A resistance spot welding machine and an inductor coil assembly comprising it

Abstract

The utility model relates to patch inductance manufacturing technical field, especially a kind of resistance spot welding machine and the inductor coil assembly welding machine including it. Resistance spot welding machine includes rack, upper welding arm, lower welding arm and cloth drive part. Upper welding arm and lower welding arm are all by rack load, and two execute opposite movement to exert clamping pressure to the assembly to be welded, or execute opposite movement to release after welding assembly. Cloth drive part is used to drive rack to execute Y direction step movement, and step distance is adapted to the spacing of two welding spots on single inductor coil;After single inductor coil is welded, the assembly to be welded executes X direction translation movement, and step distance is adapted to the arrangement spacing of multiple inductor coils. In this way, effectively ensure that upper welding arm and lower welding arm can be accurately stopped at the welding spot of each inductor coil, avoid the deviation problem of welding spot alignment from the root, and then help to improve the welding quality and production efficiency of inductor coil assembly.

Description

Technical Field

[0001] This utility model relates to the field of surface mount inductor manufacturing technology, and in particular to a resistance spot welding machine and a welding machine for inductor coil assemblies including the same. Background Technology

[0002] In the field of electronic component manufacturing, inductor coil assemblies are a core upstream product in the fabrication of surface mount inductors. They typically consist of a conductive plate and multiple inductor coils arranged linearly along the X-axis, and the two are fixed together by a soldering process. Since the soldering quality directly determines the structural stability of the inductor coil assembly and has a critical impact on the final precision and electrical parameter consistency of the surface mount inductor, this process is crucial. Currently, semi-automatic spot welding equipment is widely used in the industry for welding inductor coil components. While semi-automatic spot welding equipment can automate the clamping and welding actions of the welding arm through mechanical structures, initially solving the problems of low efficiency and high labor intensity of manual operation, it still has significant technical limitations when facing the core scenario of continuous welding of multiple inductor coils. Specifically, these limitations are as follows: 1) The semi-automatic spot welding equipment uses a continuous motion mode to drive the welding arm. It does not have a step motion control function that matches the spacing between the welding points. It is difficult to ensure that the welding arm stays stably at each welding point and completes precise welding. This results in poor welding consistency of inductor coil components in the same batch, which cannot meet the production standards of high-precision electronic components. 2) When the welding operation needs to switch from the current inductor coil to the next inductor coil, the translation of the component to be welded mostly relies on a coarse stroke control mechanism. It lacks a precise positioning design that matches the coil arrangement spacing. It is very easy for the solder joint of the next inductor coil to fail to be precisely aligned with the welding arm due to the deviation of the translation step distance, which in turn causes quality problems such as welding offset and cold solder joint. In severe cases, it may even lead to the scrapping of the component. Therefore, it is urgent for technical personnel to solve the above problems. Utility Model Content

[0003] The purpose of this invention is to provide a resistance spot welding machine that solves the problems of existing semi-automatic spot welding equipment that uses continuous motion mode to drive the welding arm, making it difficult to ensure accurate welding of two welding points of a single inductor coil, causing welding point misalignment, and resulting in poor consistency of welding in the same batch.

[0004] This utility model relates to a resistance spot welding machine for welding a conductor board and multiple inductor coils arranged linearly along the X-direction into a single inductor coil assembly. The resistance spot welding machine includes a frame, an upper welding arm, a lower welding arm, and a stowage drive unit. Both the upper and lower welding arms are loaded by the frame and move in opposite directions to apply clamping pressure to the assembly to be welded, or move away from each other to release the welded assembly. The stowage drive unit is connected to the frame and drives the frame to perform Y-direction stepping motion, with the step distance matching the spacing between two welding points on a single inductor coil. During the stepping motion of the frame, the upper and lower welding arms sequentially align with the two welding points on a single inductor coil. After the welding of a single inductor coil is completed, the assembly to be welded performs X-direction translational motion, with the step distance matching the arrangement spacing of the multiple inductor coils, allowing the upper and lower welding arms to align with the next inductor coil, thereby welding and fixing each inductor coil to the conductor board one by one.

[0005] As a further improvement to the technical solution disclosed in this utility model, the push-in drive unit includes a linear motor module, a Y-axis slide rail slider assembly, and a Y-axis sliding stage; the linear motor module is connected to the Y-axis sliding stage in a transmission manner; the Y-axis sliding stage supports the frame, and under the guidance of the Y-axis slide rail slider assembly, it performs Y-axis stepping motion under the driving force of the linear motor module.

