Inductor assembly welding machine

Abstract

The utility model relates to patch inductance manufacturing technical field, especially a kind of inductance coil assembly welding mechanical. Material tray is set apart four independent stations along circumference, and it is inductance coil placement station, wire plate placement station, welding station, inductance coil assembly blanking station in turn along clockwise direction.Each station is fixedly installed with positioning jig. When equipment operates, intermittent indexing drive unit drives material tray to carry out intermittent clockwise rotation, drives each positioning jig synchronous switching station, i.e. after the material of current station is completed operation, next station immediately flows to corresponding operating position and prepares to start process, and the waiting time between processes is greatly shortened;Translation drive unit is used to drive material tray overall translation, to adjust the relative position of material tray and spot welding machine. Furthermore, relying on circumferential circulation design, when a station needs local adjustment, it only needs to suspend the station operation alone, and does not affect the normal operation of other stations.

Description

Technical Field

[0001] This utility model relates to the field of surface mount inductor manufacturing technology, and in particular to an inductor coil assembly soldering machine. Background Technology

[0002] In the field of electronic component manufacturing, the welding of inductor coils to lead boards is the core process in the preparation of inductor coil assemblies.

[0003] In the current industry landscape, fully automated welding equipment has become the mainstream choice, but significant technical shortcomings remain in practical applications, particularly in material handling and workstation connection, making it difficult to adapt to the demands of efficient and compact production. Existing equipment generally employs a linear conveyor track design, with loading, welding, and unloading stations arranged sequentially along the track, relying entirely on continuous track transmission for material flow. While this layout is simple in structure and has low initial costs, it suffers from several technical limitations: 1) Significant waiting time exists between processes. After the material at one workstation is processed, it must wait for the track to transport it to the next workstation, and subsequent steps can only begin after the previous process is completed, hindering efficient connection and significantly slowing down the overall process rhythm; 2) Workstations are linked via the track, and if any workstation malfunctions (such as material jamming or positioning deviation), the entire equipment must be shut down for troubleshooting and adjustment, preventing targeted operation at the faulty workstation and extending production downtime, severely disrupting continuity; 3) The linear layout requires reserving independent working space for each workstation along the track, and track extension must consider material transport redundancy, resulting in a large overall footprint for the equipment.

[0004] Therefore, it is urgent for technical personnel to solve the above problems. Utility Model Content The purpose of this invention is to provide a welding machine for inductor coil components, which aims to solve the problems of existing fully automated welding equipment using a linear conveyor track layout, resulting in the need for the entire machine to be shut down due to any failure at any station, poor production continuity, large equipment footprint, low space efficiency, and time-consuming process connections.

[0005] This utility model relates to an inductor coil assembly welding machine, used to weld multiple inductor coils to a lead sheet as a single unit. The inductor coil assembly welding machine includes a material tray, a positioning fixture, an intermittent indexing drive unit, a translation drive unit, and a spot welding machine; The material tray has four independent workstations spaced around its circumference, which are arranged in a clockwise direction as follows: inductor coil placement workstation, conductor board placement workstation, welding workstation, and inductor coil assembly unloading workstation; each independent workstation is fixedly equipped with a positioning fixture. The positioning fixture is equipped with both a coil positioning groove that matches the shape of the inductor coil and a plate positioning groove that matches the shape of the conductor board. The intermittent indexing drive unit is connected to the material tray drive to drive the material tray to rotate intermittently clockwise, so that each positioning fixture can switch workstations; The translation drive unit is connected to the intermittent indexing drive unit for performing translational motion together with the material tray to adjust the relative position of the material tray and the spot welding machine. The spot welding machine is set up at the welding station to perform spot welding operations on the inductor coil and the lead plate in the positioning fixture at the welding station.

[0006] As a further improvement to the technical solution disclosed in this utility model, the intermittent indexing drive unit includes a motor and a cam indexer; the output shaft of the motor is connected to the input shaft of the cam indexer; and the output end of the cam indexer is connected to the material tray.

[0007] As a further improvement to the technical solution disclosed in this utility model, the translation drive unit includes a linear motor module, a slide rail slider assembly, and a platform; the mover of the linear motor module is fixedly connected to the platform; the platform achieves directional sliding motion through the slide rail slider assembly; the motor uses the platform as its mounting base, and its output shaft passes through the platform.

[0008] As a further improvement to the technical solution disclosed in this utility model, the inductor coil assembly welding machine also includes a pressure device; the pressure device is set at the welding station and is used to apply downward pressure to the conductor plate in the positioning fixture of the welding station before the spot welding machine performs the spot welding operation.

