Safety capacitor core cladding resistance welding system
The automated resistance welding system for safety capacitor cores has solved the problems of unstable welding quality and low efficiency, achieving a highly efficient and reliable welding process and ensuring the electrical performance and lifespan of safety capacitors.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHANGHAI EAGTOP ELECTRONICS TECH
- Filing Date
- 2025-02-25
- Publication Date
- 2026-04-21
AI Technical Summary
Traditional welding methods make it difficult to precisely control the contact pressure, current magnitude, and energizing time between the electrode and the workpiece, resulting in unstable welding quality, low production efficiency, and uneven heat distribution that affects the internal structure and electrical performance of safety capacitor cores.
An automated, safety-compliant capacitor core resistance welding system is adopted, including a welding unit and a positioning and conveying unit. The contact pressure is monitored by a clamping module and a pressure monitoring gauge. Combined with a positioning slide and a contour jig, automated material conveying is achieved to ensure welding quality and internal structural stability.
It improves welding quality, ensures strong solder joints, reduces the occurrence of incomplete soldering, increases production efficiency, reduces heat damage, and extends the service life of safety capacitors.
Smart Images
Figure CN224143713U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of resistance welding technology, specifically to a resistance welding system for a safety-compliant capacitor core. Background Technology
[0002] Safety capacitors play a crucial role in electronic circuits, and their performance and quality directly affect the safety and stability of the entire circuit system. The core of a safety capacitor is typically composed of multiple layers of different dielectric materials and electrode foils. Traditional core-pack welding methods have the following drawbacks: 1. Unstable welding quality; Current common welding processes, such as spot welding, are difficult to precisely control when welding safety capacitor cores. This can easily lead to problems such as incomplete soldering and insufficient solder joint strength. Incomplete soldering may cause poor contact during use, affecting the electrical performance and even causing circuit failures. 2. Low production efficiency; Conventional welding operations mostly rely on manual labor or semi-automated equipment. When spot welding safety capacitor cores one by one, frequent adjustments to the workpiece position and parameter settings are required, making the operation cumbersome and difficult to meet the needs of large-scale production. Furthermore, the subjective factors of manual operation further increase the inconsistency in welding quality. 3. Welding has a significant impact on the internal structure of safety capacitor cores; some welding processes generate a lot of heat during operation, and the heat distribution is uneven, which can easily cause thermal damage to the dielectric materials and electrode foils inside the safety capacitor core, altering their original electrical characteristics and reducing the quality and service life of the safety capacitor. Utility Model Content
[0003] To address the shortcomings of existing technologies, the purpose of this utility model is to provide a resistance welding system for safety capacitor cores that can ensure accurate welding positions and improve welding quality; it can also flexibly adapt to safety capacitor cores of different sizes and specifications, ensuring internal structural stability during welding and enhancing the versatility of the welding system; and the overall automated welding process can better meet the requirements of large-scale industrial production.
[0004] The technical solution adopted in this utility model is: a safety-compliant capacitor core resistance welding system, including a welding unit and a positioning and conveying unit; the welding unit includes a clamping module, the output end of which is connected to a welding electrode head, the welding electrode head is driven to move vertically up and down by the clamping module, and a pressure monitoring gauge is also provided on the clamping module, the monitoring end of which abuts against the mounting part at the upper end of the welding electrode head, for monitoring the contact pressure between the welding electrode head and the capacitor core; the positioning and conveying unit includes a base, a positioning slide is provided at the upper end of the base, a guide rail module for driving the positioning slide is provided inside the base, a detachable contour positioning base plate is installed at the upper end of the positioning slide, and a contour fixture for accommodating the welded capacitor core is provided on the contour positioning base plate.
[0005] In this technical solution, the entire resistance welding system implements automated welding through welding units, and the positioning and conveying unit automatically feeds materials during the welding process. The clamping module of the welding unit can drive the welding electrode head to press down on the capacitor core package to achieve positioning and clamping, ensuring that the safety capacitor core package will not loosen during the welding process, thus guaranteeing welding quality. During the clamping process, a pressure monitoring gauge is used to monitor the downward pressure to ensure that the applied clamping force is always within a reasonable range, avoiding problems such as poor welding or damage to the safety capacitor core package due to excessive or insufficient pressure. The positioning and conveying unit for loading and unloading is equipped with a guide rail module on the base to drive the positioning slide to the corresponding loading / unloading position and the position to be welded. Different specifications of contour positioning base plates and contour jigs are installed according to welding needs to improve the versatility of this system.
