A support block and welding system

Abstract

This utility model discloses a support block, comprising: an arc-shaped recess located at one end of the support block in the horizontal direction, and recessed inward in the horizontal direction; the inner contour of the arc-shaped recess is adapted to the outer peripheral contour of the winding portion of the inductor to accommodate a portion of the winding portion; two support portions located on both sides of the arc-shaped recess; the two support portions correspond one-to-one with two metal sheets and two terminals, each support portion contacting and supporting its corresponding metal sheet in the horizontal direction; two arc-shaped protrusions corresponding one-to-one with the two support portions; each arc-shaped protrusion is located below its corresponding support portion, and each arc-shaped protrusion protrudes horizontally from the plane of the support portion; the arc-shaped protrusions abut against the terminals. This utility model's support block increases the contact area with the metal sheets while avoiding interference with the coil, significantly improving welding stability and solder joint strength, and greatly extending the service life of the support block. This utility model also provides a welding system.

Description

Technical Field

[0001] This utility model relates to the field of ultrasonic welding technology, and in particular to a support block and welding system. Background Technology

[0002] When ultrasonically welding inductor coils to copper sheets, an extremely robust support structure must be provided in the horizontal direction aligned with the welding head. This support, together with the ultrasonic welding head, coil, and copper sheet, must form a stable energy transfer system to achieve a high-quality weld. Since the ultrasonic welding equipment itself is a standard module, the design quality of the support block becomes a core factor determining the weld strength and reliability.

[0003] However, existing support block solutions have many drawbacks, severely restricting production efficiency and product quality: First, traditional support block materials have insufficient wear resistance or poor structural design, making them prone to severe wear after frequent high-frequency vibration and pressure impact, resulting in a short service life and frequent replacement, which not only increases maintenance costs but also affects the continuous operation efficiency of the production line; Second, the contact area between existing support blocks and copper sheets is insufficient or unevenly distributed, failing to provide sufficient and uniform support force during welding, making it difficult to completely suppress the slight slippage or vibration of the copper sheets, resulting in welding energy loss and unstable interface bonding strength; More importantly, some support blocks, due to unreasonable structural avoidance design, are prone to accidentally contacting or squeezing the coil winding part during welding, or failing to provide sufficient support area for the copper sheets, leading to an imbalance in welding pressure transmission, which may damage the coil insulation layer or magnetic core, ultimately causing the pull-out strength of the solder joint to fail to meet design requirements, making it difficult to improve product yield. Utility Model Content

[0004] The purpose of this invention is to solve the problems of existing support blocks, which suffer from structural defects leading to easy wear, insufficient contact area with the metal sheet, and easy interference or damage to the coil during welding, thus failing to simultaneously meet the requirements of long service life, high support stability, and good welding reliability. This invention provides a support block and welding system that increases the contact area with the metal sheet while avoiding interference with the coil, significantly improving welding stability and weld strength, and greatly extending the service life of the support block.

[0005] To solve the above-mentioned technical problems, this utility model discloses a support block for supporting the metal sheet horizontally during ultrasonic welding of the inductor's posts and metal sheets. The inductor includes a core, a winding portion, and posts. The support block includes: an arc-shaped recess located at one end of the support block in the horizontal direction, and recessed inward in the horizontal direction; the inner contour of the arc-shaped recess is adapted to the outer peripheral contour of the winding portion of the inductor to accommodate a portion of the winding portion; two support portions located on both sides of the arc-shaped recess; the two support portions correspond one-to-one with the two metal sheets and the two posts, and each support portion is used to contact and support its corresponding metal sheet in the horizontal direction; two arc-shaped protrusions correspond one-to-one with the two support portions; each arc-shaped protrusion is located below its corresponding support portion, and each arc-shaped protrusion protrudes horizontally from the plane of the support portion; the arc-shaped protrusions abut against the posts.

[0006] By employing the aforementioned technical solution, the arc-shaped concave portion of the support block, through its precise fit with the contour of the winding section, effectively avoids interference with the inductor's winding section and prevents insulation damage, while simultaneously limiting its own expansion range. This ensures that the support sections on both sides maintain sufficient structural width to stably support the metal sheet. Meanwhile, the arc-shaped convex portion below the support section replaces the edge contact in existing solutions with a curved surface contact, significantly reducing pressure when contacting the terminal block and preventing scratches or damage to the terminal block surface. The combined effect of these two components ensures uniform pressure transmission and vibration suppression at the interface between the metal sheet and the terminal block during welding, thereby improving welding quality. Furthermore, by reducing stress concentration and mechanical wear, it significantly extends the overall service life of the support block.

