Ultrasonic wire harness welding device

Abstract

The utility model discloses an ultrasonic wire harness welding device which comprises an ultrasonic welding assembly, an ultrasonic system and a first driving device, the first driving assembly is a first air cylinder, the ultrasonic system comprises a triple set and a bottom die, the first driving assembly is a first air cylinder, and the first driving assembly drives the triple set to move downwards to achieve ultrasonic welding; the welding machine body is used for installing the ultrasonic welding assembly. The base assembly is located below the ultrasonic welding assembly and the welding machine body. The clamp assembly is installed in the first air cylinder welding machine body with the first driving assembly, the first driving assembly is the first air cylinder clamp assembly, the first driving assembly is the first air cylinder clamp assembly, the first driving assembly is the first air cylinder base assembly, and the first driving assembly is the first air cylinder clamp assembly and is located below the ultrasonic welding assembly. The first driving assembly is a first air cylinder clamp assembly, comprises a product tool and a clamping mechanism and is used for positioning and fixing a wire harness. Through reasonable component layout and design, the structure is more compact, and the cost and the energy consumption are reduced.

Description

Technical Field

[0001] This utility model relates to the field of ultrasonic welding technology, specifically to an ultrasonic wire harness welding device. Background Technology

[0002] Ultrasonic welding, as an advanced welding technology, possesses numerous significant advantages, such as high fusion strength, good conductivity, no sparks, near-cold processing, no melting of the welding material (preserving the original properties of the metal), excellent conductivity after welding (extremely low or near-zero resistivity), low requirements for the surface of the weld metal (welding can be performed in oxidized or electroplated states), short welding time, and the absence of any flux, gas, or solder. Furthermore, the welding process is spark-free, making it environmentally friendly and safe. However, ultrasonic welding places high demands on the welding process. Improper welding parameter settings or insecure workpiece positioning can significantly reduce the service life and conductivity of the welded product.

[0003] Wire harness welding is a welding technique that uses ultrasonic technology to weld copper or aluminum wires onto copper or aluminum sheets. It is widely used in the wire harness industry. In common applications, the conductive cross-sectional area of ​​the copper or aluminum wires is typically between 1 and 200 mm². 2 The thickness of the copper or aluminum sheet is about 0.5 to 5 mm. The welding area is generally planar. The structure of its plug-in part is diverse, such as square or round, and they are collectively referred to as terminals in the industry.

[0004] Currently, for 5-25mm 2 For ultrasonic wire harness welding machines, there are problems such as complex structure, numerous components, high energy consumption, and high overall cost. Furthermore, the cross-section of copper and aluminum wires after stripping is circular, while ultrasonic welding requires the terminals to be rectangular. Existing technologies often rely on relatively complex devices and processes to achieve these welding requirements, which is not conducive to carrying out wire harness welding work efficiently and at low cost. Utility Model Content

[0005] In view of this, the purpose of this utility model is to overcome the defects in the prior art and provide an ultrasonic wire harness welding device to solve the technical problems of existing ultrasonic wire harness welding machines, such as complex structure, high cost, and insufficient adaptability to welding metal wire harnesses of different diameters during the welding process. It enables flexible adjustment of the welding position to facilitate welding of metal wire harnesses of different diameters, while ensuring welding effect and operational safety.

[0006] This utility model discloses an ultrasonic wire harness welding device, comprising:

[0007] An ultrasonic welding assembly includes an ultrasonic system and a first driving assembly. The ultrasonic system includes a triple assembly and a bottom mold. The first driving assembly drives the triple assembly to move downward to achieve ultrasonic welding.

[0008] A welding machine body, wherein the welding machine body is used to mount ultrasonic welding components;

[0009] The base assembly is located below the ultrasonic welding assembly and the welding machine body;

[0010] A clamping assembly is installed inside the welding machine body. The clamping assembly is located above the base assembly and below the ultrasonic welding assembly. The clamping assembly includes product tooling and a clamping mechanism for positioning and fixing the wire harness.

[0011] As a preferred embodiment, the base assembly includes a pull-out device, a base body, and electrical components. The electrical components are installed above the bottom of the pull-out device. Slides are provided on both sides of the pull-out device, and the pull-out device and the base body are slidably connected through the slides, so that the pull-out device can slide smoothly in and out relative to the base body.