[0006] As a further improvement to the technical solution disclosed in this utility model, the linear motor module includes a servo motor and a ball screw mechanism; the control pulse equivalent of the servo motor is no greater than 0.001mm, and the lead accuracy of the ball screw mechanism is controlled within ±0.01mm.

[0007] As a further improvement to the technical solution disclosed in this utility model, the resistance spot welding machine also includes an X-axis fine-tuning unit and an X-axis slide rail slider assembly; the X-axis fine-tuning unit is mounted on a Y-axis sliding stage and directly applies adjustment force to the frame; the X-axis slide rail slider assembly is assembled between the frame and the Y-axis sliding stage to guide the frame to move in the X-axis direction and cooperates with the X-axis fine-tuning unit to adjust the relative position of the frame in the X-axis direction.

[0008] As a further improvement to the technical solution disclosed in this utility model, the X-axis fine-tuning unit is composed of a first bolt adjustment subunit and a second bolt adjustment subunit; the first bolt adjustment subunit and the second bolt adjustment subunit cooperate to realize bidirectional fine-tuning of the relative position of the frame in the X direction. Both are fixedly installed on the Y-axis sliding table and are symmetrically arranged on both sides of the Y-axis sliding table along the X direction; by turning the first bolt adjustment subunit, the frame can be pushed to translate along the X direction, or by turning the second bolt adjustment subunit, the frame can be pushed to translate in the opposite direction along the X direction.

[0009] Furthermore, this utility model also discloses an inductor coil assembly welding machine, including a material tray, a positioning fixture, an intermittent indexing drive unit, a translation drive unit, and the aforementioned resistance spot welding machine; the material tray is provided with four independent workstations spaced circumferentially, and each workstation is fixedly mounted with a positioning fixture; the intermittent indexing drive unit is driven by the material tray to drive the material tray to achieve intermittent circumferential rotation; the translation drive unit is driven by the intermittent indexing drive unit to drive the intermittent indexing drive unit together with the material tray to perform translational movement; the resistance spot welding machine is set up corresponding to the welding workstations to perform spot welding operations on the inductor coils and lead plates in the positioning fixtures at the welding workstations.

[0010] In practical applications, the resistance spot welding machine disclosed in this utility model can achieve at least the following beneficial technical effects, specifically: 1) The mounting drive unit can drive the frame to perform Y-axis stepping motion, and its step distance is precisely matched with the distance between the two solder points on a single inductor coil; during the frame's Y-axis stepping process, the upper and lower welding arms are simultaneously driven to precisely align the two solder points of the inductor coil to be welded in sequence. In this way, it effectively ensures that the upper and lower welding arms can accurately stop at each solder point, so as to avoid the occurrence of solder point alignment deviation problems and ensure the consistency of welding parameters of inductor coil components in the same batch; 2) The Y-axis stepping of the frame is driven by the placement drive unit to complete the precise welding of the double solder points of a single inductor coil. After the coil is welded, the component to be welded performs X-axis translational movement, and the translational step distance is precisely matched with the arrangement spacing of multiple inductor coils. The upper and lower welding arms can be accurately aligned with the next inductor coil to be welded. In this way, not only is the precise alignment design goal of continuous welding of multiple inductor coils achieved, but also the quality problems such as welding misalignment and cold solder joints are avoided, and the scrap rate of inductor coil components is reduced. Attached Figure Description

[0011] 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.

[0012] Figure 1 This is a three-dimensional schematic diagram of the welding machine for the inductor coil assembly disclosed in this utility model.

[0013] Figure 2 This is a three-dimensional schematic diagram from another perspective of the welding machinery for the inductor coil assembly disclosed in this utility model.

[0014] Figure 3 yes Figure 1 Side view.

[0015] Figure 4 This is a three-dimensional schematic diagram of the resistance spot welding machine disclosed in this utility model from one perspective.

[0016] Figure 5 This is a three-dimensional schematic diagram of the resistance spot welding machine disclosed in this utility model from another perspective.

[0017] 1-Material tray; 2-Positioning fixture; 3-Intermittent indexing drive unit; 4-Translation drive unit; 5-Resistance spot welding machine; 51-Frame; 52-Upper welding arm; 53-Lower welding arm; 54-Infeed drive unit; 541-Motor linear module; 542-Y-direction slide rail slider assembly; 543-Y-direction sliding stage; 55-X-direction fine adjustment unit; 551-First bolt adjustment subunit; 552-Second bolt adjustment subunit; 56-X-direction slide rail slider assembly. Detailed Implementation