[0006] Preferably, the clamping module is provided with a mounting bracket on its outer side, and the mounting bracket is provided with an adapter plate for connecting the three-dimensional robotic arm.
[0007] Preferably, the upper end of the clamping module is provided with a welding cable connector that is connected to the welding electrode head via a cable.
[0008] Preferably, the base is provided with photoelectric limiting modules at both ends corresponding to the sliding direction of the positioning slide.
[0009] Preferably, the base end is provided with a control line interface for signal connection with the guide rail module.
[0010] Preferably, it also includes a control system that is signal-connected to the welding unit and the positioning and conveying system, the control system being connected to a teach pendant assembly and a control button assembly.
[0011] The beneficial effects of this utility model are:
[0012] 1. This system can significantly improve the quality of welding of safety capacitor cores, ensuring that the welds are firm and free of incomplete welds during the welding process, guaranteeing the reliability of electrical connections at the welded parts, and improving the overall performance stability of the safety capacitor.
[0013] 2. This system can improve the production efficiency of welding safety capacitor cores, realize the automation or semi-automation control of the welding process, reduce manual intervention, reduce quality differences caused by manual operation, and meet the needs of mass production.
[0014] 3. This system can optimize the heat generation and distribution during the welding process, reduce the damage to the internal structure of the safety capacitor core caused by welding heat conduction, ensure that the original electrical properties of the dielectric material inside the safety capacitor core are not damaged, and extend the service life of the safety capacitor. Attached Figure Description
[0015] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.
[0016] Figure 1 This is a structural diagram of the safety capacitor core resistance welding system provided in the embodiments of this utility model.
[0017] Figure 2 This is a schematic diagram of the welding unit of the safety capacitor core-clad resistance welding system provided in this embodiment of the utility model. Figure 1 .
[0018] Figure 3 This is a schematic diagram of the welding unit of the safety capacitor core-clad resistance welding system provided in this embodiment of the utility model. Figure 2 .
[0019] Figure 4 This is a schematic diagram of the positioning and conveying unit of the safety capacitor core resistance welding system provided in this embodiment of the utility model. Figure 1 .
[0020] Figure 5 This is a schematic diagram of the positioning and conveying unit of the safety capacitor core resistance welding system provided in this embodiment of the utility model. Figure 2 .
[0021] Figure 6 This is a control schematic diagram of the safety capacitor core resistance welding system provided in the embodiments of this utility model.
[0022] Reference numerals in the attached drawings: clamping module 100, welding electrode head 200, assembly part 210, pressure monitoring gauge 300, base 400, positioning slide 500, guide rail module 600, contour positioning base plate 700, contour jig 800, mounting bracket 900, adapter plate 910, welding cable connector 1000, photoelectric limit module 1100, control line interface 1200, teach pendant assembly 1300, control button assembly 1400, robotic arm 1500, safety capacitor core package 1600. Detailed Implementation
[0023] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings. These embodiments are merely illustrative of the present invention and should not be construed as limiting the scope of protection of the present invention.
[0024] It should be noted that, unless otherwise stated, the technical or scientific terms used in this application shall have the ordinary meaning as understood by one of ordinary skill in the art to which this utility model pertains.
[0025] like Figures 1 to 5 As shown in the figure, a specific embodiment of this utility model provides a resistance welding system for safety capacitor core packages. This system is used to achieve high-efficiency and high-quality welding of safety capacitor core packages. It includes a welding unit and a positioning and conveying unit. The welding unit includes a clamping module 100, with a welding electrode head 200 connected to the output end of the lower end of the clamping module 100. The welding electrode head 200 is driven to move vertically up and down by the clamping module 100. A pressure monitoring gauge 300 is also provided on the clamping module 100. The pressure monitoring gauge 300 monitors... The measuring end abuts against the assembly part 210 located on the upper end of the welding electrode head 200, and is used to monitor the contact pressure between the welding electrode head 200 and the safety capacitor core package 1600; the positioning and conveying unit includes a base 400, a positioning slide 500 is provided on the upper end of the base 400, a guide rail module 600 for driving the positioning slide 500 is provided inside the base 400, a detachable contour positioning base plate 700 is installed on the upper end of the positioning slide 500, and a contour jig 800 for accommodating the safety capacitor core package 1600 to be welded is provided on the contour positioning base plate 700.