[0012] As a preferred embodiment, the product tooling includes a platform, and a terminal contour groove is installed on the top of the platform.

[0013] As a preferred embodiment, the clamping assembly includes a positioning component and a wire clamping component. The positioning component is installed inside the welding machine body and includes a left stop block, a right stop block, and a rear stop block, which are respectively used to press against the left side, right side, and rear side of the terminal to form a welding space. The wire clamping component includes a wire clamping cylinder and a clamping claw. The wire clamping cylinder drives the clamping claw to fix and clamp the wire harness during the welding process.

[0014] As a preferred embodiment, a visual door assembly is provided on the front side of the welding machine body.

[0015] As a preferred embodiment, the visualization door assembly includes a door panel, which is connected to the upper part of the welding machine body via a damping hinge. A small door that can be raised and lowered is provided in the middle of the door panel, and a drive cylinder is provided on one side of the small door. The drive cylinder is connected to the small door via a connector to drive the small door to move up and down.

[0016] As a preferred embodiment, the triplet assembly includes a welding head, an amplitude transformer, and an amplitude modulator, with one end of the amplitude transformer connected to the welding head and the other end of the amplitude transformer connected to the welding head.

[0017] As a preferred embodiment, the first driving component is a first cylinder, which drives the welding head to move downward, so that the welding head contacts the wire harness to be welded, thereby realizing ultrasonic welding.

[0018] As a preferred embodiment, the welding device further includes an interactive device, which is a human-machine integrated screen used to set welding parameters, view equipment operating status, and obtain fault prompt information.

[0019] The beneficial effects of this utility model are: the ultrasonic wire harness welding device disclosed in this utility model, through reasonable component layout and design, has a more compact structure compared with similar devices in the prior art, reducing manufacturing costs and energy consumption, and has a higher cost performance.

[0020] The integrated human-machine interface provides a user-friendly interface, allowing operators to easily set welding parameters, view equipment status, and handle fault information. Meanwhile, the visual door component facilitates observation of the welding process; closing the small door during welding prevents injury from welding spatter and accidental movement of the welding head.

[0021] The product tooling and clamping mechanism in the fixture assembly can accurately position and firmly clamp terminals and wire harnesses of different specifications, ensuring the accuracy of the welding position, avoiding welding quality problems caused by poor positioning, and improving the quality and consistency of welded products.

[0022] The pull-out mechanism and slide rail design of the base assembly facilitate the maintenance and repair of electrical components, improving the maintainability of the equipment. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the external structure of this utility model;

[0025] Figure 2 This is a schematic diagram of the clamping mechanism.

[0026] Figure 3 This is a schematic diagram of the wire clamping assembly structure;

[0027] Figure 4 This is a schematic diagram of the small door drive cylinder structure.

[0028] Reference numerals in the attached drawings: 1. Welding machine body; 2. Pull-out device; 3. Base body; 4. Electrical components; 5. Slide rail; 6. Platform; 7. Terminal contouring groove; 8. Left stop block; 9. Right stop block; 10. Wire clamping cylinder; 11. Gripper; 12. Door panel; 13. Damping hinge; 14. Small door; 15. Drive cylinder; 16. Human-machine interface screen; 17. Connector; 18. Output shaft. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0030] In the description of the embodiments of this application, the terms "upper," "lower," "front," "rear," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. In addition, the terms "first," "second," etc., are only used for distinction in description and have no special meaning.

[0031] Figures 1-4 This is a schematic diagram of the structure of the present invention, as shown below. Figure 1 As shown, an ultrasonic wire harness welding device in this embodiment includes an ultrasonic welding assembly, which includes an ultrasonic system and a first driving assembly. The ultrasonic system includes a triple assembly and a bottom mold. The first driving assembly drives the triple assembly to move downward to achieve ultrasonic welding.

[0032] Welding machine body 1, which is used to install ultrasonic welding components;

[0033] The base assembly is located below the ultrasonic welding assembly and the welding machine body 1;

[0034] The clamping assembly is installed inside the welding machine body 1. The clamping assembly is located above the base assembly and below the ultrasonic welding assembly. The clamping assembly includes product tooling and clamping mechanism for positioning and fixing the wire harness.

