An ultrasonic welding device

Abstract

The utility model belongs to ultrasonic welding equipment technical field provides a kind of ultrasonic welding device, comprising: support platform;First welding mechanism and second welding mechanism are respectively arranged in the upper and lower ends of support platform, and first welding mechanism includes first welding head, and second welding mechanism includes second welding head;Fixing mechanism, it includes: two mutually close or far away clamping blocks, and the opposite end of each clamping block is equipped with fixed part.Compared with prior art, the first welding surface and the second welding surface of symmetry are set on the main line, and the first inclined surface and the second inclined surface are configured on both sides, and the clamping block with the fixed part is matched to realize the clamping without bottom die, which effectively avoids the dependence on special bottom die in traditional welding.The clamping block is contacted with the inclined surface, which firmly fixes the main line while completely exposing the upper and lower welding areas.

Description

Technical Field

[0001] This utility model belongs to the technical field of ultrasonic welding equipment, and specifically relates to an ultrasonic welding device. Background Technology

[0002] Ultrasonic welding is a solid-state welding process widely used in wire harness connections. Its basic principle is to generate a high-frequency electrical signal using an ultrasonic generator, which is then converted into high-frequency mechanical vibration by a transducer and amplified by an amplitude transformer before being transmitted to the welding head. Under applied vertical pressure, the welding head applies the vibrational energy to the contact surfaces of the metal parts to be welded, causing plastic deformation and atomic diffusion at the microscopic protrusions on the metal surface, thereby achieving a metallurgical bond at the molecular chain level without melting the material.

[0003] Traditional ultrasonic wire harness welding devices typically employ an "upper mold-lower mold" structure: a welding head (upper mold) that can move up and down cooperates with a fixed bottom mold (lower mold) to complete the welding. The wire harness to be welded is placed in the cavity of the bottom mold for positioning and support. The welding head, driven by a cylinder or servo, presses the workpiece and applies ultrasonic vibration. The welding process is completed under the clamping and energy coupling effect of the welding head and the bottom mold. However, this traditional structure exposes a series of insurmountable technical bottlenecks when facing specific application scenarios:

[0004] First, the molds are costly and lack versatility. Custom-made base molds must be used for wire harnesses with different cross-sectional shapes, sizes, or combinations to ensure positioning accuracy and pressure uniformity. This is especially true when the main wire is a large-section wire harness (e.g., cross-sectional area greater than 50mm²). 2 When manufacturing molds, the bottom molds need to have high strength, high rigidity and high wear resistance, which leads to a significant increase in manufacturing costs and complicated mold inventory management.

[0005] Secondly, in scenarios involving the cross-welding of large and small wire harnesses, traditional structures suffer from low energy transfer efficiency and structural design contradictions. For example, when a very large square main wire needs to be welded simultaneously to small square branch wires on both sides at a certain angle (e.g., 30°), the traditional welding head needs to cover the entire cross-section of the main wire to provide sufficient welding area. This results in a large welding head volume and increased mass, making it difficult to achieve high-frequency stable vibration and reducing the energy density of the welding area due to energy dispersion, thus affecting welding strength and consistency. At the same time, the bottom mold needs to support the main wire and accommodate the branch wires, greatly increasing structural complexity and even making effective positioning impossible.

[0006] In summary, existing ultrasonic welding equipment faces multiple challenges when dealing with welding tasks involving large-section main lines and multiple branch lines, including high mold costs, limited applicability, low energy utilization efficiency, and difficulties in structural implementation. Therefore, there is an urgent need for a new type of ultrasonic welding equipment and process that can accurately fix irregularly shaped main lines, expose the welding area, independently control the welding posture of upper and lower branch lines, and efficiently transmit ultrasonic energy without the need for a dedicated base mold, thereby balancing welding quality, equipment versatility, and manufacturing economy. Utility Model Content

[0007] The technical problem to be solved by this utility model is to provide an ultrasonic welding device in light of the current state of the technology.

[0008] The technical solution adopted by this utility model to solve the above-mentioned technical problems is as follows: An ultrasonic welding device is proposed for welding main lines and branch lines.

[0009] The main line includes at least partially parallel first welding surface and second welding surface, with first inclined surfaces symmetrically arranged on both sides of the first welding surface, and second inclined surfaces symmetrically arranged on both sides of the second welding surface;

[0010] The welding apparatus includes:

[0011] Support platform;

[0012] A first welding mechanism and a second welding mechanism are respectively disposed at the upper and lower ends of the support platform. The first welding mechanism includes a first welding head, and the second welding mechanism includes a second welding head. The first welding head is used to weld a first branch line on the first welding surface, and the second welding head is used to weld a second branch line on the second welding surface. The vibration direction of the first welding head is parallel to the extension direction of the first branch line, and the vibration direction of the second welding head is parallel to the extension direction of the second branch line, so that the main line can be arranged to cross the first branch line and the second branch line.

[0013] A fixing mechanism includes: two clamping blocks that can move closer to or further away from each other; each clamping block has a fixing part at its facing end; the fixing part is configured such that when the two clamping blocks move closer to each other, they can simultaneously form a mating contact with the first inclined surface and the second inclined surface on the same side of the main line; wherein...