[0009] As a further improvement to the technical solution disclosed in this utility model, the pressure application device includes a slide cylinder, a support frame, and a pressure plate; the slide cylinder is arranged below the material tray and is used to drive the support frame to perform lifting and lowering movements; the pressure plate is mounted on the support frame and is positioned on the positioning fixture located at the welding station.

[0010] As a further improvement to the technical solution disclosed in this utility model, the inductor coil assembly welding machine also includes a stripping device; the stripping device is set at the inductor coil assembly unloading station, and is used to apply stripping force to the inductor coil assembly when the inductor coil assembly is welded and switched to the inductor coil assembly unloading station with the positioning fixture.

[0011] As a further improvement to the technical solution disclosed in this utility model, the positioning fixture is provided with multiple unloading holes; the unloading device includes a cylinder, a mounting base and unloading needles; the cylinder is used to drive the mounting base to perform lifting and lowering movements, and it is fixed on the platform; the multiple unloading needles are all inserted on the mounting base and correspond one-to-one with the positions of the unloading holes.

[0012] As a further improvement to the technical solution disclosed in this utility model, the inductor coil assembly welding machine also includes an optical fiber sensor, a first laser displacement sensor, and a second laser displacement sensor; the optical fiber sensor is set directly opposite the lead wire board placement station to monitor whether the lead wire board is correctly placed; the first laser displacement sensor is set directly opposite the inductor coil placement station to monitor whether the inductor coil is correctly placed; and the second laser displacement sensor is set directly opposite the inductor coil assembly unloading station to monitor the welding quality of the inductor coil assembly.

[0013] In practical applications, the inductor coil assembly welding machine disclosed in this utility model can achieve at least the following beneficial technical effects, specifically: 1) The material tray is set with four independent workstations at circumferential intervals. Each workstation rotates clockwise intermittently with the material tray, sequentially entering the positions for inductor coil loading, conductor board loading, inductor coil assembly soldering, and inductor coil assembly unloading. During this process, as soon as the material at the previous workstation completes its current operation, it is already transferred to the dedicated work position at the next workstation to prepare for the start of the process. There is no need to wait for the previous process to be completed before proceeding to the next step, which effectively shortens the waiting time between processes and significantly speeds up the overall process connection. 2) When a workstation requires partial operation or adjustment, only the operation at that workstation needs to be paused. If the adjustment can be completed in a short time and the material tray is currently in a stationary state, the stationary state can be appropriately extended to complete the operation. If a longer adjustment is required, only the operation module of that workstation needs to be shut down. The material tray can still drive other unadjusted workstations to continue operating normally at the original pace, without affecting the progress of other processes. This fundamentally ensures the continuous and uninterrupted production process and avoids the situation where the entire machine stops due to a local problem. 3) The inductor coil assembly welding machine has a small overall footprint, which can flexibly adapt to the compact layout requirements of different factories and significantly reduce the space occupied. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this utility model 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 utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a three-dimensional schematic diagram of the welding machine for the inductor coil assembly disclosed in this utility model.

[0016] Figure 2This is a three-dimensional schematic diagram from another perspective of the welding machinery for the inductor coil assembly disclosed in this utility model.

[0017] Figure 3 yes Figure 1 Side view.

[0018] Figure 4 This is a three-dimensional schematic diagram of the positioning fixture in the welding machine for inductor coil components disclosed in this utility model.

[0019] Figure 5 This is a schematic diagram showing the state of the material tray, intermittent indexing drive unit, and translation drive unit after they have been assembled in the inductor coil assembly welding machine disclosed in this utility model.

[0020] Figure 6 yes Figure 5 Side view.

[0021] Figure 7 This is a three-dimensional schematic diagram of the pressure device in the welding machine for inductor coil components disclosed in this utility model.

[0022] Figure 8 This is a three-dimensional schematic diagram of the unloading device in the welding machinery for inductor coil components disclosed in this utility model (the positioning fixture is shown in the form of double-dotted lines).

[0023] 1-Material tray; 2-Positioning fixture; 21-Coil positioning groove; 22-Plate positioning groove; 23-Removal hole; 3-Intermittent indexing drive unit; 31-Motor; 32-Cam indexer; 4-Translation drive unit; 41-Linear motor module; 42-Slide rail slider assembly; 43-Platform; 5-Spot welding machine; 6-Pressure application device; 61-Slide table cylinder; 62-Support frame; 63-Pressure plate; 7-Removal device; 71-Cylinder; 72-Mounting base; 73-Removal needle; 8-Fiber optic sensor; 9-First laser displacement sensor; 10-Second laser displacement sensor. Detailed Implementation