[0035] In this embodiment, the base assembly includes a pull-out device 2, a base body 3, and an electrical component 4. The electrical component 4 is installed above the bottom of the pull-out device 2. Slide rails 5 are provided on both sides of the pull-out device 2, and the pull-out device 2 and the base body 3 are slidably connected via the slide rails 5, allowing the pull-out device to slide smoothly in and out relative to the base body. This facilitates convenient maintenance of the electrical component 4 installed at the bottom of the pull-out device 2. During maintenance, the pull-out device 2 is pulled out from the base body 3 along the slide rails 5, exposing the electrical component 4 for easy inspection, repair, and replacement by maintenance personnel. After maintenance, the pull-out device 2 is pushed back into the base body along the slide rails 5 and secured, ensuring normal electrical connection and structural stability of the entire device.

[0036] In some embodiments, the product fixture includes a platform 6, on which a terminal contouring groove 7 is mounted. The shape and size of the platform 6 can be designed and adjusted according to different wire harnesses and terminal specifications, exhibiting good versatility and adaptability. The shape of the terminal contouring groove 7 matches the terminal to be soldered, ensuring that the terminal is accurately positioned in a preset position, providing precise spatial positioning assurance for subsequent soldering operations.

[0037] In some embodiments, the clamping assembly includes a positioning assembly and a wire clamping assembly. The positioning assembly is installed inside the welding machine body 1 and includes a left stop 8, a right stop 9, and a rear stop (not shown in the figure), which are respectively used to press against the left, right, and rear sides of the terminal to form a welding space. The left stop 8, right stop 9, and rear stop (not shown in the figure) can be of an adjustable structure, and their relative positions and spacing can be flexibly adjusted by an adjustment mechanism to adapt to the welding requirements of terminals and wire harnesses of different sizes. The wire clamping assembly includes a wire clamping cylinder 10 and a clamping jaw 11. The wire clamping cylinder 10 drives the clamping jaw 11 to fix and clamp the wire harness during the welding process. This prevents the wire harness from loosening or shifting during welding and ensures the stability of the relative position of the wire harness and the terminal during ultrasonic energy transfer and welding.

[0038] In some embodiments, a visualization door assembly is provided on the front side of the welding machine body 1, which facilitates observation of the welding situation inside the welding machine body 1.

[0039] like Figure 4As shown, in some embodiments, the visualization door assembly includes a door panel connected to the upper part of the welding machine body 1 via a damping hinge 13. A small, liftable door 14 is located in the middle of the door panel. A drive cylinder 15 is located on one side of the small door 14, connected to the small door via a connector 17. The connector 17 is fixedly connected to the output shaft 18 of the drive cylinder 15. A guide rail is located on the other side of the small door, allowing the drive cylinder 15 to drive the small door to move up and down along the guide rail. The damping hinge 13 has a suitable damping coefficient, ensuring smooth and safe opening and closing of the door panel. When it is necessary to replace components inside the welding machine, the door panel is rotated upwards and fixed in place, facilitating internal maintenance and component replacement. The small door is made of a transparent material (such as transparent acrylic) to ensure good visibility. During welding, the visualization door assembly prevents welding spatter and accidental movement of the welding head from injuring the operator, and allows the operator to observe the welding status in real time to promptly detect and handle any potential abnormalities.

[0040] In some embodiments, the triplet assembly includes a welding head, an amplitude transformer, and an amplitude modulator, with one end of the amplitude transformer connected to the welding head and the other end of the amplitude transformer connected to the welding head.

[0041] In some embodiments, the first driving component is a first cylinder, which drives the welding head to move downward, so that the welding head contacts the wire harness to be welded, thereby realizing ultrasonic welding.

[0042] This embodiment also includes an interactive device, which can be a human-machine interface screen 16. Various welding parameters, such as ultrasonic power, welding time, and pressure, can be set. Operators can input corresponding parameters on the human-machine interface screen 16 according to different wire harness and terminal specifications and welding process requirements, achieving precise control of the welding process. Simultaneously, the operator can view the equipment's operating status, including the working status of each component (such as the ultrasonic system's operating frequency, the drive unit's stroke position, and the working status of each cylinder) and sensor data (such as pressure sensors and displacement sensors), providing comprehensive equipment information and facilitating understanding of the equipment's operation. Furthermore, when equipment malfunctions, the human-machine interface screen 16 will promptly display fault information, helping operators quickly locate and resolve problems, improving the device's operational convenience and intelligence.