[0007] The service life of the support block in this embodiment significantly surpasses that of traditional designs—under the same working conditions, the fatigue life is increased dramatically from 2,000 cycles to 20,000 cycles, representing a tenfold increase in durability and greatly reducing equipment maintenance frequency and overall costs. Simultaneously, the welding support stability provided by this support block is significantly enhanced, leading to breakthroughs in the mechanical properties of the weld joints formed with its assistance. The average pull-out force of the weld joints increases from 500N to 1,000N, doubling the strength, fully demonstrating the core role of this support block in improving welding quality and connection reliability.

[0008] According to another specific embodiment of the present invention, the support portion and the arc-shaped protrusion are transitioned by a circular arc.

[0009] By adopting the above technical solution, the support part and the arc-shaped protrusion are connected by a rounded arc. The smooth curved surface connection replaces the traditional sharp angle or right angle turn, effectively eliminating stress concentration points and significantly reducing the risk of fatigue cracks or fractures at this critical connection under high-frequency vibration loads. At the same time, the rounded arc transition optimizes the force flow transmission path, making the welding pressure more evenly distributed throughout the support block, further enhancing the structural durability and thus extending the service life of the support block in long-term repetitive operations.

[0010] According to another specific embodiment of this utility model, the support block is made of high alloy tool steel.

[0011] By adopting the above technical solution, the high-alloy tool steel support block, with its ultra-high hardness and wear resistance, solves the defects of easy scratches, deformation and wear on the soft surface of aluminum under high-frequency vibration of metal sheets; its high strength and high toughness can resist welding impact loads, avoid permanent deformation or fracture of aluminum due to insufficient fatigue strength, thus maintaining a stable support plane and dimensional accuracy in long-term repetitive operation, eliminating welding position deviation and quality fluctuation caused by tooling wear, and greatly improving production yield and equipment life.

[0012] According to another specific embodiment of the present invention, the support portion is provided with a burr area, which is used to contact the metal sheet in the horizontal direction.

[0013] By adopting the above technical solution, multiple burrs in the burr area tightly bite the metal plate valve surface in the horizontal direction through their sharp protrusions. The local embedding effect significantly increases the static friction force, effectively suppressing any slight slippage or vibration of the metal plate relative to the support during the welding process. This ensures that the welding energy is accurately applied to the interface between the post and the metal plate rather than being lost in relative displacement, thereby ensuring the accuracy of the weld point position and the reliability of the connection strength.

[0014] According to another specific embodiment of the present invention, the burr area includes a plurality of burrs, each burr having a length of 0.3 mm to 0.4 mm in the horizontal direction.

[0015] Using the above technical solution, compared with burrs less than 0.3 mm in length (e.g., 0.2 mm), the burrs in this solution have a greater advantage in resisting welding vibration and wear.

[0016] According to another specific embodiment of the present invention, the width of the support part is 7mm to 10mm, the height of the support part is 5mm to 7mm, and the width direction, height direction and horizontal direction of the support part are perpendicular to each other.

[0017] Compared with embodiments with cross-sectional dimensions smaller than this range (e.g., width < 7mm and / or height < 5mm), this solution significantly increases the cross-sectional area of ​​the support, thereby greatly improving its compressive strength and structural rigidity. It can effectively resist the high-frequency vibration impact generated by ultrasonic welding and avoid plastic deformation or fatigue fracture caused by stress concentration. At the same time, the larger contact area reduces the pressure per unit area, which not only prevents pressure damage to the surface of the metal sheet but also reduces its own wear rate. This maintains stable support accuracy during repeated operations, and comprehensively achieves better process stability and equipment durability.

[0018] According to another specific embodiment of the present invention, the width of the arc-shaped recess is 16mm to 17mm, and the depth of the arc-shaped recess in the horizontal direction is 3mm to 4mm.

[0019] An embodiment of this utility model also discloses a welding system based on the aforementioned support block, comprising: the aforementioned support block; a worktable, wherein the support block is disposed on the worktable; two clamps, spaced apart along the width direction on the worktable; the two clamps being used to clamp two metal sheets respectively; a mounting base, disposed on the worktable and arranged opposite to the support block in the horizontal direction, the mounting base being movable in the horizontal direction toward or away from the clamps; the mounting base being used to support and fix an inductor; and a lifting mechanism, the lifting mechanism being used to drive the support block to move in the horizontal direction toward the clamps, and to restrict the support block to move in the horizontal direction away from the clamps.

[0020] Using the above technical solution, in the initial state, the clamp holds the metal sheet, the mounting base carrying the inductor is located on one side of the clamp and is horizontally spaced from the clamp, and the support block is located on the other side of the clamp and is horizontally spaced from the clamp. Then, the mounting base moves forward, causing the inductor's leads to contact the metal sheet and complete alignment. Simultaneously, the lifting mechanism pushes the support block forward to contact the metal sheet and provide support. During welding, the ultrasonic welding head applies high-frequency vibration, and under the rigid reference provided by the support block, the metallurgical bonding between the leads and the metal sheet is completed. Finally, the ultrasonic welding head is lifted, the support block is retracted, and the mounting base returns to its original position.