[0014] When the clamping blocks approach each other, the main line is fixed by the contact between the fixing part and the first inclined surface and the second inclined surface on the same side, while keeping the welding area of ​​the first welding surface and the second welding surface fully exposed.

[0015] In the aforementioned ultrasonic welding device, the angle between the main line and the first branch line is 30°±2°, and the angle between the main line and the second branch line is 30°±2°.

[0016] In the aforementioned ultrasonic welding apparatus, the fixing mechanism includes:

[0017] A support plate, which is movably disposed on the support platform, wherein one of the clamping blocks is fixed on the support plate;

[0018] A first driving member is horizontally disposed on the support platform, and the support plate is connected to the output end of the first driving member. The first driving member is used to drive the support plate to move on the support platform.

[0019] The second driving component is erected on the support platform;

[0020] A connector is provided at the output end of the second drive member, and the other end of the connector is connected to another clamping block. It is used to convert the output power of the second drive member into the movement of the clamping block on the support plate, and the directions in which the two clamping blocks approach and move away from each other are perpendicular to the driving direction of the second drive member.

[0021] The third driving component is erected on the support plate;

[0022] A connecting block is disposed at the output end of the third driving element;

[0023] A positioning block, disposed at one end of the connecting block, is used to limit the first branch or the second branch;

[0024] The fourth driving member is horizontally disposed at the other end of the connecting block. Two first clamping blocks are disposed opposite each other at the output end of the fourth driving member. The fourth driving member is used to drive the two first clamping blocks to move closer or further apart from each other.

[0025] The fifth driving component is provided on the support plate at least two of them, which are arranged horizontally. Each fifth driving component has two second clamping blocks at its output end. The fifth driving component is used to drive the two second clamping blocks to move closer or further apart.

[0026] In the aforementioned ultrasonic welding apparatus, the connecting member includes:

[0027] A fixing seat is provided on the second driving member. The fixing seat is provided with a through hole that matches the shape of the clamping block. The through hole extends in a direction parallel to the first welding surface. The clamping block is movably disposed in the through hole.

[0028] A drive block is movably disposed within the fixed base in a direction perpendicular to the moving direction of the clamping block, and is connected to the output end of the second drive member;

[0029] A rolling element is rotatably mounted on the driving block. The clamping block is provided with a driving groove, which is inclined relative to the moving direction of the driving block. The rolling element is rolled within the driving groove to drive the clamping block to move when the driving block moves.

[0030] In the aforementioned ultrasonic welding apparatus, the driving groove includes a main body segment and a limiting segment disposed at the end of the main body segment, with a smooth transition between the main body segment and the limiting segment;

[0031] When the rolling element rolls within the main body segment, it drives the clamping block to move closer to or further away from the main line.

[0032] When the rolling element is in the limiting section, it is used to fix the clamping block, so that the fixing part abuts against the first inclined surface and the second inclined surface on the same side of the main line, and the direction of the force applied by the rolling element to the clamping block is parallel to the normal of the first welding surface.

[0033] In the aforementioned ultrasonic welding apparatus, the first welding mechanism includes:

[0034] A first support frame is mounted on the support platform;

[0035] The sixth driving component is erected on the first support frame;

[0036] A first connecting frame is disposed at the output end of the sixth driving member, and the first welding head is connected to the first connecting frame;

[0037] The first amplitude rod is mounted on the first connecting frame and connected to the first welding head;

[0038] The first transducer is located at the end of the first amplitude transformer that is away from the first welding head.

[0039] In the aforementioned ultrasonic welding apparatus, the first connecting frame includes:

[0040] Base plate;

[0041] A main body block is disposed on the base plate, and a positioning recess is provided on the main body block, the positioning recess extending parallel to the vibration direction of the first welding head;

[0042] A welding head connecting block is used to connect the first welding head. The welding head connecting block is provided with a positioning protrusion that is adapted to the positioning recess.

[0043] A first limiting block is disposed on the main body block and is disposed opposite to the positioning recess. One end of the first limiting block is movably abutted against the welding head connecting block. When the positioning protrusion is inserted into the positioning recess, the first limiting block and the positioning recess are respectively located on both sides of the welding head connecting block along the vibration direction.

[0044] The second limiting block is disposed on the main body block, and one end of the second limiting block moves against the end of the welding head connecting block along the vibration direction of the first welding head.

[0045] In the aforementioned ultrasonic welding apparatus, the second welding mechanism includes:

[0046] Second support frame;

[0047] The seventh driving component is erected on the second support frame;

[0048] The second connecting frame is disposed at the output end of the seventh driving member, and the second welding head is connected to the second connecting frame;

[0049] The second amplitude rod is mounted on the second connecting frame and connected to the second welding head;

[0050] A second transducer is disposed at the end of the second amplitude transformer away from the second welding head; wherein...

[0051] The output shafts of the sixth and seventh driving components are coaxially arranged.

[0052] In the aforementioned ultrasonic welding device, an eighth driving component is erected on the support platform. The output end of the eighth driving component is provided with a positioning pin, and the support plate is provided with a positioning hole. The eighth driving component is used to drive the positioning pin to be inserted into the positioning hole, thereby fixing and releasing the support plate.

