Ultrasonic continuous welding device

Abstract

The utility model discloses an ultrasonic continuous welding device which comprises a truss gantry, a mechanical arm, an ultrasonic welding assembly and a controller, the mechanical arm is arranged on the truss gantry, the ultrasonic welding assembly is arranged on the mechanical arm, and the mechanical arm and the ultrasonic welding assembly are connected with the controller and controlled by the controller. The mechanical arm can drive the ultrasonic welding assembly to move, and ultrasonic continuous welding is conducted on the workpiece through the ultrasonic welding assembly. According to the ultrasonic continuous welding device, ultrasonic continuous welding is conducted on the workpiece through the welding wheel of the ultrasonic welding assembly, friction loss of the workpiece and a welding head is avoided in the process of making contact with the workpiece, the welding steps are simple and efficient, the welding modes are flexible and diverse, various complex paths such as a 1 shape, an L shape and an S shape can be formed under the support of a mechanical arm, and the welding efficiency is improved. And the welding efficiency is high by adopting a sequential wave emitting form.

Description

Technical Field

[0001] The utility model belongs to the technical field of ultrasonic welding, and in particular relates to an ultrasonic continuous welding device. Background Art

[0002] There are various connection methods used for composite components, including riveting, gluing, bolting and welding. The welding connection methods mainly consist of resistance welding, induction welding and ultrasonic welding. Existing ultrasonic welding is mainly spot welding, that is, the ultrasonic welding head welds after contacting the workpiece and then immediately loses contact with the workpiece. Its welding range is small and can only perform small-scale connections, and long-distance welding between workpieces cannot be achieved.

[0003] Ultrasonic welding requires two conditions: a high-frequency vibrating welding head and close contact between the welding head and the workpiece, while applying a certain amount of pressure. In the existing continuous ultrasonic welding process, the welding head needs to be in close contact with the workpiece surface. The welding head then generates waves, converting electrical energy into high-frequency mechanical vibrations, which in turn generate high temperatures, causing the workpieces to melt and achieve a connection. During the continuous welding process, the welding head needs to move along the workpiece surface while generating waves to achieve the continuous welding effect.

[0004] However, existing ultrasonic welding equipment requires friction movement with the workpiece during operation, so it has the following disadvantages:

[0005] 1) Damage to the workpiece or welding head: During the ultrasonic continuous welding process, the workpiece needs to be pressed and the welding head needs to be moved. Since the welding head and the workpiece are not smooth surfaces, huge friction will be generated at the contact point between the two. This friction does not help welding at all, and will wear the workpiece and welding head under long-term movement, resulting in reduced welding accuracy and damage to the workpiece surface.

[0006] 2) Welding preparation is complicated: Due to the huge friction generated during the welding process, displacement between the workpieces is easy to occur. Therefore, to ensure welding accuracy, the traditional welding process requires a lot of fixtures to fix the workpieces, which consumes a lot of manpower and material resources during the fixing process.

[0007] 3) Rigid welding method: The existing ultrasonic continuous welding method can only be used along a straight line or the projection of the straight line on a curve. It is difficult to weld an "S" shaped path with curvature;

[0008] 4) Low welding efficiency: Existing ultrasonic welding equipment can only continuously generate waves for about 15 seconds. After 15 seconds of continuous wave generation, it is necessary to pause the wave generation for a while before continuing the wave generation. This makes it difficult to perform long-distance ultrasonic continuous welding, resulting in low welding efficiency. Utility Model Content

[0009] In order to solve the technical problems existing in the prior art, the purpose of the present utility model is to provide an ultrasonic continuous welding device.

[0010] In order to achieve the above purpose and the above technical effects, the technical solution adopted by the present invention is:

[0011] An ultrasonic continuous welding device includes a truss gantry, a robotic arm, an ultrasonic welding assembly and a controller. The robotic arm is arranged on the truss gantry, and the ultrasonic welding assembly is arranged on the robotic arm. The robotic arm and the ultrasonic welding assembly are respectively connected to the controller and controlled by the controller. The robotic arm can move relative to the truss gantry, and the robotic arm can drive the ultrasonic welding assembly to move. The welding wheel of the ultrasonic welding assembly is a circular structure formed by combining several discs and several disc-like structures. The ultrasonic welding assembly can perform ultrasonic continuous welding on workpieces.