[0021] According to another specific embodiment of the present invention, the mounting base includes:

[0022] A mounting groove is provided to accommodate the end of the inductor core; the bottom wall of the mounting groove is provided with a negative pressure adsorption hole, which is used to adsorb and fix the end of the inductor core.

[0023] A support platform is arranged around the mounting groove. The support platform is used to support the end of the winding portion of the inductor. The distance between the support platform and the bottom wall of the mounting groove is adapted to the distance from the end of the core of the inductor to the end of the winding portion.

[0024] The above technical solution places the support platform on a plane higher than the bottom wall of the mounting slot, and this height difference is matched with the distance from the end of the inductor core to the end of the winding section. This ensures that when the end of the core is attracted to the bottom wall of the mounting slot by negative pressure, the end of the winding section is precisely in contact with the surface of the support platform, thereby using the mechanical contact surfaces to jointly constrain the axial displacement of the inductor. Simultaneously, it avoids the winding section from prematurely pressing against the support platform before the end of the core has fully contacted the bottom wall of the mounting slot, which would prevent the core from being suspended by the winding section and thus failing to form an effective sealing contact with the bottom wall of the mounting slot, leading to the failure of the negative pressure attraction.

[0025] According to another specific embodiment of the present invention, the support block has a guide slope at one end in the horizontal direction away from the arc-shaped concave portion, and the angle between the guide slope and the plane containing the bottom wall of the support block is an obtuse angle; the lifting mechanism includes: a driving member; a main body connected to the driving member, the driving member being used to drive the main body to move in the height direction; and a pushing part detachably connected to the main body; the pushing part is used to contact the guide slope of the support block to push the support block to move in the horizontal direction toward the clamp.

[0026] Using the above technical solution, when the drive unit is activated, the main body and the pushing part move upwards along the height direction. The top edge of the pushing part abuts against the guide slope of the support block. Since the angle between the guide slope and the plane containing the bottom wall of the support block is obtuse, the upward force of the pushing part will generate a forward component force along the direction of the guide slope. This forward component force directly pushes the entire support block to slide horizontally forward, thereby converting the vertical linear motion of the pushing part into the forward and backward linear motion of the support block, ultimately causing the support block to contact and press against the metal sheet.

[0027] In addition, compared to the existing implementation where the jacking part and the main body are an integrated structure, the jacking part needs to be replaced as a whole after wear. This design modularizes the vulnerable parts, so that the jacking part can be quickly disassembled and replaced individually after severe wear, without the need for complete scrapping. This not only significantly reduces spare parts costs and inventory pressure, but also greatly shortens maintenance downtime, and improves the sustainability and overall economy of the equipment. Attached Figure Description

[0028] Figure 1 A simplified schematic diagram illustrating the welding of the wire column and the metal sheet according to an embodiment of the present invention is shown.

[0029] Figure 2 This diagram shows a simplified schematic of the welding system according to an embodiment of the present invention from a frontal view.

[0030] Figure 3 This diagram shows a schematic representation of the welding system according to an embodiment of the present invention from a top view.

[0031] Figure 4 This is a perspective view of the wire column and metal sheet after welding according to an embodiment of the present invention;

[0032] Figure 5 This invention illustrates the three-dimensional support block of an embodiment of the present invention. Figure 1 ;

[0033] Figure 6 This invention illustrates the three-dimensional support block of an embodiment of the present invention. Figure 2 ;

[0034] Figure 7 A top view of the support block according to an embodiment of the present invention is shown;

[0035] Figure 8 This shows a front view of the support block in the horizontal direction according to an embodiment of the present invention;

[0036] Figure 9 A perspective view of the mounting base according to an embodiment of the present utility model is shown;

[0037] Figure 10 A schematic diagram showing the inductor mounted on the mounting base according to an embodiment of the present invention is provided.

[0038] Figure 11 A perspective view of the lifting mechanism according to an embodiment of the present invention is shown;

[0039] Figure 12 An exploded view of the lifting mechanism according to an embodiment of the present invention is shown;

[0040] Figure 13 This is a side view showing the lifting mechanism of this utility model pushing the support block to move horizontally in an embodiment of the present invention. Detailed Implementation

[0041] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. Although the description of this utility model will be presented in conjunction with preferred embodiments, this does not mean that the features of this utility model are limited to this embodiment. On the contrary, the purpose of describing the utility model in conjunction with the embodiments is to cover other options or modifications that may be derived based on the claims of this utility model. To provide a deep understanding of this utility model, many specific details will be included in the following description. This utility model may also be implemented without using these details. Furthermore, to avoid confusion or obscuring the focus of this utility model, some specific details will be omitted in the description. It should be noted that, without conflict, the embodiments and features in the embodiments of this utility model can be combined with each other.