[0043] In actual operation, the terminal to be welded is first accurately placed in the terminal conformal groove 7. The design of the terminal conformal groove 7 matches the terminal, providing precise initial positioning. Then, by adjusting the left, right, and rear stops in the positioning assembly, they are pressed against the perimeter of the terminal, forming a welding space to ensure the terminal does not shift position during the entire welding process. Next, the wire harness is passed through the preset positioning channel. When the wire harness reaches the predetermined position, the clamping cylinder 10 is activated, driving the gripper 11 to clamp the wire harness, preparing for subsequent welding operations. After completing the above preparations, the small door 14 is closed. This small door 14 is made of transparent material (such as transparent acrylic), allowing operators to safely observe the internal welding process while preventing potential spatter from injuring surrounding personnel. Finally, the first cylinder pushes the welding head precisely down to the position of the wire harness, simultaneously emitting ultrasonic waves to begin the welding operation. During the welding process, the welding head stably transmits ultrasonic energy to the contact area between the wire harness and the terminal, achieving an efficient and secure connection between the two, thus completing the entire welding process.

[0044] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this utility model without departing from the spirit and scope of the technical solutions of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. An ultrasonic wire harness welding device, characterized in that, include: An ultrasonic welding assembly includes an ultrasonic system and a first driving assembly. The ultrasonic system includes a triple assembly and a bottom mold. The first driving assembly drives the triple assembly to move downward to achieve ultrasonic welding. A welding machine body, wherein the welding machine body is used to mount ultrasonic welding components; The base assembly is located below the ultrasonic welding assembly and the welding machine body; A clamping assembly is installed inside the welding machine body. The clamping assembly is located above the base assembly and below the ultrasonic welding assembly. The clamping assembly includes product tooling and a clamping mechanism for positioning and fixing the wire harness.

2. The ultrasonic wire harness welding device according to claim 1, characterized in that: The base assembly includes a pull-out device, a base body, and electrical components. The electrical components are installed above the bottom of the pull-out device. Slides are provided on both sides of the pull-out device. The pull-out device and the base body are slidably connected through the slides, so that the pull-out device can slide smoothly in and out relative to the base body.

3. The ultrasonic wire harness welding device according to claim 1, characterized in that: The product tooling includes a platform, and a terminal contour groove is installed on the top of the platform.

4. The ultrasonic wire harness welding device according to claim 1, characterized in that: The clamping assembly includes a positioning assembly and a wire clamping assembly. The positioning assembly is installed inside the welding machine body and includes a left stop, a right stop, and a rear stop, which are respectively used to press against the left side, right side, and rear side of the terminal to form a welding space. The wire clamping assembly includes a wire clamping cylinder and clamping claws, wherein the wire clamping cylinder drives the clamping claws to fix and clamp the wire harness during the welding process.

5. The ultrasonic wire harness welding device according to claim 1, characterized in that: A visualization door assembly is provided on the front side of the welding machine body.

6. The ultrasonic wire harness welding device according to claim 5, characterized in that: The visualization door assembly includes a door panel, which is connected to the upper part of the welding machine body via a damping hinge. A small door that can be raised and lowered is provided in the middle of the door panel. A drive cylinder is provided on one side of the small door. The drive cylinder is connected to the small door via a connector to drive the small door to move up and down.

7. The ultrasonic wire harness welding device according to claim 1, characterized in that: The triple assembly includes a welding head, an amplitude transformer, and an amplitude modulator. One end of the amplitude transformer is connected to the welding head, and the other end of the amplitude transformer is connected to the welding head.

8. An ultrasonic wire harness welding device according to claim 7, characterized in that: The first driving component is a first cylinder, which drives the welding head to move downward, so that the welding head contacts the wire harness to be welded, thereby realizing ultrasonic welding.

9. An ultrasonic wire harness welding device according to claim 1, characterized in that: The welding device also includes an interactive device, which is a human-machine integrated screen used to set welding parameters, view equipment operating status, and obtain fault prompt information.

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