[0012] Furthermore, the truss gantry includes a frame, a beam and a slide, the slide is arranged on the beam, and the slide can reciprocate along the long side of the beam, and the beam is arranged on the frame, and the beam and the slide thereon can reciprocate along the long side of the frame.

[0013] Furthermore, the robotic arm includes a base, and the robotic arm is mounted on the slide of the truss gantry through the base, and an ultrasonic welding component is provided at the end of the robotic arm.

[0014] Furthermore, the ultrasonic welding assembly includes a welding base, a mounting base, a support frame, a welding wheel, a driving motor and a driving cylinder. The welding base is fixedly connected to the end of the robotic arm, the welding base is arranged above the mounting base, and the support frame is arranged below the mounting base. A driving cylinder is arranged between the welding base and the mounting base. The welding base and the mounting base can constitute vertical translation motion under the action of the driving cylinder. The welding wheel is installed below the support frame, and the welding wheel and the support frame form a rotating pair. The welding wheel is connected to the driving motor, and the driving motor is arranged on the support frame.

[0015] Furthermore, the driving motor is fixed to one side of the support frame, and the rotating shaft of the driving motor is connected to the welding wheel.

[0016] Furthermore, the welding wheel is a circular structure formed by combining two discs and two disc-shaped structures. A disc-shaped structure is arranged on the periphery of each disc. Several transducers are arranged on each disc. Several welding heads are arranged on each disc-shaped structure. One transducer corresponds to one welding head.

[0017] Furthermore, the welding head is wedge-shaped.

[0018] Compared with the prior art, the beneficial effects of the present invention are:

[0019] 1) No damage to the workpiece or welding head during welding: Since the utility model adopts the form of active rolling and sequential contact, the process of contacting and applying pressure with the workpiece is the form of active rolling by friction, so there is no friction loss of the workpiece and welding head during this process;

[0020] 2) The welding process is simple and convenient: Since the workpiece will not slide due to the friction between the welding head and the workpiece during the contact, pressurization and welding process, ultrasonic continuous welding can be performed with simple clamping, so the welding preparation and welding process are simple and convenient;

[0021] 3) Flexible and diverse welding methods: Since the present invention adopts a wheel-like rolling welding method, it also has the same flexibility as a wheel. With the support of moving parts such as a robotic arm, it can move out various complex paths such as "1" shape, "L" shape, "S" shape, etc., so the welding methods are flexible and diverse;

[0022] 4) High welding efficiency: The welding head wave form adopted by the present invention is to generate waves in sequence, that is, the welding head in contact with the workpiece generates waves, while the welding head not in contact with the workpiece does not need to generate waves. Since the time for a single welding head to roll over the surface of the workpiece is short, which is far less than the continuous wave time, it is theoretically possible to achieve unlimited ultrasonic continuous welding with high welding efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the overall structure of the utility model;

[0024] Figure 2 This is a structural diagram of the truss gantry of the present utility model;

[0025] Figure 3 This is a schematic structural diagram of the robotic arm of the present invention;

[0026] Figure 4 This is a schematic structural diagram of the ultrasonic welding assembly of the present invention;

[0027] Figure 5-6 They are respectively structural schematic diagrams of the welding wheel of the present utility model;

[0028] Figure 7 This is a schematic structural diagram of the mold of the present utility model;

[0029] Figure 8 This is a working schematic diagram of a friction-free ultrasonic continuous welding method of the present invention. DETAILED DESCRIPTION

[0030] The present invention is described in detail below so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more precise definition of the protection scope of the present invention.

[0031] The following is a brief summary of one or more aspects to provide a basic understanding of these aspects. This summary is not an exhaustive overview of all conceivable aspects and is neither intended to identify key or critical elements of all aspects nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form as a prelude to the more detailed description that will be provided later.

