Electric drive controller laser welding system

Abstract

The utility model provides an electric drive controller laser welding system which comprises a tray used for containing an electric drive controller. The conveying assembly is used for promoting the tray to move in the X-axis direction; the jacking and press-fitting assembly comprises a jacking mechanism and a press-fitting mechanism, the press-fitting mechanism is located above the jacking mechanism, the jacking mechanism is used for jacking the tray, and the press-fitting mechanism is used for press-fitting the electric drive controller on the tray; the laser emitting assembly comprises a composite laser output unit used for conducting laser welding on the electric drive controller. The detection assembly comprises a positioning detection unit, an in-welding detection unit, a laser ranging unit and a post-welding detection unit; and the composite laser output unit is arranged, high-quality welding of the electric drive controller is achieved, the risk of overvoltage and overcurrent is greatly reduced, effective heat conduction is better facilitated, the temperature rise of the electric drive controller structure is reduced, the thermal stability of a device is improved, the service life of the device is prolonged, and the bolt cost and the labor cost are reduced.

Description

TECHNICAL FIELD

[0001] The utility model relates to laser welding technical field especially relates to a kind of electric drive controller laser welding system. BACKGROUND

[0002] Electric drive controller is an important part in new energy vehicles, electric drive controller plays key roles such as energy conversion, motor control, kinetic energy recovery in new energy vehicles, and is the core component to realize efficient and safe operation of electric vehicles. The connection mode of positive and negative poles and output copper plate is bolt connection, and the following problems exist in the above bolt connection:

[0003] 1. If bolt connection is not firm enough, it may cause the connection point to melt or break under high current or high voltage, increasing the risk of overvoltage and overcurrent.

[0004] 2. In vibration test, bolt is easy to loosen and cause discharge due to gap, resulting in unstable current.

[0005] 3. The bolt connection may increase the contact resistance due to oxidation, corrosion or contamination, thereby increasing power loss and heat generation.

[0006] 4. Bolt connection is not conducive to effective heat conduction, resulting in high junction temperature of electric drive controller, affecting the thermal stability and life of the device.

[0007] 5. High labor cost. INVENTION CONTENT

[0008] In view of the deficiencies of the prior art, the purpose of the present utility model is to provide an electric drive controller laser welding system, which is provided with a composite laser output unit to realize high-quality welding of the electric drive controller, greatly reducing the risk of overvoltage and overcurrent, and being more conducive to effective heat conduction, reducing the structure temperature rise of the electric drive controller, improving the thermal stability and life of the device, and reducing the cost of bolts and labor cost.

[0009] The embodiments of the utility model are realized by the following technical solutions:

[0010] An electric drive controller laser welding system, comprising:

[0011] A tray for accommodating an electric drive controller;

[0012] A conveying assembly for moving the tray along the X-axis direction;

[0013] A jacking and pressing assembly, the jacking and pressing assembly comprises a jacking mechanism and a pressing mechanism, the pressing mechanism is located above the jacking mechanism, the jacking mechanism is used to jack the tray, and the pressing mechanism is used to press the electric drive controller on the tray;

[0014] The laser exit assembly comprises a composite laser output unit for laser welding the electric drive controller;

[0015] The detection assembly comprises a positioning detection unit, a welding detection unit, a laser ranging unit, and a post-welding detection unit. The positioning detection unit is used to detect the positioning state of the electric drive controller. The welding detection unit is used to detect the welding process and feedback data in real time. The laser ranging unit is used to measure the height compensation to ensure the welding focal length. The post-welding detection unit detects the welding quality of the electric drive controller.

[0016] According to a preferred embodiment, the composite laser output unit comprises a blue composite laser, and the output beam of the blue composite laser comprises an inner circle and an outer circle to form a composite spot.

[0017] According to a preferred embodiment, the infrared wavelength of the inner circle is 1080 nm, and the blue wavelength of the outer circle is 455 nm.

[0018] According to a preferred embodiment, the core diameter of the inner circle is 20 μm, and the core diameter of the outer circle is 600 μm.