[0042] It should be noted that in this specification, similar reference numerals and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0043] In the description of this embodiment, it should be noted that the terms "upper", "lower", "inner", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship that the utility model product is usually placed in during use. They are only for the convenience of describing the utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the utility model.

[0044] The terms “first”, “second”, etc., are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0045] In the description of this embodiment, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set up," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment based on the specific circumstances.

[0046] To make the objectives, technical solutions, and advantages of this utility model clearer, the embodiments of this utility model will be described in further detail below with reference to the accompanying drawings.

[0047] refer to Figure 1 and Figure 2 ,in, Figure 1 A simplified schematic diagram showing the welding of the terminals 11 and the metal sheet 20 of the inductor 10 is shown. Figure 2 A schematic diagram of the welding system 100 is shown from a frontal view. Embodiments of this application provide a... Figure 2 The welding system 100 shown is used to weld the terminals 11 of the inductor 10 to the metal sheet 20, thereby fixing the inductor 10 to the PCB board and connecting it to its electrical circuit via the metal sheet 20.

[0048] In this embodiment, the metal sheet 20 is a copper sheet. It is understood that this application does not limit the specific type of the metal sheet 20; in other embodiments, the metal sheet 20 may also be a copper alloy sheet, etc.

[0049] Specifically, refer to Figure 2 and Figure 3 ,in, Figure 3A schematic diagram of the welding system 100 is shown from a top view. The welding system 100 includes a worktable 200, a support block 300, two clamps 400, a mounting base 500, and a lifting mechanism 600. The support block 300 is located on the worktable 200. The two clamps 400 are spaced apart along the width direction Y on the worktable 200, and are used to clamp two metal sheets 20 respectively. It is understood that this application does not limit the specific clamping method. As an optional implementation, the clamps 400 can be powered by a cylinder to drive the two opposing clamping plates to move towards or away from each other, thereby clamping and releasing the metal sheets 20.

[0050] The aforementioned mounting base 500 is disposed on the worktable 200 and is positioned opposite the support block 300 in the horizontal direction X. The mounting base 500 can move in the horizontal direction X toward or away from the clamp 400; the mounting base 500 is used to support and fix the inductor 10. It is understood that, as Figure 4 As shown, the inductor 10 includes a core 13, a winding section 12, and two terminals 11. The winding section 12 is wound around the core 13; the two terminals 11 are led out from the beginning and end of the winding section 12 and are used to connect to the metal sheet 20.

[0051] For example, such as Figure 1 and Figure 3 As shown, along the horizontal direction X, the fixture 400 is located between the mounting base 500 and the support block 300. The mounting base 500 can move toward or away from the fixture 400 under the action of the drive assembly (not shown). That is, when welding is about to be performed, the drive assembly drives the mounting base 500 to move toward the fixture 400, so that the lead 11 of the inductor 10 approaches and contacts the metal sheet 20 on the fixture 400, thus reaching the welding station, where the ultrasonic welding head 14 performs the welding action. After welding is completed, the drive assembly drives the mounting base 500 to move along the horizontal direction X and away from the fixture 400, thus returning to the initial position.

[0052] For example, the drive component described above is a cylinder. However, those skilled in the art will understand that in other embodiments, other drive components may be selected to drive the mounting base 500 to move, such as an electric slide.

[0053] refer to Figure 2The aforementioned lifting mechanism 600 is used to drive the support block 300 to move in the horizontal direction X toward the clamp 400, and to restrict the support block 300 from moving in the horizontal direction X toward the clamp 400. For example, in the initial state, the support block 300 and the metal sheet 20 on the clamp 400 have a set distance. When welding is about to begin, the lifting mechanism 600 drives the support block 300 to move in the horizontal direction X toward the metal sheet 20 on the clamp 400, gradually approaching and contacting the metal sheet 20 to support it. During welding, the lifting mechanism 600 continuously presses against the support block 300, restricting its movement in the horizontal direction X toward the clamp 400, effectively resisting the tendency of the support block 300 to retreat due to welding vibration, and ensuring that the support block 300 maintains a stable support state for the metal sheet 20 throughout the entire welding cycle.

[0054] refer to Figures 1 to 3 The specific welding process is as follows: In the initial state, the clamp 400 holds the metal sheet 20, the mounting base 500 carrying the inductor 10 is located on one side of the clamp 400 and is spaced apart from the clamp 400 in the horizontal direction X, and the support block 300 is located on the other side of the clamp 400 and is spaced apart from the clamp 400 in the horizontal direction X. Then the mounting base 500 moves forward to drive the lead post 11 of the inductor 10 to contact the metal sheet 20 to complete the alignment, and at the same time the lifting mechanism 600 pushes the support block 300 forward to contact the metal sheet 20 to provide support; during welding, the ultrasonic welding head 14 applies high-frequency vibration, and the metallurgical bonding between the lead post 11 and the metal sheet 20 is completed under the rigid reference provided by the support block 300; finally, the ultrasonic welding head 14 is lifted, the support block 300 is withdrawn, and the mounting base 500 returns to its original position.