[0032] like Figure 1-8 As shown, an ultrasonic continuous welding device solves the limitation of existing ultrasonic welding equipment that can only move by friction during continuous welding. The device mainly includes: a truss gantry 1, a robotic arm 2, an ultrasonic welding component 3, a mold 4 and a controller 5, wherein the robotic arm 2 is arranged on the truss gantry 1, and the truss gantry 1 and the robotic arm 2 together constitute a spatial motion mechanism. The spatial motion mechanism includes but is not limited to a robotic arm, a truss, a connecting rod device, a virtual axis and other structural forms that can achieve spatial motion. The ultrasonic welding component 3 is arranged on the robotic arm 2, and the robotic arm 2 can move relative to the truss gantry 1. The robotic arm 2 can drive the ultrasonic welding component 3 to move. The ultrasonic welding component 3 is a welding actuator that is in direct contact with the workpiece. The mold 4 is used to place the workpiece to keep the workpiece in a certain shape. The robotic arm 2 and the ultrasonic welding component 3 are respectively connected to the controller 5 and controlled by the controller 5. The controller 5 is used to control the movement and process parameters of the entire equipment.

[0033] The truss gantry 1 includes a frame 11, a beam 12 and a slide 13. The beam 12 is arranged on the frame 11 and can reciprocate along the long side of the frame 11. The slide 13 is arranged on the beam 12 and can reciprocate along the long side of the beam 12, so the slide 13 can have longitudinal and lateral movements.

[0034] The robotic arm 2 includes a base 21, which is mounted on the slide 13. The end 22 of the robotic arm 2 has three translational degrees of freedom relative to the base 21: "front and back", "left and right", and "up and down", and also has three rotational degrees of freedom around the "front and back", "left and right", and "up and down".

[0035] The ultrasonic welding assembly 3 includes a welding base 31, a mounting base 32, a support frame 33, a welding wheel 34, a driving motor 35, and a driving cylinder 36, wherein the welding base 31, the mounting base 32, and the support frame 33 are arranged in sequence from top to bottom, the welding base 31 is fixedly connected to the end 22 of the robotic arm 2, and a translation constraint is formed between the welding base 31 and the mounting base 32 through a guide rail and a slider. The welding base 31 and the mounting base 32 constitute a vertical translation motion under the action of the driving cylinder 36, the welding wheel 34 is installed at the lower part of the support frame 33, and the welding wheel 34 and the support frame 33 constitute a rotating pair. The welding wheel 34 can rotate on the support frame 33, and the driving motor 35 is fixed to one side of the support frame 33, and its rotating shaft is connected to the welding wheel 34. The driving motor 35 can drive the welding wheel 34 to rotate.

[0036] The welding wheel 34 is composed of two identical left and right parts, which combine to form a complete circle. Each part includes a disc composed of several transducers 341 and a disc-shaped structure composed of several welding heads 342. The transducers 341 convert high-frequency electrical energy into mechanical motion of the same frequency, while the structure of the welding heads 342 can be customized according to actual production needs.

[0037] In the present invention, multiple transducers 341 are combined into a transducer group arranged in a circle, and each transducer 341 is equipped with a welding head 342 to form a welding wheel 34; each transducer 341 is powered on and off in sequence, so that the corresponding welding head 342 vibrates and stops in sequence.

[0038] In order to enable the transducer 341 and the welding head 342 to form a disc-shaped structure, the welding head 342 is designed as a wedge-shaped structure, which is at a certain angle to the center of the disc. At the same time, in order to enable the end of the welding head to form a smooth transition outer circle of the welding wheel 34, the arc of the end of the welding head coincides with the outer circle b of the welding wheel. When two transducers and welding heads are grouped together and fit into the workpiece, the welding head has a certain angle a. Since the welding wheel 34 is a combination of the transducer 341 and the welding head 342, it is large at the top and small at the bottom. In order to prevent the two parts of the welding wheel 34 from interfering, a certain inclination angle is required. The range value of the angle a is greater than the angle of contact (interference) of the two parts of the welding wheel 34, but an angle that is too large will affect the movement range of the welding wheel. Therefore, the angle a is based on preventing the two parts of the welding wheel 34 from interfering.

