Wiring harness shaping and welding equipment

Abstract

The utility model discloses wire harness shaping and welding equipment. The wire harness shaping and welding equipment comprises a rack; the welding bottom frame is arranged on the rack; the welding top frame is arranged on the rack and located above the welding bottom frame; the top terminal is movably arranged on the welding top frame; the bottom terminal is arranged on the welding underframe, and the wire harness and the end part of the connecting terminal are stacked on the bottom terminal; and the limiting assembly is used for limiting the wire harness and the end part of the connecting terminal. The plane positions of the end portion of the connecting terminal and the end portion of the wire harness are locked through the limiting assembly so that the end portion of the connecting terminal and the end portion of the wire harness can be always kept in an aligned state, at the moment, the top terminal is pressed downwards, a loop between the top terminal and the bottom terminal is conducted, the end portion of the wire harness and the end portion of the connecting terminal are rapidly heated, and the surfaces of the wire harness and the connecting terminal are melted to form welding. The limiting assembly ensures that the wire harness end and the connecting terminal are always in an aligned state, the welding quality is good, the welding steps are simple and convenient, and the welding efficiency is high.

Description

Technical Field

[0001] This application relates to the field of welding technology, and in particular to a wire harness shaping and welding device. Background Technology

[0002] An inductor is an electronic component used to handle electric current in a circuit. Inductors are widely used in electronic equipment fields such as industrial control, automotive electronics, new energy, and high-current switching regulators. An inductor generally consists of a magnetic core, a coil, and a housing. The two ends of the coil form connecting terminals, which are used to connect external wiring harnesses, thereby guiding external current into the coil.

[0003] The existing welding process for connecting terminals and wire harnesses requires twisting the ends of the wire harness together, aligning the connecting terminals, and then welding them together. This cumbersome process is time-consuming and labor-intensive, resulting in low welding efficiency and difficulty in ensuring consistent welding quality. Even slight misalignment between the wire harness and the connecting terminals can easily lead to welding failure, resulting in substandard quality and scrap.

[0004] Therefore, it is necessary to propose a wire harness shaping and welding equipment to improve welding efficiency and ensure welding quality, which has become an important technical problem that needs to be solved urgently. Utility Model Content

[0005] This application provides a wire harness shaping and welding device, which aims to solve the problems of low welding efficiency and difficulty in ensuring uniform welding quality between connection terminals and wire harnesses in the prior art.

[0006] To achieve the above objectives, this application proposes a wire harness shaping and welding device, comprising: a frame; a welding base frame disposed on the frame; a welding top frame disposed on the frame and located above the welding base frame; a top terminal movably disposed on the welding top frame; a bottom terminal disposed on the welding base frame, with the ends of the wire harness and the connecting terminal overlapping the bottom terminal; and a limiting component for limiting the ends of the wire harness and the connecting terminal.

[0007] In some embodiments, the device further includes: a welding table movably disposed on a welding base; a welding plate disposed on the welding table, the welding plate having a window, and a limiting component mounted on the welding plate; and a mounting component mounted on the welding table and located at the window, with a bottom terminal disposed on the mounting component.

[0008] In some embodiments, the limiting component includes: a fixed clamp disposed on the welding plate; a movable clamp movably disposed on the welding plate; and a clamp driver for driving the movable clamp to move.

[0009] In some embodiments, the limiting component further includes: a first end plate disposed on the welding plate, and a fixing clamp connected to the first end plate; a second end plate disposed on the welding plate, and a clamp driven mounted on the second end plate; two surrounding plates disposed between the first end plate and the second end plate, and a movable clamp movably disposed between the two surrounding plates, the surrounding plates being provided with through holes for wire harnesses and connecting terminals to pass through.

[0010] In some embodiments, the limiting component further includes: a slide groove disposed on the enclosure; and a protrusion, wherein a movable clamp is disposed on the protrusion and the protrusion is adapted to the slide groove.

[0011] In some embodiments, the device further includes a welding groove disposed on the mounting member, and a bottom terminal disposed on the welding groove.

[0012] In some embodiments, the device further includes: a welding drive disposed on a welding top frame; and a telescopic rod disposed on the welding drive, the telescopic rod being connected to a top terminal.

[0013] In some embodiments, it further includes: a wire fixing plate, which is disposed on the telescopic rod and has wire fixing holes.