[0055] The following section will first describe the specific structure of the support block 300 with reference to the accompanying drawings.

[0056] like Figures 4 to 7 As shown, the support block 300 includes a front end portion 301 and a rear end portion 302 in the horizontal direction X. The front end portion 301 faces the clamp 400. The front end portion 301 has an arc-shaped recess 310, which is recessed inward in the horizontal direction X to form an arc-shaped space for accommodating a portion of the winding portion 12. When the support block 300 moves forward and presses against the metal sheet 20, the winding portion 12 of the inductor 10 is embedded in this arc-shaped recess 310. This prevents the support block 300 from squeezing the protruding winding portion 12, which could cause insulation damage to the winding portion 12, thus ensuring the electrical performance and structural integrity of the inductor 10.

[0057] For example, the contour of the arc-shaped recess 310 is adapted to the outer peripheral contour of the winding portion 12 of the inductor 10. The width H1 of the arc-shaped recess 310 is 16mm to 17mm, specifically, for example, 16mm, 16.5mm, 17mm, etc. The depth H2 of the arc-shaped recess 310 in the horizontal direction X is 3mm to 4mm, specifically, for example, 3mm, 3.5mm, 4mm, etc.

[0058] In this embodiment, the length H1 of the arc-shaped recess 310 in the width direction Y is 16.5 mm, the arc radius R1 is 12.2 mm, and the depth H2 of its indentation in the horizontal direction X is 3.5 mm. It can be understood that the specific dimensions of the arc-shaped recess 310 are determined by the dimensions of the winding portion 12 it needs to avoid. The larger the outer diameter of the winding portion 12, the larger the arc radius R1, the length H1 in the width direction Y, and the depth H2 of the arc-shaped recess 310.

[0059] refer to Figure 3 and Figure 5 A support portion 320 is provided on each side of the arc-shaped recess 310 in the width direction Y. The two support portions 320 correspond one-to-one with the two metal pieces 20 and the two posts 11. Each support portion 320 is used to contact and support its corresponding metal piece 20 in the horizontal direction X. For example, the two support portions 320 are symmetrically arranged about the arc-shaped recess 310 so as to correspond one-to-one with the two posts 11 located on the radial sides of the winding portion 12. Thus, during welding, a part of the winding portion 12 of the inductor 10 is accommodated in the arc-shaped recess 310 of the support block 300, while the posts 11 led out from the radial sides of the winding portion 12 and the metal pieces 20 to be welded are respectively opposite to the support portions 320 on both sides of the arc-shaped recess 310 in the horizontal direction X, so that each support portion 320 can accurately provide an independent horizontal support force to its corresponding metal piece 20, thereby forming a stable force flow transmission path during the welding process.

[0060] For example, such as Figure 5 and Figure 8As shown, the width H3 (i.e., the length in the width direction Y) of the support part 320 is 7mm to 10mm, and the height H4 of the support part 320 is 5mm to 7mm. The width direction Y, the height direction Z, and the horizontal direction X of the support part 320 are mutually perpendicular. In this embodiment, the width H3 of the support part 320 is 8.45mm, and the height H4 of the support part 320 is 6.6mm. Compared with embodiments with cross-sectional dimensions smaller than this range (e.g., width H3 < 7mm and / or height H4 < 5mm), this solution significantly increases the cross-sectional area of ​​the support part 320, thereby greatly improving its compressive strength and structural rigidity. It can effectively resist the high-frequency vibration impact generated by ultrasonic welding and avoid plastic deformation or fatigue fracture caused by stress concentration. At the same time, the larger contact area reduces the pressure per unit area, which not only prevents pressure damage to the surface of the metal sheet 20 but also reduces its own wear rate, thus maintaining stable support accuracy in repetitive operations and comprehensively achieving better process stability and equipment durability.

[0061] In addition, the inner contour of the aforementioned arc-shaped recess 310 is adapted to the outer peripheral contour of the winding portion 12. While achieving precise avoidance of the winding portion 12 of the inductor 10, it strictly limits the ineffective expansion of the arc-shaped recess 310, ensuring that the support portions 320 on both sides retain sufficient structural width (such as 8.45mm in this embodiment). This avoids collision damage between the winding portion 12 and the support block 300 on the one hand, and maintains sufficient contact area between the support portion 320 and the metal sheet 20 on the other hand. This ensures the uniform distribution of support force and vibration resistance during welding, and significantly reduces the wear rate of the support portion 320 itself by reducing local pressure. Ultimately, it achieves the dual goals of component protection and tooling longevity simultaneously under complex working conditions.