[0018] The present invention will be further described in detail below with reference to specific embodiments. Figures 1-3 The 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 resistance spot welding machine 5. The positioning fixture 2 serves as the core for positioning the inductor coil and the lead plate, and it is fixedly assembled with the material tray 1. The material tray 1 has four independent workstations spaced circumferentially, arranged clockwise as follows: inductor coil placement station, lead plate placement station, welding station, and inductor coil assembly unloading station. Each independent workstation is fixedly equipped with the positioning fixture 2, allowing each workstation to sequentially enter its corresponding working position as the material tray 1 rotates intermittently. The positioning fixture 2 is used to stably position the inductor coil and the lead plate, preventing displacement due to force or temperature changes during welding and ensuring accurate weld point positioning. The intermittent indexing drive unit 3 is connected to the material tray 1 via a transmission mechanism. It drives the material tray 1 to achieve intermittent circumferential rotation, sequentially transferring the positioning fixture 2 containing the inductor coil and lead plate to the corresponding working position of the resistance spot welding machine 5. Simultaneously, the welded inductor coil assembly is transferred out of the welding industrial area, achieving cyclic switching of workstations. The translation drive unit 4 is connected to the intermittent indexing drive unit 3 via a transmission mechanism, driving the intermittent indexing drive unit 3 and the material tray 1 to perform translational movement as a whole. In practical applications, the translation drive unit 4 can flexibly adjust the relative position of the material tray 1 and the resistance spot welding machine 5 according to parameters such as the specifications and dimensions of the inductor coil and lead plate, and the weld point spacing, adapting to the welding requirements of different types of inductor coil assemblies. The resistance spot welding machine 5 is fixedly set at the working position corresponding to the material tray 1, used to perform spot welding operations on the inductor coil and lead plate located in the positioning fixture 2 at that position, completing a stable connection between the two.

[0019] like Figure 4 , Figure 5 As shown, the resistance spot welding machine 5 mainly consists of a frame 51, an upper welding arm 52, a lower welding arm 53, a feed drive unit 54, an X-axis fine-tuning unit 55, and an X-axis slide rail slider assembly 56. The frame 51 serves as the supporting foundation for the resistance spot welding machine 5. Both the upper welding arm 52 and the lower welding arm 53 are supported by the frame 51 and possess degrees of freedom for both moving towards and away from each other. When the upper welding arm 52 and the lower welding arm 53 move towards each other, they apply uniform clamping pressure to the inductor coil and the conductor plate, ensuring a tight fit during welding. When they move away from each other, the welded inductor coil assembly can be released for easy transfer to subsequent workstations. The feed drive unit 54 is connected to the frame 51 via a transmission. It drives the frame 51 to perform Y-axis stepping motion, and the step distance is perfectly matched with the distance between the two solder points on a single inductor coil. This ensures that the upper welding arm 52 and the lower welding arm 53 are accurately aligned with each solder point to be welded, avoiding solder point misalignment. The X-axis slide rail slider assembly 56 is mounted between the frame 51 and the Y-axis sliding stage 543, providing guidance for the X-axis movement of the frame 51. The X-axis fine-tuning unit 55 uses the Y-axis sliding stage 543 as its mounting base. Its output end is in direct contact with the frame 51, and it works with the X-axis slide rail slider assembly 56 to achieve fine adjustment of the relative position of the frame 51 in the X-axis direction, further compensating for assembly errors or material deviations and improving welding alignment accuracy.

[0020] Similarly, Figure 4 , Figure 5 As shown, the drive unit 54 specifically consists of a linear motor module 541, a Y-axis slide rail slider assembly 542, and a Y-axis sliding stage 543. The linear motor module 541 is connected to the Y-axis sliding stage 543 by transmission, providing power for the Y-axis movement of the Y-axis sliding stage 543; the Y-axis sliding stage 543 is used to support the frame 51, and under the guidance and constraint of the Y-axis slide rail slider assembly 542 and the driving force of the linear motor module 541, it smoothly performs Y-axis stepping motion.

[0021] As a further optimization of the above technical solution, the linear motor module 541 preferably adopts a combination structure of a servo motor and a ball screw mechanism. Furthermore, the control pulse equivalent of the servo motor is no greater than 0.001mm, and the lead accuracy of the ball screw mechanism is controlled within ±0.01mm. Thus, through a high-precision power output and transmission structure, the positioning accuracy of the frame 51, along with the upper welding arm 52 and the lower welding arm 53, in performing the Y-axis stepping motion is ensured, laying a good foundation for improving subsequent welding quality.