[0014] This application proposes a wire harness shaping and welding device, comprising: a frame; a welding base frame disposed on the frame; a welding top frame disposed on the frame and located above the welding base frame; a top terminal movably disposed on the welding top frame; a bottom terminal disposed on the welding base frame, with the ends of the wire harness and the connecting terminal overlapping the bottom terminal; and a limiting component for limiting the ends of the wire harness and the connecting terminal. During the welding process between the wire harness and the connecting terminal, the end of the connecting terminal is first placed on the bottom terminal, and then the end of the wire harness is placed on top of the end of the connecting terminal. The limiting component locks the planar positions of the ends of the connecting terminal and the end of the wire harness, ensuring they remain aligned. At this point, the top terminal presses down, pressing the end of the wire harness towards the end of the connecting terminal until the circuit between the top terminal and the bottom terminal is completed. Under the resistance of the ends of the wire harness and the connecting terminal, the ends of the wire harness and the connecting terminal rapidly heat up, melting their surfaces and forming a weld. The limiting component ensures that the wire harness end and the connection terminal are always aligned, resulting in good welding quality, simple welding steps, and high welding efficiency. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, wherein:

[0016] Figure 1 This is a three-dimensional structural schematic diagram of the wire harness shaping and welding equipment in one embodiment of this application;

[0017] Figure 2 for Figure 1 Enlarged view of part A in the middle;

[0018] Figure 3 This is a top view of the welding base frame in one embodiment of this application;

[0019] Figure 4 for Figure 3 A magnified view of part B in the middle. Detailed Implementation

[0020] 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 a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0021] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in the embodiments of this application are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0022] It should also be noted that when a component is described as "fixed to" or "set on" another component, it can be directly on the other component or there may be an intervening component present. When a component is described as "connected to" another component, it can be directly connected to the other component or there may be an intervening component present.

[0023] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed in this application.

[0024] See Figure 1 , Figure 2 , Figure 3 and Figure 4As shown, this application proposes a wire harness shaping and welding device, comprising: a frame 1; a welding base frame 3, the welding base frame 3 being disposed on the frame 1; a welding top frame 4, the welding top frame 4 being disposed on the frame 1 and located above the welding base frame 3; a top terminal, the top terminal being movably disposed on the welding top frame 4; a bottom terminal, the bottom terminal being disposed on the welding base frame 3, the ends of the wire harness and the connecting terminal being stacked on the bottom terminal; and a limiting component, the limiting component being used to limit the ends of the wire harness and the connecting terminal.

[0025] The frame 1 is the structural foundation of the wire harness shaping and welding equipment. All other structures in the equipment are directly or indirectly connected to the frame 1. The bottom of the frame 1 has several mounting feet 2 for fixing it. The welding top frame 4 is the structural foundation for the top terminals, and the welding bottom frame 3 is the structural foundation for the bottom terminals. The bottom and top terminals constitute a welding assembly. The top terminals are connected to a first wire 7, and the bottom terminals are connected to a second wire. Both the first and second wires are electrically connected to a power source. After the bottom and top terminals make indirect contact through the wire harness and connecting terminals, the circuit is completed. High temperatures are generated by the resistance between the wire harness and connecting terminals, melting the surfaces of the wire harness and connecting terminals to form a weld. A control switch is installed on either the first or second wire to control the welding process. The limiting assembly is the core equipment of the shaping and welding equipment, used to limit the position of the wire harness and connecting terminals, ensuring alignment between them.

[0026] Specifically, during the welding process between the wire harness and the connecting terminal, the end of the connecting terminal is first placed on top of the bottom terminal, and then the end of the wire harness is placed on top of the end of the connecting terminal. A limiting component locks the lateral position of the connecting terminal and the wire harness ends, ensuring they remain aligned. At this point, the top terminal is pressed down, pressing the wire harness end towards the connecting terminal end until a circuit is established between the top and bottom terminals. Under the resistance of the wire harness and connecting terminal ends, high temperatures are rapidly generated, melting the surfaces of the wire harness and the connecting terminal, forming a weld. The limiting component ensures that the wire harness and connecting terminal ends remain aligned, resulting in high-quality welding, a simple welding process, and high welding efficiency.

[0027] In detail, in this embodiment, after the coil and magnetic core form an inductor structure, the connecting terminals are welded to the wire harness. After welding, the inductor structure is encapsulated in the housing to form an inductor. The coil uses film-coated flat aluminum wire, and the two connecting terminals are the two ends of the film-coated flat aluminum wire, with the cross-sectional area of ​​the connecting terminals being oblong. Several wires are arranged inside the wire harness. During the welding process, the wire harness and coil are held by hand or clamped by a jig to limit the longitudinal position of the ends of the connecting terminals and the ends of the wire harness. The longitudinal direction refers to the length direction of the connecting terminals, and the lateral direction refers to the width direction of the connecting terminals. The structure of the limiting component is not limited here, as long as it can form a limiting space for the ends of the wire harness and the ends of the connecting terminals.

