacing the welding wire chuck to correspond to the passing of different welding wires. The welding wire chuck can be disassembled and assembled from the transducer body with a hexagonal wrench. The funnel shape designed on the welding wire chuck is more conducive to the welding wire passing from top to bottom, which plays a guiding role. The welding wire passes through the hole of the welding wire chuck, and the diameter of the hole is 10 to 15 wires larger than the diameter of the welding wire, forming a gap contact. After the welding wire chuck obtains the ultrasonic frequency, it can be better transmitted to the welding wire.

[0056] In another embodiment of the present application, the ultrasonic transducer imparts a specific ultrasonic frequency to the welding wire clamp, which drives the welding wire passing through the welding wire clamp to produce the same frequency. When welding is performed, the unique CMT welding technology inserts the welding wire into the molten pool. At this moment, the ultrasonic frequency on the welding wire acts on the metal droplets, stirring the inside of the metal droplets. This can refine the grains, so that the metal components finally welded have better mechanical properties. In addition, this design is more suitable for special metal composite materials. For example, the welding wire of the conventional substrate is added with grains with a higher melting point to improve the mechanical properties of the material. However, after the conventional arc welding machine melts the welding wire, the grains in the material will be significantly stacked at the bottom layer instead of being dispersed. To solve this problem, the material grains in the molten pool before cooling and solidification can be evenly distributed and dispersed by using ultrasonic frequency resonance, thereby ensuring ideal mechanical properties.

[0057] On the left, the grains in the molten pool are accumulated at the bottom, and on the right, the grains in the molten pool are evenly distributed in the molten pool due to the resonance of the ultrasonic frequency.

[0058] In another embodiment of the present application, a wire feeding mechanism is arranged on the welding power supply (including a water tank), and a cable on it includes welding wire, shielding gas, cooling water, positive line, signal line, etc., which are connected to the push-pull motor. The welding power supply is connected to the ultrasonic power supply, and the ultrasonic power supply is connected to the ultrasonic transducer. The welding power supply leads to a ground wire connected to the substrate. The above equipment is controlled by the control system. Before welding starts, the ultrasonic equipment is turned on in advance so that the welding wire can obtain a specific ultrasonic frequency at the beginning of welding.

[0059] The preferred embodiments of the present invention are described in detail above. However, the present invention is not limited to the specific details in the above embodiments. Within the technical concept of the present invention, various equivalent transformations can be made to the technical scheme of the present invention, and these equivalent transformations all belong to the protection scope of the present invention.

Claims

1. Ultrasonic composite welding gun, characterized in that: include: A connecting unit, which is connected and fixed to the motion execution structure during operation; A wire pushing and pulling unit is arranged on the connecting unit and is used for pushing the welding wire; The welding gun body is arranged on one side of the wire-pushing and pulling unit, and the welding wire passes through the welding gun body to reach the working area; The ultrasonic transducer unit is formed with a hollow wire-threading portion. The ultrasonic transducer unit is coaxially arranged between the wire-pushing and pulling unit and the welding gun body. When working, the ultrasonic transducer unit applies vibration to the welding wire.

2. The ultrasonic composite welding gun according to claim 1, characterized in that: The push-pull wire unit, ultrasonic transducer unit and welding gun body are coaxially fixed on the connecting unit. At least when working, the welding wire passes through the push-pull wire unit, ultrasonic transducer unit and welding gun along a straight or nearly straight moving path.

3. The ultrasonic composite welding gun according to claim 1, characterized in that: A welding wire holder is detachably connected to one side of the ultrasonic transducer unit, and vibration is applied to the welding wire through the welding wire holder.

4. The ultrasonic composite welding gun according to claim 1, characterized in that: The connecting unit comprises: The welding gun bracket is used to support and fix the push-pull wire unit and the ultrasonic transducer unit. A gun head fixing frame, used to form a connection portion of the welding gun body; Connecting block, used for detachable connection with motion actuator.

5. The ultrasonic composite welding gun according to any one of claims 1 to 4, characterized in that: The ultrasonic transducer unit comprises: A hollow tube body, with an insulating sleeve on the inner wall and threads on the outer wall; An upper end cover is screwed to one end of the hollow tube body; A lower end cover is screwed to the other end of the hollow tube body; The working piece, including piezoelectric ceramics and pole pieces, is sleeved on the hollow tube body and located between the upper end cover and the lower end cover, and an insulating tube is arranged between the working piece and the hollow tube body; The welding wire clamp is coaxially fixed on the lower end cover.

6. The ultrasonic composite welding gun according to claim 1, characterized in that: A conductive clamp, a water, electricity and gas separation block, a cooling water joint and a shielding gas joint are arranged on one side of the push-pull wire unit; a water, electricity and gas access block is arranged on the welding gun body, and the water, electricity and gas access block is detachably connected to the welding gun body.

7. The ultrasonic composite welding gun according to claim 1, characterized in that: The connection unit is provided with a plurality of pipeline grooves or pipeline troughs.

8. The ultrasonic composite welding gun according to claim 1, characterized in that: The operating frequency of the ultrasonic transducer unit is 10KHz to 80KHz.

9. The ultrasonic composite welding gun according to claim 3, characterized in that: The wire feeding end of the welding wire clamp is funnel-shaped, and the cross-section gradually decreases along the moving direction of the welding wire.

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