[0053] Compared with the prior art, the present invention has the following beneficial effects:

[0054] (1) By setting symmetrical first and second welding surfaces on the main line, and configuring first and second inclined surfaces on both sides, and cooperating with clamping blocks with fixing parts, bottom mold-free clamping is achieved, effectively avoiding the dependence on special bottom molds in traditional welding. The clamping blocks, through contact with the inclined surfaces, firmly fix the main line while fully exposing the upper and lower welding areas. In addition, the first and second welding heads apply vibrations along the extension direction of the branch line, so that the main line and the branch line are arranged in a cross pattern, which significantly improves the directional transmission efficiency of ultrasonic energy at the welding interface and overcomes the energy dispersion problem caused by the traditional large-size welding head covering the entire cross section.

[0055] (2) By adopting a connecting structure that includes a drive block, rolling elements, and an inclined drive groove, the vertical movement of the second drive element can be efficiently converted into the horizontal movement of the clamping block, thereby achieving adaptive clamping of the main line. This transmission mechanism is compact and responsive, avoiding the clamping loosening problem caused by insufficient rigidity in traditional pneumatic or hydraulic clamps. It is especially suitable for the stable fixation of large-section main lines in high-energy ultrasonic welding processes, effectively preventing welding offset or incomplete welding caused by clamping failure.

[0056] (3) By setting the main line segment and the limiting segment in the drive groove, and making the rolling element apply a force parallel to the normal direction of the welding surface to the clamping block within the limiting segment, it is ensured that the clamping block always presses against the main line slope in the optimal direction during the welding process. This not only enhances the clamping stability, but also ensures that the pressure is evenly distributed around the welding area, avoiding workpiece deformation or wear caused by local stress concentration in traditional bottom molds, and further improving the consistency of welding quality. Attached Figure Description

[0057] Figure 1 This is a plan view of an ultrasonic welding device according to this utility model.

[0058] Figure 2 This is a perspective view of an ultrasonic welding device according to this utility model.

[0059] Figure 3 It is a three-dimensional diagram of the fixed mechanism.

[0060] Figure 4 yes Figure 3 A magnified view of a portion of point A in the middle.

[0061] Figure 5 This is a cross-sectional view of the main welding position.

[0062] Figure 6 This is a partial sectional view of the second drive component, connector, and clamping block when they are connected.

[0063] Figure 7 This is a 3D diagram of the driver block.

[0064] Figure 8 This is a 3D view of the clamping block.

[0065] Figure 9 It is a 3D diagram of the fixed base.

[0066] Figure 10 It is a three-dimensional view of the first branch line when the third driving component, connecting block, positioning block, fourth driving component, and positioning block are used together to fix it.

[0067] Figure 11 This is a perspective view of the fifth driving component and the second clamping block when they are connected.

[0068] Figure 12 This is a three-dimensional view of the first welding mechanism.

[0069] Figure 13 This is a three-dimensional view of the second welding mechanism.

[0070] Figure 14 yes Figure 12 A three-dimensional view of the middle part of the structure.

[0071] Figure 15 It is a 3D view of the main block.

[0072] Figure 16 It is a 3D view of the welding head connecting block and the first welding head being connected.

[0073] In the diagram, 100 is the main line; 101 is the first welding surface; 102 is the second welding surface; 103 is the first inclined plane; 104 is the second inclined plane; 200 is the first branch line; 300 is the second branch line; 400 is the support platform; 401 is the eighth driving component; 402 is the positioning pin; 500 is the first welding mechanism; 501 is the first welding head; 502 is the first support frame; 503 is the sixth driving component; 504 is the first connecting frame; 505 is the first amplitude transformer; 506 is the first transducer; 507 is the base plate; 508 is the main block; 509 is the positioning recess; 510 is the welding head connecting block; 511 is the positioning protrusion; 512 is the first limiting block; 513 is the second limiting block; 600 is the second welding mechanism; 601 is the second... 602. Welding head; 603. Second support frame; 604. Seventh driving component; 605. Second connecting frame; 606. Second amplitude transformer; 607. Second transducer; 708. Fixing mechanism; 709. Clamping block; 700. Fixing part; 700. Support plate; 701. First driving component; 702. Second driving component; 703. Connecting component; 704. Third driving component; 705. Connecting block; 706. Positioning block; 710. Fourth driving component; 711. First clamping block; 712. Fifth driving component; 713. Second clamping block; 714. Fixing seat; 715. Through hole; 716. Driving block; 717. Rolling component; 718. Driving groove; 719. Main body section; 720. Limiting section; 721. Positioning hole. Detailed Implementation

[0074] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0075] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in this utility model embodiment are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0076] like Figures 1 to 6 As shown, this utility model provides an ultrasonic welding device for welding the main line 100 to the branch line.

[0077] The main line 100 includes at least partially parallel first welding surface 101 and second welding surface 102. The first welding surface 101 has a first inclined surface 103 symmetrically arranged on both sides, and the second welding surface 102 has a second inclined surface 104 symmetrically arranged on both sides.