[0024] The present invention will be further described in detail below with reference to specific embodiments. Figures 1-3The diagram shows the structure of the inductor coil assembly welding machine disclosed in this utility model. It is mainly composed of a material tray 1, a positioning fixture 2, an intermittent indexing drive unit 3, a translation drive unit 4, and a spot welding machine 5. The material tray 1 has four independent workstations spaced circumferentially, arranged clockwise as follows: inductor coil placement station, conductor plate placement station, welding station, and inductor coil assembly unloading station. Each independent workstation is fixedly equipped with a positioning fixture 2, allowing each workstation to sequentially enter its corresponding working position as the material tray 1 rotates intermittently. That is, when the material at the previous workstation completes its current operation, the material at the next workstation has already moved to its designated working position and is ready to start the process, without waiting for the previous process to finish before proceeding to the next step. This effectively shortens the waiting time between processes and significantly accelerates the overall process connection speed. Furthermore, if a certain workstation requires partial operation or adjustment, only that workstation needs to be paused. Short-term adjustments can extend the material tray dwell time, while long-term adjustments will shut down the module of that workstation. The other workstations will continue to operate at their original pace, fundamentally ensuring that the production process remains uninterrupted and avoiding downtime of the entire machine.

[0025] like Figure 4 As shown, the positioning fixture 2 is provided with a coil positioning groove 21 that matches the shape of the inductor coil and a plate positioning groove 22 that matches the shape of the conductor board. In this way, in practical applications, the initial positional accuracy of the inductor coil and the conductor board is ensured, laying the foundation for the accuracy of subsequent soldering.

[0026] like Figure 3 , Figure 6 As shown, the intermittent indexing drive unit 3 is connected to the material tray 1 and is used to drive the material tray 1 to rotate intermittently clockwise to complete the switching of the workstations of each positioning fixture 2. The intermittent indexing drive unit 3 specifically includes a motor 31 and a cam indexer 32. The output shaft of the motor 31 is connected to the input shaft of the cam indexer 32, and the output end of the cam indexer 32 is connected to the material tray 1. With the help of the high-precision indexing characteristics of the cam indexer, the angular error of each rotation of the material tray 1 is controlled within a very small range, thereby ensuring the accuracy of the workstation switching and avoiding the impact of workstation offset on the welding quality.

[0027] like Figure 5 , Figure 6 As shown, the translation drive unit 4 is connected to the intermittent indexing drive unit 3 for driving the intermittent indexing drive unit 3 together with the material tray 1 to perform translational movement, so as to flexibly adjust the relative position of the material tray 1 and the spot welding machine 5, thereby adapting to the welding requirements of materials of different specifications.

[0028] The translation drive unit 4 includes a linear motor module 41, a slide rail slider assembly 42, and a platform 43. The mover of the linear motor module 41 is fixedly connected to the platform 43, and the platform 43 achieves directional sliding motion through the slide rail slider assembly 42. The linear motor drive method ensures the smoothness of the translation process and the accuracy of position control. The motor 31 is mounted on the platform 43, and its output shaft passes through the platform 43. In this way, the equipment structure layout is effectively optimized, space occupation is reduced, and it can flexibly adapt to the compact layout requirements of different factories, significantly reducing the occupation of space resources.

[0029] As Figures 1-3 As shown, the spot welding machine 5 is set at the welding station and is used to perform spot welding operations on the inductor coil and the lead plate in the positioning fixture 2 at the welding station.

[0030] To further improve the quality of spot welding, and as a further optimization of the above technical solution, the inductor coil assembly welding machine is also equipped with a pressure device 6. For example... Figures 1-3 , Figure 7 As shown, the pressure application device 6 is located at the welding station and includes a sliding cylinder 61, a support frame 62, and a pressure plate 63. The sliding cylinder 61 is arranged below the material tray 1 and is used to drive the support frame 62 to perform lifting and lowering movements. The pressure plate 63 uses the support frame 62 as its mounting base and applies pressure to the positioning fixture 2 located at the welding station. Before the spot welding machine 5 performs the spot welding operation, the sliding cylinder 61 drives the pressure plate 63 to descend, applying a stable downward pressure to the conductor plate inside the positioning fixture 2 to ensure that the inductor coil is tightly attached to the conductor plate, thereby avoiding problems such as incomplete weld joints caused by gaps.

[0031] To address the issue of unloading inductor coil assemblies after soldering, the inductor coil assembly soldering machine is also equipped with a material unloading device 7, which is located at the inductor coil assembly unloading station (such as...). Figures 1-3 As shown). Figure 4 The positioning fixture 2 shown has multiple material ejection holes 23. For example... Figure 8 As shown, the stripping device 7 includes a cylinder 71, a mounting base 72, and stripping needles 73. The cylinder 71 drives the mounting base 72 to perform lifting movements, and it is fixed to the platform 43. Multiple stripping needles 73 are inserted into the mounting base 72 and correspond one-to-one with the stripping holes 23. In practical applications, when the inductor coil assembly is soldered and switched to the unloading station with the positioning fixture 2, the cylinder 71 drives the mounting base 72 to rise, and the stripping needles 73 pass through the stripping holes 23 to apply an upward stripping force to the inductor coil assembly, easily separating the assembly from the positioning fixture, which helps improve unloading efficiency.