[0062] Furthermore, the support portion 320 is provided with a burr area 321, which is used to contact the metal sheet 20 in the horizontal direction X. The multiple burrs in the burr area 321 tightly engage with the valve surface of the metal sheet 20 in the horizontal direction X through their sharp protrusions. By utilizing the local embedding effect, the static friction is significantly increased, effectively suppressing any slight slippage or vibration of the metal sheet 20 relative to the support portion 320 during the welding process. This ensures that the welding energy is precisely applied to the interface between the post 11 and the metal sheet 20 rather than being lost in relative displacement, thereby ensuring the accuracy of the weld point position and the reliability of the connection strength.

[0063] For example, each burr in the burr region 321 has a length of 0.3 mm to 0.4 mm in the horizontal direction X, which is more advantageous in resisting welding vibration and wear compared to burrs with a length of less than 0.3 mm (e.g., 0.2 mm).

[0064] In this embodiment, each burr is shaped like a truncated pyramid, with the smaller end used to contact the metal sheet 20 and the larger end located on the vertical plane where the support 320 is located. The length of the burr in the horizontal direction X refers to the straight-line distance from the smaller end to the larger end.

[0065] In this embodiment, the length of each burr in the horizontal direction X is 0.375 mm. Those skilled in the art will understand that in other embodiments, the length of each burr in the horizontal direction X can also be 0.3 mm, 0.35 mm, 0.4 mm, etc.

[0066] like Figure 5 As shown, each support portion 320 has an arc-shaped protrusion 330 below it. Each arc-shaped protrusion 330 protrudes horizontally X out of the vertical plane of its corresponding support portion 320, and the arc-shaped protrusion 330 is used to abut against the terminal 11. Exemplarily, the support portion 320 and the arc-shaped protrusion 330 are connected by a rounded arc.

[0067] The arc-shaped protrusion 330 contacts the columnar outer surface of the post 11. Compared with the sharp straight edge structure in the existing embodiment, it significantly reduces the contact pressure and avoids the surface of the post 11 being squeezed, scratched or worn due to stress concentration during the welding process. At the same time, the arc-shaped contact provides a more stable guiding and limiting effect, which can effectively suppress the radial movement of the post 11 under high-frequency vibration and ensure that the welding energy is accurately applied to the interface between the post 11 and the metal sheet 20, thereby improving the welding quality while protecting the structural integrity of the post 11.

[0068] In this embodiment, the support block 300 is made of high-alloy tool steel. Specifically, the support block 300 is made of materials imported from Germany. K390 has extremely high hardness and wear resistance, which can significantly extend the service life of support block 300.

[0069] Compared with the aluminum support block 300 in the existing embodiments, the high-alloy tool steel support block 300, with its ultra-high hardness and wear resistance, solves the defects of aluminum material's soft surface being prone to scratches, deformation and wear under high-frequency vibration of metal sheet 20; its high strength and high toughness can resist welding impact loads, avoid permanent deformation or fracture of aluminum material due to insufficient fatigue strength, thus maintaining a stable support plane and dimensional accuracy in long-term repetitive operation, eliminating welding position deviation and quality fluctuation caused by tooling wear, and greatly improving production yield and equipment life.

[0070] By adopting the above technical solution, the arc-shaped concave portion 310 of the support block 300, through its precise adaptation to the contour of the winding portion 12, effectively avoids the winding portion 12 of the inductor 10, preventing insulation damage, while limiting its own expansion range, ensuring that the two side support portions 320 maintain sufficient structural width to stably support the metal sheet 20; while the arc-shaped convex portion 330 below the support portion 320 replaces the edge contact in the existing solution with arc surface contact, significantly reducing pressure when it abuts the terminal 11, avoiding scratching or damaging the surface of the terminal 11. The synergistic effect of the two ensures the uniform transmission of interface pressure and vibration suppression between the metal sheet 20 and the terminal 11 during the welding process, thereby improving the welding quality, and significantly extends the overall service life of the support block 300 by reducing stress concentration and mechanical wear.

[0071] The service life of the support block 300 in this embodiment significantly exceeds that of traditional designs—under the same working conditions, the fatigue life is increased dramatically from 2,000 cycles to 20,000 cycles, representing a tenfold increase in durability and greatly reducing equipment maintenance frequency and overall costs. Simultaneously, the welding support stability provided by the support block 300 is significantly enhanced, resulting in a breakthrough in the mechanical properties of the weld joints formed with its assistance. The average pull-out force of the weld joints increases from 500N to 1,000N, doubling the strength, fully demonstrating the core role of the support block 300 in improving welding quality and connection reliability.

[0072] The following section will describe in detail the specific structure of the mounting base 500 with reference to the accompanying drawings.