[0078] The welding apparatus includes: a support platform 400; a first welding mechanism 500 and a second welding mechanism 600, respectively disposed at the upper and lower ends of the support platform 400. The first welding mechanism 500 includes a first welding head 501, and the second welding mechanism 600 includes a second welding head 601; the first welding head 501 is used to weld a first branch line 200 on the first welding surface 101, and the second welding head 601 is used to weld a second branch line 300 on the second welding surface 102.

[0079] The vibration direction of the first welding head 501 is parallel to the extension direction of the first branch line 200, and the vibration direction of the second welding head 601 is parallel to the extension direction of the second branch line 300, so that the main line 100 can be arranged to cross the first branch line 200 and the second branch line 300.

[0080] The fixing mechanism 700 includes two clamping blocks 701 that can move closer to or further away from each other, and each clamping block 701 has a fixing part 702 at its opposite end. The fixing part 702 is configured such that when the two clamping blocks 701 move closer to each other, they can simultaneously form a mating contact with the first inclined surface 103 and the second inclined surface 104 on the same side of the main line 100.

[0081] When the clamping blocks 701 approach each other, the main line 100 is reliably clamped by the fixing part 702 in contact with the first inclined surface 103 and the second inclined surface 104 on the same side, while ensuring that the areas to be welded on the first welding surface 101 and the second welding surface 102 are fully exposed, which facilitates the welding operation.

[0082] The design concept of this scheme is as follows: First, the main line 100 is preprocessed to create a symmetrical structure in at least a local area.

[0083] The symmetrical structure includes a first welding surface 101 and a second welding surface 102 that are parallel to each other, and a first inclined surface 103 and a second inclined surface 104 located on the outer sides of the two welding surfaces, respectively.

[0084] In one embodiment, the cross-section of the symmetrical structure can be a regular hexagon; in other embodiments, a polygonal structure such as a regular octagon or a regular decagon can also be used.

[0085] In addition, an arc transition can also be used between the first inclined surface 103 and the second inclined surface 104 on the same side to adapt to different process requirements.

[0086] After pretreatment, the main line 100 is placed on the fixing mechanism 700 for clamping and fixing. During the clamping process, the two clamping blocks 701 move towards each other, and their fixing parts 702 are respectively attached to the first inclined surface 103 and the second inclined surface 104 on the same side of the main line 100.

[0087] In one specific embodiment, when the local cross-section of the main line 100 is a regular hexagon, the fixing part 702 can be designed as a V-shaped structure, which fits tightly against two adjacent inclined surfaces of the outer side wall of the main line 100.

[0088] This clamping method securely fixes the main line 100 while fully exposing the first welding surface 101 and the second welding surface 102, without affecting the welding operation of the branch line on the aforementioned welding surfaces, thus eliminating the need for a traditional dedicated bottom mold.

[0089] After the main line 100 is fixed, the first branch line 200 and the second branch line 300 are positioned and fixed on the first welding surface 101 and the second welding surface 102, respectively. Subsequently, the first welding mechanism 500 and the second welding mechanism 600 weld the main line 100 to the corresponding branch line through the first welding head 501 and the second welding head 601, respectively.

[0090] During the welding process, the first welding mechanism 500 and the second welding mechanism 600 can work synchronously: at this time, the first welding head 501 and the second welding head 601 simultaneously press the workpiece and apply ultrasonic vibration, and the two provide dynamic support for each other, without the need for an additional bottom mold.

[0091] Of course, the welding of the first welding head 501 and the second welding head 601 can also be carried out in steps: when one of the welding heads is welding, the other welding head can act as a static support component to provide reaction force to maintain welding stability.

[0092] In summary, this solution achieves bottom-mold-free clamping by setting symmetrical first welding surfaces 101 and second welding surfaces 102 on the main line 100, and configuring first inclined surfaces 103 and second inclined surfaces 104 on both sides, in conjunction with clamping blocks 701 with fixing parts 702, effectively avoiding the reliance on special bottom molds in traditional welding.

[0093] The clamping block 701 makes contact with the first inclined surface 103 and the second inclined surface 104 on the same side as the main body 100, which not only firmly fixes the main line 100, but also fully exposes the upper and lower welding areas.

[0094] In addition, the first welding head 501 and the second welding head 601 apply vibration along the extension direction of the branch line, so that the main line 100 and the branch line are arranged in a cross pattern, which significantly improves the directional transmission efficiency of ultrasonic energy at the welding interface and overcomes the energy dispersion problem caused by the traditional large-size welding head covering the entire cross section.

[0095] In one embodiment, the angle between the main line 100 and the first branch line 200 is 30°±2°, and the angle between the main line 100 and the second branch line 300 is 30°±2°.

[0096] The angle between the main line 100 and the first and second branch lines 300 is limited to 30°±2°. This angle has been verified by the process to optimize the ultrasonic energy transmission path while ensuring mechanical strength, and avoid stress concentration or energy reflection loss caused by excessively large or small angles.

[0097] This design is particularly suitable for scenarios where large and small wire harnesses are connected at cross points. It solves the problem of weak welding or wire harness damage caused by uncontrollable angles in traditional structures, and improves welding consistency and reliability.