[0019] According to a preferred embodiment, the gantry and a front three-axis moving assembly are further included. The front three-axis moving assembly is arranged on the gantry. The front three-axis moving assembly comprises a front X-axis moving mechanism for adjusting the position of the laser exit assembly in the X-axis direction, a front Y-axis moving mechanism for adjusting the position of the laser exit assembly in the Y-axis direction, and a front Z-axis moving mechanism for adjusting the position of the laser exit assembly in the Z-axis direction.

[0020] According to a preferred embodiment, the pressing mechanism is arranged on the gantry. The pressing mechanism is provided with a pressing plate,

[0021] The welding detection unit is arranged on one side of the composite laser output unit, and the positioning detection unit is arranged above the pressing plate.

[0022] According to a preferred embodiment, a rack and a rear three-axis moving assembly are further included. The rack is located on one side of the gantry. The rear three-axis moving assembly is arranged on the gantry. The rear three-axis moving assembly comprises a rear X-axis moving mechanism for adjusting the position of the post-welding detection unit in the X-axis direction, a rear Y-axis moving mechanism for adjusting the position of the post-welding detection unit in the Y-axis direction, and a rear Z-axis moving mechanism for adjusting the position of the post-welding detection unit in the Z-axis direction.

[0023] According to a preferred embodiment, the number of gantries is two, the two gantries are arranged side by side, and the pressing mechanism is horizontally arranged between the two gantries and the two ends of the pressing mechanism are slidably connected with the side walls of the two gantries.

[0024] A welding method of an electric drive controller laser welding system, comprising the following steps:

[0025] In step S10, the parameters of the blue light composite laser are set in advance, including infrared light power, blue light power, and welding time; the parameters of the galvanometer are set, including welding speed, swing amplitude, swing trajectory, and welding length.

[0026] In step S20, the electric drive controller is placed on the tray and conveyed to the corresponding welding station of the laser exit assembly through the conveying assembly.

[0027] In step S30, the jacking mechanism lifts the tray on which the electric drive controller is placed, and the pressing mechanism is pressed towards the tray on which the electric drive controller is placed, and the electric drive controller on the tray is pressed and positioned under the joint action of the jacking mechanism and the pressing mechanism.

[0028] In step S40, the welding position of the electric drive controller on the tray is measured by the laser ranging unit, and the ranging value obtained by the laser ranging unit is compensated by the PLC program to ensure the welding focal length.

[0029] In step S50, the blue light composite laser welds the electric drive controller, and the welding process of the electric drive controller is continuously monitored by the welding detection unit during the welding process. If the electric drive controller welding NG occurs, an alarm is immediately sent and the welding is stopped to return to step S20 for welding repair. If there is no alarm, step S60 is performed.

[0030] In step S60, the jacking mechanism controls the tray to descend, and the tray is conveyed to the post-welding detection station through the conveying assembly.

[0031] In step S70, the electric drive controller of the tray is detected by the post-welding detection unit. When the post-welding detection unit determines that the electric drive controller is NG, an instruction is sent to immediately alarm and return to step S20 for repair. When the post-welding detection unit determines that the electric drive controller is not NG, the electric drive controller is output through the conveying assembly, and the welding process is ended.

[0032] In step S10, the parameters of the blue light composite laser set in advance are as follows: the infrared light power is 800-2500W, the blue light power is 1000-1800W, and the welding time is 100-500ms.

[0033] The parameters of the galvanometer are set as follows: the welding speed is 40-80mm / s, the swing amplitude is 0.8-1.2mm, the swing trajectory is a spiral line, and the welding length is set according to actual needs.

[0034] The technical scheme of the utility model embodiment has at least the following advantages and beneficial effects:

[0035] The utility model discloses set jacking pressure assembly, positioning detection unit, welding detection unit, laser ranging unit, welding detection unit after welding can be accurate positioning and overall monitoring to electric drive controller, is provided with composite laser output unit, realizes to electric drive controller high quality welding, greatly reduces the risk of overvoltage and overcurrent, is more favorable to effective heat conduction, and the structure temperature of electric drive controller reduces, improves the thermal stability and life of device, reduces bolt cost and artificial cost, improves the connection strength of drive controller copper bar, guarantees the long-term stability of electric drive controller, effectively reduces the phenomenon of big spatter, oxidation and welding porosity of welding copper, effectively improves the welding effect of electric drive controller, can reach the smooth and even of welding surface after welding, and there is no dust particle. BRIEF DESCRIPTION OF DRAWINGS

[0036] In order to more clearly illustrate the technical scheme of the utility model embodiment, the following will be briefly introduced to the drawing needed to be used in the embodiment, it should be understood that the following drawings only show some embodiments of the utility model, therefore should not be regarded as the limitation to the scope, for ordinary skilled person in the art, under the premise of not paying the creative labor, can also obtain other related drawings according to these drawings.