[0028] The frame 1, welded base frame 3, and welded top frame 4 are all welded from cold-rolled steel plates and bars. The surface of frame 1 is powder-coated, giving it strong stability and corrosion resistance. It also possesses excellent mechanical properties, allowing the wire harness shaping and welding equipment to adapt to diverse and harsh environmental conditions. Both the bottom and top terminals are made of nickel alloy, which has good conductivity and high-temperature resistance, facilitating welding.

[0029] See Figure 1 and Figure 2 As shown, in some embodiments, the system further includes: a welding table 11, movably mounted on the welding base 3; a welding plate 10, mounted on the welding table 11, with a gap between the welding plate 10 and the welding table 11 to facilitate the routing of the second conductor; the welding plate 10 having a window; and a limiting component mounted on the welding plate 10; and a mounting member 21, mounted on the welding table 11 and located at the window, with a bottom terminal mounted on the mounting member 21. The mounting member 21 is used to support the bottom terminal, and is made of bakelite, also known as phenolic plastic. Bakelite is non-absorbent, non-conductive, heat-resistant, high-strength, and has good formability.

[0030] In this embodiment, multiple windows can be provided on the welding plate 10. Different windows correspond to different specifications of mounting parts 21 and limiting components. Due to the different specifications of inductors, the connecting terminals and wire harnesses also have different specifications. Multiple windows are beneficial for accommodating connecting terminals and wire harnesses of different specifications. The welding table 11 is movably mounted on the welding base 3, and the top terminal can also move along the top surface of the welding top frame 4 to align the top terminal with the bottom end of different windows. The above structure enhances the adaptability of the wire harness shaping welding equipment and improves its practicality. The structure for driving the movement of the welding table 11 and the structure for driving the top terminal to move in a planar manner are mature existing technologies, and no specific limitations are made on their structure here.

[0031] See Figure 1 and Figure 2As shown, in some embodiments, the limiting component includes: a fixed clamp 18 disposed on the welding plate 10; a movable clamp 19 movably disposed on the welding plate 10; and a clamp drive 9 for driving the movable clamp 19 to move. The right end face of the fixed clamp 18 is flush with the left end face of the bottom terminal. By driving the left end face of the movable clamp 19 to be flush with the right end face of the bottom terminal through the clamp drive 9, a limiting space is formed between the fixed clamp 18 and the movable clamp 19. The ends of the wire harness and the connecting terminals are placed within the limiting space, ensuring that they remain aligned. The clamp drive 9 is preferably a cylinder, and it is equipped with an output rod 12 connected to the movable clamp 19. The fixed clamp 18 and the movable clamp 19 are made of bakelite.

[0032] See Figure 1 and Figure 2 As shown, in some embodiments, the limiting component further includes: a first end plate 16, disposed on the welding plate 10, with a fixing clamp 18 connected to the first end plate 16; a second end plate 13, disposed on the welding plate 10, with a clamp drive 9 mounted on the second end plate 13; both the first end plate 16 and the second end plate 13 are mounted to the welding plate 10 by fasteners 15, preferably screws; the first end plate 16 and the second end plate 13 are the structural bases for the fixing clamp 18 and the movable clamp 19, respectively, with the movable clamp 19 indirectly mounted on the second end plate 13; and two surrounding plates 14, disposed between the first end plate 16 and the second end plate 13, with the movable clamp 19 movably disposed between the two surrounding plates 14; the surrounding plates 14 are provided with through holes 17 for wire harnesses and connecting terminals to pass through. The surrounding plates 14 are used to enclose the welding area to improve the safety of the welding process. The inner diameter of the through hole 17 is significantly larger than the cross-sectional area of ​​the wire harness and the connecting terminal, allowing both to pass through the through hole 17 easily.

[0033] See Figure 1 and Figure 2 As shown, in some embodiments, the limiting component further includes: a slide groove 20 disposed on the surrounding plate 14; and a protrusion, on which a movable clamp 19 is disposed, the protrusion being adapted to the slide groove 20. The cooperation between the slide groove 20 and the protrusion is used to limit the moving direction of the movable clamp 19, making the moving direction of the movable clamp 19 more stable.