[0098] Furthermore, the fixed mechanism 700 includes:

[0099] Support plate 703: It is movably mounted on support platform 400, and one of the clamping blocks 701 is fixed on support plate 703;

[0100] First driving component 704: Horizontally mounted on support platform 400, with support plate 703 connected to the output end of first driving component 704. First driving component 704 is used to drive support plate 703 to move horizontally on support platform 400;

[0101] Second drive component 705: erected on support platform 400;

[0102] Connector 706: Located at the output end of the second drive member 705, with the other end connected to another clamping block 701, used to convert the output power of the second drive member 705 into movement of the clamping block 701 relative to the support plate 703. The directions in which the two clamping blocks 701 approach or move away from each other are perpendicular to the driving direction of the second drive member 705.

[0103] Third driving component 707: vertically mounted on support plate 703;

[0104] Connector block 708: Located at the output end of the third drive unit 707;

[0105] Positioning block 709: Located at one end of connecting block 708, used to limit the first branch 200 or the second branch 300;

[0106] Fourth driving component 710: It is horizontally arranged at the other end of the connecting block 708. Two first clamping blocks 711 are arranged opposite each other at the output end of the fourth driving component 710. The fourth driving component 710 is used to drive the two first clamping blocks 711 to move closer or further apart from each other.

[0107] Fifth driving member 712: At least two fifth driving members 712 are arranged at intervals on the support plate 703. Each fifth driving member 712 is horizontally arranged. Each fifth driving member 712 has two second clamping blocks 713 at its output end. The fifth driving member 712 is used to drive the two second clamping blocks 713 to move closer or further apart from each other.

[0108] The support plate 703 is part of the fixing mechanism 700, such as the support structure of one of the clamping blocks 701, the fifth driving member 712 and the second clamping block 713. It can move horizontally on the support platform 400 through the horizontally set first driving member 704 (preferably a cylinder), which facilitates the picking and putting of the main line 100.

[0109] The second drive component 705 can be a cylinder, hydraulic cylinder, or motor, etc. By employing a second drive component 705 arranged vertically and using a connector 706 to convert the driving force into the movement of the clamping block 701 parallel to the normal direction of the welding surface, spatial decoupling between the driving direction and the clamping action direction is achieved. This design not only facilitates the layout of the drive components but also effectively utilizes limited space, improves the overall integration of the machine, and ensures smooth and reliable clamping action.

[0110] The third driving component 707 can also be a cylinder, hydraulic cylinder or motor, etc., while the fourth driving component 710 is preferably a double-headed cylinder, and the two first clamping blocks 711 set at its output end constitute a fixing structure for the first branch line 200 or the second branch line 300.

[0111] In this scheme, each side of the first welding mechanism 500 and the second welding mechanism 600 is equipped with a combination of a third driving component 707, a connecting block 708, a positioning block 709, a fourth driving component 710, and a first clamping block 711, which are used to fix the first branch line 200 and the second branch line 300 respectively, so as to ensure the welding accuracy between the first branch line 200, the second branch line 300 and the main line 100.

[0112] The fifth driving component 712 is preferably a double-headed cylinder, which drives the two second clamping blocks 713 to move closer and further apart, thereby clamping and fixing the area outside the welding position of the main line 100.

[0113] By setting up a composite fixing mechanism 700 containing multiple driving components (first to fifth driving components 712), independent and precise control of the overall position of the main line 100, the area outside the welding zone, and the upper and lower branch lines is achieved.

[0114] The fifth drive component 712 provides auxiliary clamping to the non-welding area of ​​the main wire 100 to prevent displacement during welding. The fourth drive component 710 limits and clamps the first branch wire 200 and the second branch wire 300 to ensure alignment with the welding surface of the main wire 100. The support plate 703 works in conjunction with the multi-directional drive structure, replacing the positioning function of the traditional bottom mold. This solution completely eliminates the reliance on complex bottom molds, significantly reduces mold costs, and significantly improves adaptability to different wire harness combinations.

[0115] Furthermore, connector 706 includes:

[0116] Fixed base 714: It is provided on the second driving member 705 and has a through hole 715 adapted to the shape of the clamping block 701. The through hole 715 extends in a direction parallel to the first welding surface 101, and the clamping block 701 is movably disposed in the through hole 715.

[0117] Drive block 716: It is movably disposed in the fixed base 714, and its moving direction is perpendicular to the moving direction of the clamping block 701, and is connected to the output end of the second drive member 705;

[0118] Rolling element 717: Rotatably mounted on drive block 716; clamping block 701 is provided with drive groove 718, which is inclined relative to the moving direction of drive block 716, and the rolling element 717 is rolled in drive groove 718 to drive clamping block 701 to move when drive block 716 moves.

[0119] Reference Figure 3 and Figure 6 When the second driving component 705 drives the driving block 716 along Figure 6 When the roller 717 moves from bottom to top, it rolls along the drive groove 718. Because the drive block 716 is confined within the fixed seat 714, it can only move in the vertical direction (i.e.,...). Figure 6 The clamping block 701 is constrained within the through hole 715 and can only move in the horizontal direction (i.e., vertical direction). Figure 6 The rolling motion of the rolling element 717 in the drive groove 718 converts the vertical motion of the drive block 716 into the horizontal motion of the clamping block 701.