[0037] Figure 1 It is a front view structural schematic diagram of the electric drive controller laser welding system provided by the utility model embodiment;

[0038] Figure 2 It is a rear view structural schematic diagram of the electric drive controller laser welding system provided by the utility model embodiment;

[0039] Figure 3 It is a three-dimensional structural schematic diagram of the electric drive controller laser welding system provided by the utility model embodiment;

[0040] Figure 4 It is a welding method flow chart of the electric drive controller laser welding system provided by the utility model embodiment.

[0041] Icon: 1, conveying assembly;2, tray;3, jacking mechanism;4, pressure assembly;5, composite laser output unit;6, positioning detection unit;7, welding detection unit;8, laser ranging unit;9, welding detection unit after welding;10, gantry;11, front X-axis moving mechanism;12, front Y-axis moving mechanism;13, front Z-axis moving mechanism;14, rack;15, rear X-axis moving mechanism;16, rear Y-axis moving mechanism;17, rear Z-axis moving mechanism. DETAILED DESCRIPTION

[0042] For better understanding and implementation, the technical solutions in the embodiments of the present application will be clearly and completely described in the following with reference to the drawings in the embodiments of the present application.

[0043] In the description of the present application, it should be noted that the directions or position relationships indicated by the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like are based on the directions or position relationships shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as limiting the present application in that the devices or elements indicated thereby must have a specific direction, be constructed in a specific direction and be operated.

[0044] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present application belongs. The terminology used in the description of the present application herein only for the purpose of describing specific embodiments and is not intended to limit the present application.

[0045] Embodiment

[0046] Please refer to Figures 1 to 4 A kind of electric drive controller laser welding system, comprising: tray 2, for containing electric drive controller;Conveying assembly 1, to cause tray 2 to move along X axis direction;Jacking and press assembly, jacking and press assembly includes jacking mechanism 3 and press assembly 4, press assembly 4 is located above jacking mechanism 3, jacking mechanism 3 is used to jacking tray 2, press assembly 4 is used to press the electric drive controller on tray 2;Laser emission assembly, including the composite laser output unit 5 for laser welding electric drive controller;Detection assembly, including positioning detection unit 6, welding detection unit 7, laser ranging unit 8, post-welding detection unit 9;Positioning detection unit 6 is used to detect the positioning state of electric drive controller, welding detection unit 7 is used to detect welding process and feedback data in real time, laser ranging unit 8 is used to measure distance compensation height to ensure welding focal length, post-welding detection unit 9 detects electric drive controller weld quality.

[0047] According to a preferred embodiment, the composite laser output unit 5 includes a blue light composite laser, and the blue light composite laser output beam includes an inner circle and an outer circle to form a composite spot.

[0048] According to a preferred embodiment, the infrared light wavelength of the inner circle is 1080 nm, and the blue light wavelength of the outer circle is 455 nm.

[0049] According to a preferred embodiment, the core diameter of the inner circle is 20 μm, and the core diameter of the outer circle is 600 μm.

[0050] According to a preferred embodiment, the gantry 10 and a front three-axis moving assembly are further included, the front three-axis moving assembly is arranged on the gantry 10, and the front three-axis moving assembly comprises a front X-axis moving mechanism 11 for adjusting the position of the laser emitting assembly in the X-axis direction, a front Y-axis moving mechanism 12 for adjusting the position of the laser emitting assembly in the Y-axis direction, and a front Z-axis moving mechanism 13 for adjusting the position of the laser emitting assembly in the Z-axis direction.