[0022] like Figure 4 , Figure 5As shown, the X-axis fine-tuning unit 55 is composed of a first bolt adjustment subunit 551 and a second bolt adjustment subunit 552. Both the first bolt adjustment subunit 551 and the second bolt adjustment subunit 552 are fixedly installed on the Y-axis sliding stage 543 and symmetrically arranged on both sides of the Y-axis sliding stage 543 along the X-axis, forming a bidirectional adjustment structure. In practical applications, when the first bolt adjustment subunit 551 is turned, it applies a thrust along the X-axis to the frame 51, causing the frame 51 to perform a translational movement along the X-axis; while when the second bolt adjustment subunit 552 is turned, it applies a thrust in the opposite direction along the X-axis to the frame 51, causing the frame 51 to translate in the opposite direction along the X-axis. The two work together to achieve bidirectional fine-tuning of the relative position of the frame 51 in the X-axis, thereby meeting the precision calibration requirements under different welding scenarios.

[0023] Finally, it should be noted that the continuous switching of workstations achieved by the intermittent indexing drive unit 3, combined with the high-precision alignment achieved by the placement drive unit 54 and the X-axis fine-tuning unit 55, eliminates the waiting time difference and alignment deviation between processes. In this way, the production efficiency of inductor coil assemblies is improved, and the consistency of welding quality of finished products in the same batch is guaranteed. This effectively reduces quality problems such as welding offset and incomplete welding caused by misalignment, and reduces the scrap loss rate of inductor coil assemblies.

[0024] 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 resistance spot welding machine for welding a conductor board and a plurality of inductor coils arranged linearly along the X direction into a single unit to form an inductor coil assembly, characterized in that, The system includes a frame, an upper welding arm, a lower welding arm, and a placement drive unit. Both the upper and lower welding arms are supported by the frame and move in opposite directions to apply clamping pressure to the component to be welded, or move away from each other to release the welded component. The placement drive unit is connected to the frame and drives the frame to perform Y-axis stepping motion, with the step distance matching the distance between two solder points on a single inductor coil. During the stepping motion of the frame, the upper and lower welding arms sequentially align with the two solder points on a single inductor coil. After the single inductor coil is welded, the component to be welded performs X-axis translational motion, with the step distance matching the spacing between multiple inductor coils, allowing the upper and lower welding arms to align with the next inductor coil, thus welding and fixing each inductor coil to the lead plate one by one.

2. The resistance spot welding machine according to claim 1, characterized in that, The drive unit includes a linear motor module, a Y-axis slide rail slider assembly, and a Y-axis sliding stage; the linear motor module is connected to the Y-axis sliding stage; the Y-axis sliding stage supports the frame and, guided by the Y-axis slide rail slider assembly, performs Y-axis stepping motion under the driving force of the linear motor module.

3. The resistance spot welding machine according to claim 2, characterized in that, The linear motor module includes a servo motor and a ball screw mechanism; the control pulse equivalent of the servo motor is no greater than 0.001 mm, and the lead accuracy of the ball screw mechanism is controlled within ±0.01 mm.

4. The resistance spot welding machine according to any one of claims 2-3, characterized in that, It also includes an X-axis fine-tuning unit and an X-axis slide rail slider assembly; the X-axis fine-tuning unit is mounted on the Y-axis sliding stage and directly applies adjustment force to the frame; the X-axis slide rail slider assembly is assembled between the frame and the Y-axis sliding stage to guide the frame to translate along the X-axis and cooperates with the X-axis fine-tuning unit to adjust the relative position of the frame in the X-axis.

5. The resistance spot welding machine according to claim 4, characterized in that, The X-axis fine-tuning unit is composed of a first bolt adjustment subunit and a second bolt adjustment subunit. The first bolt adjustment subunit and the second bolt adjustment subunit work together to achieve bidirectional fine-tuning of the relative position of the frame in the X-axis direction. Both are fixedly installed on the Y-axis sliding table and are symmetrically arranged on both sides of the Y-axis sliding table along the X-axis. The frame can be pushed to translate along the X-axis by turning the first bolt adjustment subunit, or the frame can be pushed to translate in the opposite direction along the X-axis by turning the second bolt adjustment subunit.

6. A welding machine for inductor coil assemblies, characterized in that, The system includes a material tray, a positioning fixture, an intermittent indexing drive unit, a translation drive unit, and a resistance spot welding machine as described in any one of claims 1-5. The material tray has four independent workstations spaced circumferentially, each with the positioning fixture fixedly mounted on it. The intermittent indexing drive unit is driven by the material tray and drives it to achieve intermittent circumferential rotation. The translation drive unit is driven by the intermittent indexing drive unit and drives it to perform translational motion along with the material tray as a whole. The resistance spot welding machine is positioned corresponding to the welding workstation and is used to perform spot welding operations on the inductor coil and lead plate within the positioning fixture at the welding workstation.

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