[0034] See Figure 3 and Figure 4 As shown, in some embodiments, it further includes a welding groove 22, which is disposed on the mounting member 21, and the bottom terminal is disposed in the welding groove 22. The welding groove 22 is used to initially accommodate the connecting terminal to clarify the welding position, so that the relevant operators can quickly extend the end of the connecting terminal to the welding position. The depth of the welding groove 22 is less than the thickness of the end of the connecting terminal.

[0035] See Figure 1 As shown, in some embodiments, the system further includes: a welding drive 5, which is disposed on the welding top frame 4; and a telescopic rod 6, which is disposed on the welding drive 5 and connected to a top terminal. The welding drive 5 is either a hydraulic cylinder or a pneumatic cylinder. The welding drive 5 drives the telescopic rod 6 to perform reciprocating linear motion, thereby driving the top terminal to perform reciprocating linear motion. Preferably, the welding drive 5 is connected to a mounting plate, which is movably mounted on the welding top frame 4. The position of the top terminal can be adjusted by adjusting the position of the mounting plate, thereby aligning it with the bottom terminal.

[0036] See Figure 1 As shown, in some embodiments, it further includes a wire fixing plate 8, which is disposed on the telescopic rod 6 and has a wire fixing hole. The wire fixing hole is used to restrict the first wire 7 and prevent the first wire 7 from getting tangled on other structures when the telescopic rod 6 makes reciprocating linear motion or planar movement.

[0037] The above description is only a part or preferred embodiment of this application. Neither the text nor the drawings should limit the scope of protection of this application. All equivalent structural transformations made using the content of this application's specification and drawings under the overall concept of this application, or direct / indirect applications in other related technical fields, are included within the scope of protection of this application.

Claims

1. A wire harness shaping and welding device, characterized in that, include: Rack (1); Welding base frame (3), the welding base frame (3) is disposed on the frame (1); A welding top frame (4) is disposed on the frame (1) and located above the welding base frame (3); Top terminal, which is movably disposed on the welding top frame (4); Bottom terminal, the bottom terminal is disposed on the welding base frame (3), and the ends of the wire harness and the connecting terminal are both stacked on the bottom terminal; A limiting component, the limiting component being used to limit the ends of the wire harness and the connecting terminal; Also includes: Welding table (11), which is movably mounted on the welding base frame (3). A welding plate (10) is disposed on the welding table (11). The welding plate (10) is provided with a window. The limiting component is installed on the welding plate (10). Mounting component (21), which is mounted on the welding station (11) and located in the window, with the bottom terminal disposed on the mounting component (21).

2. The wire harness shaping and welding equipment according to claim 1, characterized in that, The limiting component includes: Fixture (18) is disposed on the welding plate (10); A movable clamp (19) is movably disposed on the welding plate (10). A clamp drive (9) is used to drive the moving clamp (19) to move.

3. The wire harness shaping and welding equipment according to claim 2, characterized in that, The limiting component also includes: The first end plate (16) is disposed on the welding plate (10), and the fixing clamp (18) is connected to the first end plate (16). The second end plate (13) is disposed on the welding plate (10), and the clamp drive (9) is mounted on the second end plate (13). Two enclosure plates (14) are disposed between the first end plate (16) and the second end plate (13). The movable clamp (19) is movably disposed between the two enclosure plates (14). The enclosure plates (14) are provided with through holes (17) for wire harnesses and connecting terminals to pass through.

4. The wire harness shaping and welding equipment according to claim 3, characterized in that, The limiting component also includes: A chute (20) is provided on the enclosure (14); A protrusion, wherein the movable clamp (19) is disposed on the protrusion, and the protrusion is adapted to the groove (20).

5. The wire harness shaping and welding equipment according to claim 1, characterized in that, Also includes: Welding groove (22), the welding groove (22) is disposed on the mounting part (21), and the bottom terminal is disposed on the welding groove (22).

6. The wire harness shaping and welding equipment according to claim 1, characterized in that, Also includes: Welding drive (5), the welding drive (5) is disposed on the welding top frame (4); Telescopic rod (6), the telescopic rod (6) is disposed on the welding drive (5), and the telescopic rod (6) is connected to a top terminal.

7. The wire harness shaping and welding equipment according to claim 6, characterized in that, Also includes: A wire fixing plate (8) is provided on the telescopic rod (6), and the wire fixing plate (8) is provided with wire fixing holes.

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