[0051] According to a preferred embodiment, the press-fitting mechanism 4 is arranged on the gantry 10, and the press-fitting mechanism 4 is provided with a press-fitting plate,

[0052] The welding detection unit 7 is arranged on one side of the composite laser output unit 5, and the positioning detection unit 6 is arranged above the press-fitting plate.

[0053] According to a preferred embodiment, the gantry 14 and a rear three-axis moving assembly are further included, the gantry 14 is located on one side of the gantry 10, and the rear three-axis moving assembly is arranged on the gantry 10, and the rear three-axis moving assembly comprises a rear X-axis moving mechanism 15 for adjusting the position of the post-welding detection unit 9 in the X-axis direction, a rear Y-axis moving mechanism 16 for adjusting the position of the post-welding detection unit 9 in the Y-axis direction, and a rear Z-axis moving mechanism 17 for adjusting the position of the post-welding detection unit 9 in the Z-axis direction.

[0054] According to a preferred embodiment, the number of gantries 10 is two, the two gantries 10 are arranged side by side, the press-fitting mechanism 4 is horizontally arranged between the two gantries 10, and the two ends of the press-fitting mechanism 4 are slidably connected with the side walls of the two gantries 10.

[0055] A welding method of an electric drive controller laser welding system, comprising the following steps:

[0056] Step S10, presetting blue light composite laser parameters, infrared light power, blue light power, and welding time; setting galvanometer parameters, welding speed, swing amplitude, swing track, and welding length;

[0057] Step S20, placing the electric drive controller on the tray 2 and conveying the electric drive controller to the corresponding welding station of the laser emitting assembly through the conveying assembly 1;

[0058] Step S30, lifting the tray 2 on which the electric drive controller is placed by the jacking mechanism 3, and pressing the tray 2 on which the electric drive controller is placed by the press-fitting mechanism 4, so that the electric drive controller on the tray 2 is pressed and positioned under the joint action of the jacking mechanism 3 and the press-fitting mechanism 4;

[0059] Step S40, measuring the welding position of the electric drive controller on the tray 2 by the laser ranging unit 8, and compensating the measured value obtained by the laser ranging unit 8 through the PLC program to ensure the welding focal length;

[0060] In step S50, the blue composite laser is used to weld the electric drive controller. During the process, the welding detection unit 7 continuously monitors the welding process of the electric drive controller. If the welding of the electric drive controller is NG, an alarm is immediately triggered and the welding is stopped, returning to step S20 for welding rework. If there is no alarm, step S60 is performed.

[0061] In step S60, the lifting mechanism 3 controls the tray 2 to descend, and the tray 2 is conveyed to the post-weld inspection station via the conveying assembly 1;

[0062] In step S70, the electric drive controller of tray 2 is detected by the post-weld detection unit 9. When the post-weld detection unit 9 determines that the electric drive controller is NG, it sends an instruction to immediately alarm and returns to step S20 for rework. When the post-weld detection unit 9 determines that the electric drive controller is not NG, it outputs through the conveying component 1 and ends this welding process.

[0063] In step S10, the preset parameters of the blue composite laser are as follows: infrared power 800-2500W, blue power 1000-1800W, and welding time 100-500ms.

[0064] The galvanometer parameters are set as follows: welding speed is 40-80 mm / s, oscillation amplitude is 0.8-1.2 mm, oscillation trajectory is selected as a spiral, and welding length is set according to actual needs.

[0065] The working principle of this utility model:

[0066] like Figure 1 As shown, the welded product is an IGBT electric drive controller. The conveying component 1 can be a double-speed chain, used to transport the tray 2. The double-speed chain can transport the tray 2 in the X-axis direction, enabling the IGBT electric drive controller to move and be positioned on the tray 2. The lifting mechanism 3 can be a lifting mechanism such as an electric cylinder or a pneumatic cylinder, which can lift the tray 2 and clamp the IGBT electric drive controller with the pressing mechanism 4, adjusting the pressing force. The lifting pressure of the lifting mechanism 3 can be adjusted to adjust the reaction force on the pressing plate of the clamping mechanism. The positioning detection unit 6 can be a CCD camera, which can detect the positioning status of the IGBT electric drive controller. The front three-axis moving component is a three-axis module used for moving the composite laser output unit 5. The composite laser output unit 5 includes a collimating lens, a galvanometer, a field lens, and a laser emission source. In this embodiment, the laser emission source is, for example... Figure 2As shown, A is a laser emitting source; the welding detection unit 7 can realize real-time monitoring and NG feedback of the IGBT electric drive controller welding by the composite laser output unit 5; NG is a substandard product, and no NG means that the product is qualified; the laser ranging unit 8 can be selected as a laser height sensor, which compensates the height after ranging to ensure the welding focal length; the pressing plate of the pressing mechanism 4 is used to clamp the product with the jacked tray 2 to realize product positioning; the last three-axis moving assembly is a three-axis module, which supports the three-dimensional movement of the 3D detection camera of the post-welding IGBT electric drive controller; the post-welding detection unit 9 is a post-welding detection 3D camera, which can effectively detect the welding quality of the IGBT electric drive controller and NG alarm; the tray 2 is used to position the IGBT electric drive controller; the optical fiber can be used as the light transmission medium between the laser emitting source and the blue light composite laser, and the composite laser output unit 5 in the embodiment is a blue light composite laser, the output beam of which forms a composite spot, the inner circle core diameter of the composite spot is 20 μm, the infrared light wavelength of the inner circle is 1080 nm, the outer circle core diameter is blue light 600 μm, and the blue light wavelength of the outer circle is 455 nm. The inner ring is infrared light, and the outer ring is blue light. The above value range includes both ends of the value, such as the infrared light power 800-2500W, which includes 800W and 2500W.

[0067] In the embodiment, the electric drive controller is an IGBT electric drive controller, the infrared light and blue light composite and galvanometer laser welding method is adopted, high-quality welding of the electric drive controller is realized, the risk of overvoltage and overcurrent is greatly reduced, the heat conduction is more effective, the structure temperature rise of the IGBT electric drive controller is reduced, the thermal stability and service life of the device are improved, the bolt cost and labor cost are reduced, the connection strength of the IGBT electric drive controller copper bar is improved, the long-term stability of the IGBT electric drive controller is ensured, the current industry welding copper problems such as large spatter, oxidation and welding porosity are solved by adopting the red and blue light composite welding technical scheme, the welding effect of the IGBT electric drive controller is effectively improved, the welding surface is smooth and flat after welding, there is no dust particle, the effective melting width is greater than or equal to 1 mm, and the effective melting depth is greater than or equal to 0.2 mm.

[0068] The tray 2 in the embodiment is provided with a connecting groove matched with the IGBT electric drive controller, which can accommodate the IGBT electric drive controller and position the IGBT electric drive controller. Figure 1As shown, the conveying assembly 1 conveys the IGBT electric drive controller of the tray 2 from left to right, and when the IGBT electric drive controller is conveyed to the jacking mechanism 3, the conveying assembly 1 stops conveying, and the electric cylinder or air cylinder of the jacking mechanism 3 jacks up the tray 2 and the IGBT electric drive controller upward, so that the tray 2 and the IGBT electric drive controller are positioned in cooperation with the press-fitting plate. Specifically, the welding detection unit 7 and the laser ranging unit 8 are connected with the output end of the composite laser output unit 5, the moving end of the front X-axis moving mechanism 11 drives the welding detection unit 7 and the output end (including a collimating mirror, a galvanometer and a field lens) of the composite laser output unit 5 to move, so as to facilitate adjustment of the welding focal length; the moving end of the front X-axis moving mechanism 11 can drive the front Y-axis moving mechanism 12 to move in the X-axis direction, and the moving end of the front Y-axis moving mechanism 12 can drive the Z-axis moving mechanism to move in the Y-axis direction, and similarly, the rear three-axis moving assembly is used to control the position of the post-welding detection unit 9 in the X-axis, Y-axis and Z-axis directions, and the post-welding detection unit 9 is arranged on the moving end of the rear Y-axis moving mechanism 16. The post-welding detection unit 9 is arranged on the rear three-axis moving assembly, and the rear three-axis moving assembly is arranged on the support, and the support is located on the left side of the gantry 10, after the welding process is completed, i.e. after step S70, the qualified IGBT electric drive controller flows to the right. That is, the welding machining process is ended, and if there is no NG, the qualified IGBT electric drive controller flows out through the conveying assembly 1. The press-fitting mechanism 4 is arranged between the two gantries 10, when the tray 2 is conveyed to the lower side of the press-fitting plate, the jacking mechanism 3 performs the jacking action, the press-fitting plate is a frame hollow structure, so as to realize the pressure of the IGBT electric drive controller and not to affect the output of the composite laser output unit 5 above the press-fitting plate, the front Y-axis moving mechanism 12 is located at the top of the gantry 10 and above the press-fitting mechanism 4, and the composite laser output unit 5 can move forward and backward above the press-fitting mechanism 4. In the embodiment, the problem that the transmittance may be reduced due to the possibility that the incident spot is too large or the laser divergence angle is too large in the IGBT electric drive controller welding process is solved.