[0120] In short, the rolling element 717, through its interaction with the tilting drive groove 718, pushes the clamping block 701 along... Figure 6 The middle moves from left to right, so that the fixing part 702 abuts against the first inclined surface 103 and the second inclined surface 104 on the same side of the main line 100, thereby realizing the clamping function.

[0121] Similarly, when the second driving component 705 drives the driving block 716 along... Figure 6When the middle moves from top to bottom, the rolling element 717 rolls in the opposite direction along the drive groove 718, thereby pushing the clamping block 701 along... Figure 6 Move from right to left to move the fixing part 702 away from the main line 100, thus completing the release action.

[0122] In one embodiment, the rolling element 717 includes a shaft fixed to the drive block 716 and two bearings mounted on the shaft, both bearings being located within the drive groove 718. Of course, when the thickness of the drive block 716 is small, only one bearing may be provided to meet the requirements of structural compactness.

[0123] By employing a connector 706 structure that includes a drive block 716, a rolling element 717, and an inclined drive groove 718, the vertical movement of the second drive element 705 can be efficiently converted into the horizontal movement of the clamping block 701, thereby achieving adaptive clamping of the main line 100.

[0124] This transmission mechanism is compact and responsive, avoiding the clamping loosening problem caused by insufficient rigidity of traditional pneumatic or hydraulic clamps. It is especially suitable for the stable fixation of large cross-section main line 100 in high-energy ultrasonic welding process, effectively preventing welding displacement or incomplete welding caused by clamping failure.

[0125] The drive groove 718 includes a main body segment 719 and a limiting segment 720 disposed at the end of the main body segment 719, with a smooth transition between the main body segment 719 and the limiting segment 720;

[0126] When the rolling element 717 rolls within the main body section 719, it drives the clamping block 701 to move closer to or further away from the main line 100.

[0127] When the rolling element 717 is in the limiting section 720, it is used to fix the clamping block 701, so that the fixing part 702 abuts against the first inclined surface 103 and the second inclined surface 104 on the same side of the main line 100, and the direction of the force applied by the rolling element 717 to the clamping block 701 is parallel to the normal of the first welding surface 101.

[0128] By setting the main line 100 segment and the limiting segment 720 in the drive groove 718, and by having the rolling element 717 apply a force parallel to the normal direction of the welding surface to the clamping block 701 within the limiting segment 720, it is ensured that the clamping block 701 always presses the inclined surface of the main line 100 in the optimal direction during the welding process.

[0129] This not only enhances clamping stability but also ensures that pressure is evenly distributed around the welding area, avoiding workpiece deformation or wear caused by localized stress concentration in traditional bottom molds, while further improving the consistency of welding quality.

[0130] The first welding mechanism 500 includes: a first support frame 502, which is disposed on a support platform 400; a sixth driving member 503, which is vertically disposed on the first support frame 502; a first connecting frame 504, which is disposed at the output end of the sixth driving member 503, and a first welding head 501 is connected to the first connecting frame 504; a first amplitude transformer 505, which is disposed on the first connecting frame 504 and connected to the first welding head 501; and a first transducer 506, which is disposed at the end of the first amplitude transformer 505 away from the first welding head 501.

[0131] The sixth driving component 503 is preferably a hydraulic cylinder (or a linear drive device such as a pneumatic-hydraulic booster cylinder). The first welding mechanism 500 adopts a modular design, integrating the sixth driving component 503, the first connecting frame 504, the first amplitude transformer 505, and the first transducer 506, which can realize the vertical and precise downward pressing of the welding head and the efficient transmission of high-frequency ultrasonic vibration.

[0132] This structure does not rely on the bottom mold to provide reaction force. Instead, it independently completes the welding of the upper branch line and the main line 100 through the upper welding head. This effectively solves the problem that the traditional "upper mold-lower mold" structure is unable to withstand the high load welding of large cross-section wire harnesses due to insufficient strength of the bottom mold. It is particularly suitable for reliable connection of high-energy, large cross-section wire harnesses.

[0133] The first connecting frame 504 includes: a base plate 507; a main body block 508 disposed on the base plate 507, the main body block 508 having a positioning recess 509 extending parallel to the vibration direction of the first welding head 501; a welding head connecting block 510 for connecting the first welding head 501, the welding head connecting block 510 having a positioning protrusion 511 adapted to the positioning recess 509; and a first limiting block 512 disposed on the main body block 508. The first limiting block 512 is positioned opposite to the positioning recess 509. One end of the first limiting block 512 is movably abutted against the welding head connecting block 510. When the positioning protrusion 511 is inserted into the positioning recess 509, the first limiting block 512 and the positioning recess 509 are respectively located on both sides of the welding head connecting block 510 along the vibration direction. The second limiting block 513 is positioned on the main body block 508. One end of the second limiting block 513 is movably abutted against one end of the welding head connecting block 510 along the vibration direction of the first welding head 501.

[0134] The base plate 507 is movably mounted on the first support frame 502. In one embodiment, to ensure the accuracy of the movement direction of the base plate 507, a slide rail and slider mechanism are provided between the first support frame 502 and the base plate 507.