[0026] like Figures 1 to 5 As shown, the entire resistance welding system provided in this embodiment implements automated welding through a welding unit, and the positioning and conveying unit automatically feeds materials during the welding process. Specifically, the clamping module 100 of the welding unit can drive the welding electrode head 200 to press down on the safety capacitor core package 1600 to perform positioning and clamping, ensuring that the safety capacitor core package 1600 will not loosen during the welding process, thereby ensuring welding quality. During the clamping process, a pressure monitoring gauge is used to monitor the downward pressure to ensure that the applied clamping force is always within a reasonable range, avoiding problems such as poor welding or damage to the safety capacitor core package 1600 due to excessive or insufficient pressure. In practical applications, the clamping module 100 adopts a pneumatic clamping structure to apply appropriate pressure to the safety capacitor core package 1600.
[0027] like Figures 1 to 5 As shown, in this embodiment, the positioning and conveying unit for loading and unloading materials has a guide rail module 600 on the base 400 to drive the positioning slide 500 to move to the corresponding loading / unloading position and the position to be welded. Different specifications of contour positioning base plate 700 and contour jig 800 are installed according to welding needs to improve the versatility of the system. The contour jig 800 and contour positioning base plate 700 are developed according to different sizes of existing safety capacitor core packages 1600. Before welding, the corresponding specifications can be selected and installed on the positioning slide 500. The guide rail module 600 can adopt a servo motor combined with a ball screw structure, which has the advantages of high positioning accuracy and stable transmission.
[0028] like Figure 2 and Figure 3As shown, in this embodiment, in order to install the welding electrode head 200 at the output end of the clamping module 100, the upper end of the welding electrode head 200 is provided with an assembly part 210 connected to the output end of the clamping module 100, and the monitoring end of the pressure monitoring gauge 300 abuts against the assembly part 210. Thus, when the assembly part 210 is connected to the clamping module 100, the clamping force during welding can be monitored by the contact between the pressure monitoring gauge 300 and the assembly part 210. In actual production applications, the pressure monitoring gauge 300 uses existing products, and its model and specifications are selected according to design requirements, which will not be elaborated here.
[0029] like Figure 2 and Figure 3 As shown, this system needs to move to the corresponding welding position in real time during use. To improve the degree of automation, this embodiment has a mounting bracket 900 on the outside of the welding clamping module 100, and an adapter plate 910 for connecting the three-dimensional robotic arm 1500 is provided on the mounting bracket 900. In this way, the entire welding unit can be mounted on the robotic arm 1500 through the adapter plate 910, and the robotic arm 1500 drives the welding unit to move. The robotic arm 1500, which has multiple degrees of freedom, can move precisely to the welding position to implement automated welding operations. Through the precise movement and positioning of the robotic arm, the accuracy and efficiency of the welding operation are improved.
[0030] like Figure 4 and Figure 5 As shown, to facilitate the connection of various control and connection harnesses for welding, this embodiment has a welding cable connector 1000 at the upper end of the clamping module 100, which is connected to the welding electrode head 200 via a cable. This connector is used for harness connection before equipment operation. The welding cable connector ensures interference-free signal transmission during the welding process, and the control system provides intuitive remote control capabilities through a teach pendant and buttons. This embodiment also has photoelectric limit modules at both ends of the base 400 corresponding to the sliding direction of the positioning slide 500. These modules limit the extreme movement positions of the positioning slide 500, and the photoelectric limit modules and photoelectric detection system prevent erroneous movement of the positioning slide, ensuring operational safety. Simultaneously, the end of the base 400 has a control line interface 1200 for signal connection to the guide rail module 600. The control line interface 1200 can be used to connect signal harnesses to achieve automated control. The design of each module in the entire system possesses high reliability and interchangeability, adapting to the welding requirements of different specifications of safety-compliant capacitor core packages, while providing a good foundation for future upgrades and expansions.
[0031] like Figure 6As shown, this embodiment provides a control system that is signal-connected to the welding unit and the positioning and conveying system. The control system is connected to a teach pendant assembly 1300 and a control button assembly 1400. The control system enables the teach pendant assembly 1300 to display welding parameters, store welding programs, etc., through circuit control, and sends control commands through the control button assembly 1400.