[0069] The technical means disclosed in the utility model scheme is not limited to the technical means disclosed in the above-mentioned embodiments, and also includes technical solutions composed of any combination of the above technical features. It should be noted that, for ordinary skilled persons in the art, without departing from the principles of the utility model, some improvements and refinements can be made, and these improvements and refinements are also considered to be within the protection scope of the utility model.

Claims

1. A laser welding system for an electric drive controller, characterized in that, include: Tray, used to house the electric drive controller; A conveying assembly for moving the tray along the X-axis; A lifting and pressing assembly, comprising a lifting mechanism and a pressing mechanism, wherein the pressing mechanism is located above the lifting mechanism, the lifting mechanism is used to lift the tray, and the pressing mechanism is used to press the electric drive controller on the tray. The laser emission assembly includes a composite laser output unit for laser welding the electric drive controller; The detection component includes a positioning detection unit, a welding detection unit, a laser ranging unit, and a post-weld detection unit. The positioning detection unit is used to detect the positioning status of the electric drive controller. The welding detection unit is used to detect the welding process and provide feedback data in real time. The laser ranging unit is used to measure distances to compensate for height and ensure welding focal length. The post-weld detection unit detects the weld quality of the electric drive controller.

2. The laser welding system for an electric drive controller according to claim 1, characterized in that, The composite laser output unit includes a blue composite laser, and the output beam of the blue composite laser includes an inner circle and an outer circle to form a composite light spot.

3. The laser welding system for an electric drive controller according to claim 2, characterized in that, The infrared wavelength of the inner circle is 1080nm, and the blue wavelength of the outer circle is 455nm.

4. The laser welding system for an electric drive controller according to claim 3, characterized in that, The inner circle has a core diameter of 20 μm, and the outer circle has a core diameter of 600 μm.

5. The laser welding system for an electric drive controller according to claim 2, characterized in that, It also includes a gantry and a front three-axis moving assembly. The front three-axis moving assembly is mounted on the gantry and includes a front X-axis moving mechanism for adjusting the position of the laser emission assembly in the X-axis direction, a front Y-axis moving mechanism for adjusting the position of the laser emission assembly in the Y-axis direction, and a front Z-axis moving mechanism for adjusting the position of the laser emission assembly in the Z-axis direction.

6. The laser welding system for an electric drive controller according to claim 5, characterized in that, The pressing mechanism is mounted on the gantry frame, and the pressing mechanism is equipped with a pressing plate. The welding detection unit is located on one side of the composite laser output unit, and the positioning detection unit is located above the pressure plate.

7. The laser welding system for an electric drive controller according to claim 5, characterized in that, It also includes a frame and a rear three-axis moving assembly. The frame is located on one side of the gantry, and the rear three-axis moving assembly is mounted on the gantry. The rear three-axis moving assembly includes a rear X-axis moving mechanism for adjusting the position of the post-weld inspection unit in the X-axis direction, a rear Y-axis moving mechanism for adjusting the position of the post-weld inspection unit in the Y-axis direction, and a rear Z-axis moving mechanism for adjusting the position of the post-weld inspection unit in the Z-axis direction.

8. The laser welding system for an electric drive controller according to claim 5, characterized in that, The number of gantry frames is two, and the two gantry frames are arranged side by side. The pressing mechanism is horizontally arranged between the two gantry frames, and the two ends of the pressing mechanism are slidably connected to the side walls of the two gantry frames.

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