[0039] The surface of the mold 4 is preferably an irregular curved surface that adapts to the irregular workpiece.

[0040] The process of the robotic arm 2 driving the ultrasonic welding assembly 3 to move along the direction of the long side of the workpiece is as follows:

[0041] 1) A workpiece 6 is placed on a mold 4, and the robotic arm 2 drives the ultrasonic welding assembly 3 to a specified distance above the workpiece 6, without the ultrasonic welding assembly 3 and the workpiece 6 contacting each other;

[0042] 2) driving the air cylinder 36 to inflate so that the mounting seat 32 and the portion below it move downward to contact the workpiece 6 and apply a certain pressure;

[0043] 3) The welding head 342 in contact with the workpiece 6 starts to generate waves, while other welding heads that are not in contact do not generate waves;

[0044] 4) The driving motor 35 drives the welding wheel 34 to rotate, and the robotic arm 2 simultaneously drives the welding wheel 34 to move above the workpiece 6;

[0045] 5) During the rotation process, the welding head generates waves every time it contacts the workpiece, and does not generate waves when it does not contact the workpiece;

[0046] 6) Carry out the above steps in sequence until welding is completed.

[0047] Parts or structures not specifically described in the present invention may adopt existing technologies or existing products and will not be described in detail here.

[0048] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. An ultrasonic continuous welding device, characterized in that: It includes a truss gantry, a robotic arm, an ultrasonic welding assembly and a controller. The robotic arm is arranged on the truss gantry, and the ultrasonic welding assembly is arranged on the robotic arm. The robotic arm and the ultrasonic welding assembly are respectively connected to the controller and controlled by the controller. The robotic arm can move relative to the truss gantry, and the robotic arm can drive the ultrasonic welding assembly to move. The welding wheel of the ultrasonic welding assembly is a circular structure formed by combining several discs and several disc-shaped structures. The ultrasonic welding assembly can perform ultrasonic continuous welding on the workpiece.

2. The ultrasonic continuous welding device according to claim 1, characterized in that: The truss gantry includes a frame, a beam and a slide. The slide is arranged on the beam and can reciprocate along the long side of the beam. The beam is arranged on the frame, and the beam and the slide thereon can reciprocate along the long side of the frame.

3. The ultrasonic continuous welding device according to claim 1, characterized in that: The robotic arm comprises a base, and the robotic arm is mounted on a slide plate of a truss gantry through the base. An ultrasonic welding assembly is provided at the end of the robotic arm.

4. The ultrasonic continuous welding device according to claim 1, characterized in that: The ultrasonic welding assembly includes a welding base, a mounting base, a support frame, a welding wheel, a driving motor and a driving cylinder. The welding base is fixedly connected to the end of the robotic arm, the welding base is arranged above the mounting base, and the support frame is arranged below the mounting base. A driving cylinder is arranged between the welding base and the mounting base. The welding base and the mounting base can constitute vertical translation motion under the action of the driving cylinder. The welding wheel is installed below the support frame, and the welding wheel and the support frame form a rotating pair. The welding wheel is connected to the driving motor, and the driving motor is arranged on the support frame.

5. The ultrasonic continuous welding device according to claim 4, characterized in that: The driving motor is fixed to one side of the supporting frame, and the rotating shaft of the driving motor is connected to the welding wheel.

6. The ultrasonic continuous welding device according to claim 4, characterized in that: The welding wheel is a circular structure formed by combining two discs and two disc-like structures. A disc-like structure is arranged on the periphery of each disc. Several transducers are arranged on each disc-like structure. Several welding heads are arranged on each disc. One transducer corresponds to one welding head.

7. The ultrasonic continuous welding device according to claim 6, characterized in that: The welding head is wedge-shaped.

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