[0032] The operating steps of this equipment are as follows: First, in the automated production workshop, the operator loads the safety capacitor core package 1600 into the conformal fixture 800, ensuring that the safety capacitor core package 1600 is accurately and stably positioned so that it can precisely adapt to the subsequent welding operation. Next, the conformal fixture 800 containing the safety capacitor core package 1600 is carefully placed into the conformal positioning base plate 700. Then, an experienced operator carefully selects the pre-set welding program through the teaching pendant assembly 1300 on the operating table. During the selection process, the corresponding parameters of the program are checked again to confirm whether they meet the current welding requirements of the safety capacitor core package 1600, such as welding current, welding time, and electrode pressure. After confirmation, welding is started through the control button assembly 1400. At this time, the positioning and conveying unit receives the start command and begins to run smoothly and at a constant speed, conveying the positioning slide 500 and the safety capacitor core package 1600 into place along the predetermined track.
[0033] Once the capacitor is in place, the robotic arm 1500 begins to operate flexibly according to a preset motion trajectory, precisely moving the welding electrode head 200 above the welding position on the safety capacitor core package 1600. Then, the welding electrode head 200 is steadily pressed down by the clamping module 100, ensuring full contact with the core package surface. This ensures that the safety capacitor core package 1600 does not become loose during the welding process, thereby guaranteeing welding quality.
[0034] During the welding process, operators must remain focused and closely monitor the data displayed on the clamping force monitoring table to ensure that the clamping force remains within a reasonable range. This prevents problems such as poor welding or damage to the safety capacitor core package 1600 due to excessive or insufficient pressure. Simultaneously, operators must monitor real-time changes in welding parameters, checking for stability and any abnormal fluctuations in welding current and voltage. If any abnormalities are detected in the clamping force or welding parameters, operators must immediately press the emergency stop button to halt welding and investigate the problem. If, after observation and confirmation that all data are within acceptable limits, the entire welding system will continue to automatically perform resistance welding on the safety capacitor core package 1600. The welding electrode head 200 will release energy stably according to the set time, current, and other parameters, gradually completing the welding fusion of the safety capacitor core package 1600 until all preset welding points are welded, thus successfully concluding the entire welding process. Finally, the robotic arm 1500 will return to its initial standby position in an orderly manner according to the return procedure, waiting for the next welding task instruction, and preparing for the next round of welding work on the safety capacitor core package 1600.
[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model, and they should all be covered within the scope of the claims and specification of this utility model.
Claims
1. A safety capacitive core-pack resistance welding system characterized by, Includes welding units and positioning and conveying units; The welding unit includes a clamping module (100), and the output end of the lower end of the clamping module (100) is connected to a welding electrode head (200). The welding electrode head (200) is driven to move vertically up and down by the clamping module (100). The clamping module (100) is also equipped with a pressure monitoring gauge (300). The monitoring end of the pressure monitoring gauge (300) abuts against the assembly part (210) located at the upper end of the welding electrode head (200) to monitor the contact pressure between the welding electrode head (200) and the capacitor core (1600). The positioning and conveying unit includes a base (400), a positioning slide (500) is provided on the upper end of the base (400), a guide rail module (600) for driving the positioning slide (500) is provided inside the base (400), a detachable contour positioning base plate (700) is installed on the upper end of the positioning slide (500), and a contour jig (800) for accommodating the welding capacitor core package (1600) is provided on the contour positioning base plate (700).
2. The safety-compliant capacitor core resistance welding system according to claim 1, characterized in that, The clamping module (100) is provided with a mounting bracket (900) on the outside, and the mounting bracket (900) is provided with an adapter plate (910) for connecting the three-dimensional robotic arm (1500).
3. The safety-compliant capacitor core resistance welding system according to claim 1, characterized in that, The upper end of the clamping module (100) is provided with a welding cable connector (1000) that is connected to the welding electrode head (200) via a cable.
4. The safety-compliant capacitor core resistance welding system according to claim 1, characterized in that, The base (400) is equipped with photoelectric limit modules (1100) at both ends of the sliding direction of the positioning slide (500).
5. The safety-compliant capacitor core resistance welding system according to claim 1, characterized in that, The base (400) is provided with a control line interface (1200) at its end, which is connected to the guide rail module (600) via signal.
6. The safety-compliant capacitor core-wrapping resistance welding system according to claim 1, characterized in that, It also includes a control system that is signal-connected to the welding unit and the positioning and conveying system, the control system being connected to a teach pendant assembly (1300) and a control button assembly (1400).