[0135] The first connecting frame 504, through the insertion and engagement of the positioning recess 509 and the positioning protrusion 511, combined with the bidirectional constraint of the welding head connecting block 510 in the vibration direction by the first limiting block 512 and the second limiting block 513, effectively suppresses the lateral swaying or axial movement that may occur in the welding head during high-frequency vibration.

[0136] This structure significantly improves the installation accuracy and operational stability of the welding head, ensuring that ultrasonic energy is efficiently and directionally transmitted to the welding interface, overcoming the problems of energy loss and uneven welding caused by insufficient rigidity in traditional large-size welding heads.

[0137] The second welding mechanism 600 includes: a second support frame 602; a seventh drive member 603, which is vertically mounted on the second support frame 602; a second connecting frame 604, which is mounted on the output end of the seventh drive member 603, and the second welding head 601 is connected to the second connecting frame 604; a second amplitude transformer 605, which is mounted on the second connecting frame 604 and connected to the second welding head 601; and a second transducer 606, which is mounted on the end of the second amplitude transformer 605 away from the second welding head 601; wherein the output shafts of the sixth drive member 503 and the seventh drive member 603 are coaxially arranged.

[0138] The seventh drive component 603 is preferably a hydraulic cylinder (or a linear drive device such as a pneumatic-hydraulic booster cylinder). The second welding mechanism 600 and the first welding mechanism 500 are arranged symmetrically from top to bottom, and the output shafts of the sixth drive component 503 and the seventh drive component 603 are coaxial, ensuring that the upper and lower welding heads move synchronously, are accurately aligned, and are subjected to balanced forces during the welding process.

[0139] This design not only supports simultaneous or step-by-step welding of upper and lower branches, but also effectively avoids main line 100 twisting or welding misalignment caused by asynchronous movement of upper and lower mechanisms. It is particularly suitable for symmetrical cross-welding structures, significantly improving welding efficiency and yield.

[0140] The structure of the second connecting frame 604 is the same as that of the first connecting frame 504, and will not be described again here.

[0141] An eighth driving component 401 is erected on the support platform 400. The output end of the eighth driving component 401 is provided with a positioning pin 402. The support plate 703 is provided with a positioning hole 721. The eighth driving component 401 is used to drive the positioning pin 402 to be inserted into the positioning hole 721, and is used to fix and release the support plate 703.

[0142] The eighth driving component 401 is preferably a cylinder. The eighth driving component 401 drives the positioning pin 402 to insert into the positioning hole 721 on the support plate 703, thereby achieving rigid locking and rapid release of the support plate 703 during the welding process.

[0143] This structure ensures high rigidity of the clamping system while facilitating wire harness clamping and replacement. It solves the problems of cumbersome bottom mold replacement and poor positioning repeatability in traditional systems, improves equipment flexibility and production cycle time, and is suitable for multi-variety, small-batch wire harness welding scenarios.

[0144] In summary, this solution provides an ultrasonic welding device for scenarios where a large-section main line 100 is connected to multiple branches. By innovatively constructing a symmetrical welding surface and inclined structure on the main line 100, and combining a moldless multi-degree-of-freedom clamping system, an independently vibrating welding mechanism, and a precise and coordinated drive control strategy, it fundamentally breaks through the dependence of traditional ultrasonic welding technology on a dedicated mold.

[0145] This solution not only significantly reduces mold development and maintenance costs, but also greatly improves the adaptability to irregular and large-section wire harnesses. At the same time, by aligning the ultrasonic vibration direction with the branch extension direction, it achieves efficient directional energy transfer, effectively solving long-standing technical bottlenecks such as energy dispersion, uneven pressure, and positioning difficulties in the cross welding of large and small wire harnesses.

[0146] With its compact overall structure, flexible control, and reliable process, it combines high welding quality, high production efficiency, and strong versatility, making it particularly suitable for the large-scale manufacturing needs of high-reliability wire harness connections in fields such as new energy vehicles, rail transit, and power transmission.

[0147] It should be noted that in this utility model, the use of terms such as "first," "second," and "a" is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of those features. In the description of this utility model, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly defined. The terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two elements or the interaction between two elements, unless otherwise explicitly defined. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0148] Furthermore, the technical solutions of the various embodiments of this utility model can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0149] The specific embodiments described herein are merely illustrative examples illustrating the spirit of this utility model. Those skilled in the art to which this utility model pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of this utility model or exceeding the scope defined by the appended claims.

Claims

1. An ultrasonic welding device for welding a main line and a branch line, characterized in that: The main line includes at least partially parallel first welding surface and second welding surface, with first inclined surfaces symmetrically arranged on both sides of the first welding surface, and second inclined surfaces symmetrically arranged on both sides of the second welding surface; The welding apparatus includes: Support platform; A first welding mechanism and a second welding mechanism are respectively disposed at the upper and lower ends of the support platform. The first welding mechanism includes a first welding head, and the second welding mechanism includes a second welding head. The first welding head is used to weld a first branch line on the first welding surface, and the second welding head is used to weld a second branch line on the second welding surface. The vibration direction of the first welding head is parallel to the extension direction of the first branch line, and the vibration direction of the second welding head is parallel to the extension direction of the second branch line, so that the main line can be arranged to cross the first branch line and the second branch line. A fixing mechanism includes: two clamping blocks that can move closer to or further away from each other; each clamping block has a fixing part at its facing end; the fixing part is configured such that when the two clamping blocks move closer to each other, they can simultaneously form a mating contact with the first inclined surface and the second inclined surface on the same side of the main line; wherein... When the clamping blocks approach each other, the main line is fixed by the contact between the fixing part and the first inclined surface and the second inclined surface on the same side, while keeping the welding area of ​​the first welding surface and the second welding surface fully exposed.