[0032] Finally, it should be noted that, for the purpose of achieving full-process quality monitoring, as a further optimization of the above technical solution, the inductor coil assembly welding machine is also equipped with a fiber optic sensor 8, a first laser displacement sensor 9, and a second laser displacement sensor 10. The fiber optic sensor 8 is positioned opposite the lead wire placement station to monitor whether the lead wire is correctly placed; the first laser displacement sensor 9 is positioned opposite the inductor coil placement station to monitor whether the inductor coil is correctly placed; and the second laser displacement sensor 10 is positioned opposite the inductor coil assembly unloading station to monitor the welding quality of the inductor coil assembly. Through multi-dimensional sensing and detection, the generation of defective products due to material placement deviations or welding defects is effectively avoided, ensuring the consistency of the inductor coil assembly.

[0033] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A welding machine for inductor coil assemblies, used to weld multiple inductor coils to a lead sheet as a single unit, characterized in that, This includes a material tray, positioning fixture, intermittent indexing drive unit, translation drive unit, and spot welding machine; The material tray has four independent workstations spaced circumferentially, which are arranged in a clockwise direction as follows: inductor coil placement workstation, conductor board placement workstation, welding workstation, and inductor coil assembly unloading workstation; each of the independent workstations is fixedly equipped with the positioning fixture. The positioning fixture is provided with a coil positioning groove that matches the shape of the inductor coil and a plate positioning groove that matches the shape of the conductor plate. The intermittent indexing drive unit is connected to the material tray and is used to drive the material tray to rotate intermittently clockwise, so that each positioning fixture can switch workstations. The translation drive unit is connected to the intermittent indexing drive unit and is used to drive the intermittent indexing drive unit together with the material tray to perform translational movement in order to adjust the relative position of the material tray and the spot welding machine. The spot welding machine is positioned at the welding station and is used to perform spot welding operations on the inductor coil and the lead plate within the positioning fixture at the welding station.

2. The welding machine for inductor coil assemblies according to claim 1, characterized in that, The intermittent indexing drive unit includes a motor and a cam indexer; the output shaft of the motor is drivenly connected to the input shaft of the cam indexer; the output end of the cam indexer is drivenly connected to the material tray.

3. The welding machine for inductor coil assemblies according to claim 2, characterized in that, The translation drive unit includes a linear motor module, a slide rail slider assembly, and a platform; the mover of the linear motor module is fixedly connected to the platform; the platform achieves directional sliding motion through the slide rail slider assembly; the motor uses the platform as its mounting base, and its output shaft passes through the platform.

4. The welding machine for inductor coil assemblies according to any one of claims 1-3, characterized in that, It also includes a pressure-applying device; the pressure-applying device is provided at the welding station and is used to apply downward pressure to the guide plate in the positioning fixture at the welding station before the spot welding machine performs the spot welding operation.

5. The welding machine for inductor coil assemblies according to claim 4, characterized in that, The pressure application device includes a slide cylinder, a support frame, and a pressure plate; the slide cylinder is arranged below the material tray and is used to drive the support frame to perform lifting and lowering movements; the pressure plate is mounted on the support frame and is positioned on the positioning fixture located at the welding station.

6. The welding machine for inductor coil assemblies according to claim 3, characterized in that, It also includes a stripping device; the stripping device is set at the inductor coil assembly unloading station, and is used to apply stripping force to the inductor coil assembly when the inductor coil assembly is welded and switched to the inductor coil assembly unloading station with the positioning fixture.

7. The welding machine for inductor coil assemblies according to claim 6, characterized in that, The positioning fixture has multiple unloading holes; the unloading device includes a cylinder, a mounting base, and unloading needles; the cylinder is used to drive the mounting base to perform lifting and lowering movements, and it is fixed on the platform; the multiple unloading needles are inserted into the mounting base and correspond one-to-one with the positions of the unloading holes.

8. The welding machine for inductor coil assemblies according to any one of claims 1-3, characterized in that, It also includes an optical fiber sensor, a first laser displacement sensor, and a second laser displacement sensor; the optical fiber sensor is positioned opposite the lead wire board placement station to monitor whether the lead wire board is placed correctly; the first laser displacement sensor is positioned opposite the inductor coil placement station to monitor whether the inductor coil is placed correctly; and the second laser displacement sensor is positioned opposite the inductor coil assembly unloading station to monitor the welding and forming quality of the inductor coil assembly.

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