[0073] like Figure 4 , Figure 9 and Figure 10 As shown, the mounting base 500 includes a base body 510, on which a mounting groove 520 and a support platform 530 are provided. The mounting groove 520 is used to accommodate the end of the core 13 of the inductor 10; the bottom wall of the mounting groove 520 is provided with negative pressure adsorption holes 521, which are used to adsorb and fix the end of the core 13 of the inductor 10. In this embodiment, the bottom wall of the mounting groove 520 has four centrally symmetrically distributed negative pressure adsorption holes 521.

[0074] For example, the negative pressure generated by the negative pressure adsorption hole 521 produces a vertical (i.e., height direction Z) adsorption force on the end of the core 13, overcoming its axial displacement tendency.

[0075] For example, the mounting slot 520 is U-shaped and is located near the end of the base 510, with its bottom wall extending beyond the end of the base 510, thereby facilitating the horizontal removal of the inductor 10 from the mounting slot 520.

[0076] The aforementioned support platform 530 is arranged around the mounting groove 520. The support platform 530 is used to support the end of the winding portion 12 of the inductor 10. The distance H5 between the support platform 530 and the bottom wall of the mounting groove 520 is adapted to the distance from the end of the core 13 of the inductor 10 to the end of the winding portion 12. For example, the support platform 530 is approximately in the shape of a 120° ring. The plane of the support platform 530 is higher than the plane of the bottom wall of the mounting groove 520, and this height difference H5 is adapted to the distance from the end of the core 13 of the inductor 10 to the end of the winding portion 12. This allows the end of the core 13 to be attracted to the bottom wall of the mounting groove 520 by negative pressure, and the end of the winding portion 12 to be in close contact with the surface of the support platform 530, thereby using the mechanical contact surface to jointly constrain the axial displacement of the inductor 10. At the same time, it is necessary to avoid the end of the winding part 12 pressing the support platform 530 too early before the end of the core 13 has fully contacted the bottom wall of the mounting groove 520, so that the core 13 cannot form an effective sealing contact with the bottom wall of the mounting groove 520 due to being suspended by the winding part 12, thereby causing the negative pressure adsorption to fail.

[0077] In this embodiment, the distance H5 between the support platform 530 and the bottom wall of the mounting groove 520 is 2.7mm.

[0078] Finally, the following section will describe in detail the specific structure of the lifting mechanism 600 with reference to the accompanying drawings.

[0079] refer to Figures 11 to 13 The lifting mechanism 600 includes a drive member (not shown), a main body 610, and a pushing part 620. The main body 610 is connected to the drive member, which drives the main body 610 to move along the height direction Z. Exemplarily, the drive member is a cylinder. Those skilled in the art will understand that in other embodiments, the drive member may also be an electric push rod, etc.

[0080] The pushing part 620 is detachably connected to the main body 610. For example, as shown... Figure 12 As shown, the main body 610 is a one-piece structure, which includes an extension 611 extending along the height direction Z and a connecting platform 612. The connecting platform 612 is provided at the upper end of the extension 611, and a surface 613 of the connecting platform 612 in the thickness direction (corresponding to the horizontal direction X of the support 320) has a set distance from the surface 614 on the same side of the extension 611. The pushing part 620 is fixed to the surface 613 of the connecting platform 612 and is flush with the surface 614 on the same side of the extension 611.

[0081] For example, the pusher 620 is connected to the connecting platform 612 of the main body 610 by screws.

[0082] refer to Figure 6 and Figure 13The aforementioned support block 300 has a guide slope 340 at one end (i.e., the rear end 302) in the horizontal direction X, away from the arc-shaped recess 310. The guide slope 340 forms an obtuse angle α with the plane containing the bottom wall of the support block 300. For example, the angle α between the guide slope 340 and the plane containing the bottom wall of the support block 300 is 150°. It is understood that in other embodiments, the angle α between the guide slope 340 and the plane containing the bottom wall of the support block 300 can also be 135°, 140°, 145°, etc.

[0083] refer to Figure 2 , Figures 11 to 13 The aforementioned worktable 200 is provided with an opening 201, through which the pushing part 620 passes to contact the guide slope 340 of the support block 300. It is understood that when the drive unit is activated, the main body 610 and the pushing part 620 move upwards along the height direction Z, and the top edge 621 of the pushing part 620 abuts against the guide slope 340 of the support block 300. Since the angle α between the guide slope 340 and the plane containing the bottom wall of the support block 300 is obtuse, the upward force of the pushing part 620 will generate a forward component force along the direction of the guide slope 340. This forward component force directly pushes the entire support block 300 to slide horizontally forward, thereby converting the vertical linear motion of the pushing part 620 into the forward and backward linear motion of the support block 300, ultimately causing the support block 300 to contact and press against the metal sheet 20.