2. The ultrasonic welding apparatus as described in claim 1, characterized in that, The angle between the main line and the first branch line is 30°±2°, and the angle between the main line and the second branch line is 30°±2°.

3. The ultrasonic welding apparatus as described in claim 1, characterized in that, The fixing mechanism includes: A support plate, which is movably disposed on the support platform, wherein one of the clamping blocks is fixed on the support plate; A first driving member is horizontally disposed on the support platform, and the support plate is connected to the output end of the first driving member. The first driving member is used to drive the support plate to move on the support platform. The second driving component is erected on the support platform; A connector is provided at the output end of the second drive member, and the other end of the connector is connected to another clamping block. It is used to convert the output power of the second drive member into the movement of the clamping block on the support plate, and the directions in which the two clamping blocks approach and move away from each other are perpendicular to the driving direction of the second drive member. The third driving component is erected on the support plate; A connecting block is disposed at the output end of the third driving element; A positioning block, disposed at one end of the connecting block, is used to limit the first branch or the second branch; The fourth driving member is horizontally disposed at the other end of the connecting block. Two first clamping blocks are disposed opposite each other at the output end of the fourth driving member. The fourth driving member is used to drive the two first clamping blocks to move closer or further apart from each other. The fifth driving component is provided on the support plate at least two of them, which are arranged horizontally. Each fifth driving component has two second clamping blocks at its output end. The fifth driving component is used to drive the two second clamping blocks to move closer or further apart.

4. The ultrasonic welding apparatus as described in claim 3, characterized in that, The connector includes: A fixing seat is provided on the second driving member. The fixing seat is provided with a through hole that matches the shape of the clamping block. The through hole extends in a direction parallel to the first welding surface. The clamping block is movably disposed in the through hole. A drive block is movably disposed within the fixed base in a direction perpendicular to the moving direction of the clamping block, and is connected to the output end of the second drive member; A rolling element is rotatably mounted on the driving block. The clamping block is provided with a driving groove, which is inclined relative to the moving direction of the driving block. The rolling element is rolled within the driving groove to drive the clamping block to move when the driving block moves.

5. The ultrasonic welding apparatus as described in claim 4, characterized in that, The drive groove includes a main body segment and a limiting segment disposed at the end of the main body segment, and the main body segment and the limiting segment have a smooth transition; When the rolling element rolls within the main body segment, it drives the clamping block to move closer to or further away from the main line. When the rolling element is in the limiting section, it is used to fix the clamping block, so that the fixing part abuts against the first inclined surface and the second inclined surface on the same side of the main line, and the direction of the force applied by the rolling element to the clamping block is parallel to the normal of the first welding surface.

6. The ultrasonic welding apparatus as described in claim 1, characterized in that, The first welding mechanism includes: A first support frame is mounted on the support platform; The sixth driving component is erected on the first support frame; A first connecting frame is disposed at the output end of the sixth driving member, and the first welding head is connected to the first connecting frame; The first amplitude rod is mounted on the first connecting frame and connected to the first welding head; The first transducer is located at the end of the first amplitude transformer that is away from the first welding head.

7. The ultrasonic welding apparatus as described in claim 6, characterized in that, The first connecting frame includes: Base plate; A main body block is disposed on the base plate, and a positioning recess is provided on the main body block, the positioning recess extending parallel to the vibration direction of the first welding head; A welding head connecting block is used to connect the first welding head. The welding head connecting block is provided with a positioning protrusion that is adapted to the positioning recess. A first limiting block is disposed on the main body block and is disposed opposite to the positioning recess. One end of the first limiting block is movably abutted against the welding head connecting block. When the positioning protrusion is inserted into the positioning recess, the first limiting block and the positioning recess are respectively located on both sides of the welding head connecting block along the vibration direction. The second limiting block is disposed on the main body block, and one end of the second limiting block moves against the end of the welding head connecting block along the vibration direction of the first welding head.

8. An ultrasonic welding apparatus as described in claim 6, characterized in that, The second welding mechanism includes: Second support frame; The seventh driving component is erected on the second support frame; The second connecting frame is disposed at the output end of the seventh driving member, and the second welding head is connected to the second connecting frame; The second amplitude rod is mounted on the second connecting frame and connected to the second welding head; A second transducer is disposed at the end of the second amplitude transformer away from the second welding head; wherein... The output shafts of the sixth and seventh driving components are coaxially arranged.

9. An ultrasonic welding apparatus as described in claim 3, characterized in that, An eighth driving component is erected on the support platform. The output end of the eighth driving component is provided with a positioning pin. The support plate is provided with a positioning hole. The eighth driving component is used to drive the positioning pin to be inserted into the positioning hole, which is used to fix and release the support plate.

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