[0084] For example, the pushing part 620 has a block structure with a rectangular cross-section. The top edge 621 of the part that contacts the guide slope 340 is rounded to increase the contact area with the guide slope 340 and achieve a better pushing effect.

[0085] Therefore, compared to the existing implementation where the jacking part and the main body are an integrated structure, and the jacking part needs to be replaced as a whole after wear, this design modularizes the vulnerable parts, so that the jacking part 620 can be quickly disassembled and replaced individually after severe wear, without the need for complete scrapping. This not only significantly reduces spare parts costs and inventory pressure, but also greatly shortens maintenance downtime, and improves the sustainability and overall economy of the equipment.

[0086] In addition, in this embodiment, the connecting platform 612 is provided with a plurality of screw mounting holes 615. By selecting screw mounting holes 615 at different positions or adding or removing shims, the mounting angle of the push part 620 on the connecting platform 612 can be finely adjusted, thereby changing the spatial orientation of its top edge 621, so as to adjust the contact posture between the top edge 621 of the push part 620 and the guide slope 340, ensuring that the two always achieve uniform contact, thereby significantly reducing local stress concentration and wear rate.

[0087] Although the present invention has been illustrated and described with reference to certain preferred embodiments, those skilled in the art should understand that the above description is a further detailed explanation of the present invention in conjunction with specific embodiments, and should not be construed as limiting the specific implementation of the present invention to these descriptions. Those skilled in the art can make various changes in form and detail, including some simple deductions or substitutions, without departing from the spirit and scope of the present invention.

Claims

1. A support block for horizontally supporting a metal sheet during ultrasonic welding of an inductor's posts and metal sheet, the inductor comprising a core, a winding portion, and posts, characterized in that, The support block includes: An arc-shaped recess is provided at one end of the support block in the horizontal direction and is recessed inward in the horizontal direction; the inner contour of the arc-shaped recess is adapted to the outer peripheral contour of the winding part of the inductor to accommodate a part of the winding part. Two support portions are located on both sides of the arc-shaped concave portion; the two support portions are used to correspond one-to-one with the two metal sheets and the two wire posts, and each of the support portions is used to contact and support its corresponding metal sheet in the horizontal direction. Two arc-shaped protrusions correspond one-to-one with the two support portions; each arc-shaped protrusion is located below its corresponding support portion, and each arc-shaped protrusion protrudes horizontally from the plane of the support portion; the arc-shaped protrusions are used to abut against the terminal.

2. The support block as described in claim 1, characterized in that, The support portion and the arc-shaped protrusion are connected by a circular arc.

3. The support block as described in claim 2, characterized in that, The support block is made of high alloy tool steel.

4. The support block as described in claim 3, characterized in that, The support portion is provided with a burr area, which is used to contact the metal sheet in the horizontal direction.

5. The support block as described in claim 4, characterized in that, The burr area includes multiple burrs, each burr having a horizontal length of 0.3 mm to 0.4 mm.

6. The support block as described in claim 5, characterized in that, The width of the support part is 7mm to 10mm, the height of the support part is 5mm to 7mm, and the width direction, height direction and horizontal direction of the support part are perpendicular to each other.

7. The support block as described in claim 6, characterized in that, The width of the arc-shaped recess is 16mm to 17mm, and the depth of the arc-shaped recess in the horizontal direction is 3mm to 4mm.

8. A welding system, characterized in that, include: The support block according to any one of claims 1 to 7; A workbench, wherein the support block is disposed on the workbench; Two clamps are spaced apart on the worktable along the width direction; the two clamps are used to clamp two metal sheets respectively; A mounting base is provided on the workbench and is arranged horizontally opposite to the support block. The mounting base can move horizontally toward or away from the clamp. The mounting base is used to support and fix the inductor. A lifting mechanism is provided for driving the support block to move horizontally toward the clamp and for restricting the support block to move horizontally away from the clamp.

9. The welding system as claimed in claim 8, characterized in that, The mounting base includes: A mounting groove is provided to accommodate the end of the inductor core; the bottom wall of the mounting groove is provided with a negative pressure adsorption hole, which is used to adsorb and fix the end of the inductor core. A support platform is arranged around the mounting groove. The support platform is used to support the end of the winding portion of the inductor. The distance between the support platform and the bottom wall of the mounting groove is adapted to the distance from the end of the core of the inductor to the end of the winding portion.

10. The welding system as claimed in claim 8, characterized in that, The support block has a guide slope at one end in the horizontal direction away from the arc-shaped concave part, and the angle between the guide slope and the plane where the bottom wall of the support block is located is an obtuse angle. The lifting mechanism includes: Drive components; The main body is connected to the driving member, which drives the main body to move along the height direction. The pushing part is detachably connected to the main body; the pushing part is used to contact the guide slope of the support block to push the support block to move horizontally and toward the clamp.

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