A semi-automatic dual-triaxial induction welding machine for induction brazing

Abstract

This utility model discloses a semi-automatic dual-three-axis induction welding machine for induction brazing, comprising a base, a high-frequency motor, three-axis linear modules, sensors, a suspended control cabinet, and a safety light curtain. The high-frequency motor is built into the base, and a pair of three-axis linear modules are arranged mirror-on above it. Sensors are fixed at the output ends of the modules, and precise control of lifting, forward / backward lateral movement, and left / right lateral movement is achieved through servo motors. The high-frequency motor adopts IGBT high-frequency inverter technology, with an output frequency of 10-500kHz and an efficiency of over 85%. Combined with the induction coil design, it ensures that heat is concentrated in the weld area. The dual-station layout is suitable for both automated and manual operation, improving work efficiency. The safety light curtain detects the worker's hand position to ensure operational safety. This application can achieve high-precision control of welding temperature and position, is energy-efficient, environmentally friendly, and suitable for high-silver brazing processes of materials such as copper to copper and copper to stainless steel.

Description

Technical Field

[0001] This utility model relates to the technical field of induction brazing technology, and in particular to a semi-automatic dual-triaxial induction welding machine for induction brazing. Background Technology

[0002] Induction heating technology, due to its rapid heating speed, precise temperature control, and high heating uniformity, has been widely and maturely applied in the brazing field, especially suitable for localized welding of small, precision products. This technology can effectively weld joints while avoiding alteration of the base material's metallic properties, thus ensuring weld quality. Induction brazing allows for precise temperature control by adjusting the power supply output current and heating time, and this precision can be further enhanced by combining infrared temperature feedback. Compared to traditional flame brazing, induction brazing not only offers higher weld quality and yield but also significantly better energy conversion efficiency. The energy conversion rate of induction brazing can reach over 85%, while that of flame brazing is only around 5%, thus saving at least one-third of the energy. Furthermore, induction brazing does not produce polluting gases during the heating process, making it more environmentally friendly. It also avoids the problem of large amounts of heat dissipating into the surrounding air, as seen in flame brazing, thereby improving the working environment for workers and reducing the risk of overheating in the work area.

[0003] However, despite the numerous advantages of induction brazing technology, existing equipment still has some shortcomings in practical applications. For example, traditional induction brazing equipment often struggles to balance the needs of automated production and manual operation, resulting in low equipment utilization and impacting overall work efficiency. Furthermore, existing equipment still has room for improvement in induction coil design and high-frequency power supply technology, particularly in achieving more precise energy input and control of a smaller heating area. To further improve the efficiency and precision of induction brazing, it is necessary to develop an induction welding device capable of three-axis motion control to meet the welding requirements of different workpiece thicknesses and shapes. Simultaneously, by introducing servo motor drives and high-frequency inverter technology, the stability and controllability of the heating process can be further optimized, thereby achieving rapid, localized, and precise heating effects. To address these issues, this invention aims to provide a semi-automatic dual-three-axis induction welding machine to overcome the shortcomings of existing technologies in terms of energy consumption, efficiency, and operational flexibility, while simultaneously improving welding quality and production efficiency. Utility Model Content

[0004] The purpose of this invention is to provide a semi-automatic dual-triaxial induction welding machine for induction brazing, so as to overcome the shortcomings of the existing technology.

[0005] To achieve the above objectives, this utility model provides the following technical solution: A semi-automatic dual-three-axis induction welding machine for induction brazing. This welding machine achieves precise control and efficient operation of the welding process by combining high-precision servo control technology and high-frequency power supply technology.

[0006] The welding machine includes a base, a high-frequency generator, a three-axis linear module, sensors, a suspended control cabinet, and a safety light curtain. The base serves as the basic frame of the equipment, housing the high-frequency generator to provide high-frequency current. The three-axis linear modules are arranged mirror-on-top of the base; each module includes lifting, forward / backward lateral movement, and left / right lateral movement functions, with sensors fixed at its output end. The sensors heat the welding position through the eddy current effect. The suspended control cabinet integrates the control system, uniformly managing the start and stop operations of the three-axis linear modules, the high-frequency generator, and the sensors. The safety light curtain is positioned at the manual welding station to detect the worker's hand position and ensure operational safety.

[0007] Furthermore, this invention employs a three-axis linear module speed control technology, using a servo motor as the power source and a PLC or motion controller to achieve precise control of the three-axis linear module. The three-axis linear module includes three degrees of freedom: lifting, forward / backward lateral movement, and left / right lateral movement, allowing for flexible adjustment of the sensor position to ensure precise positioning of the welding position. The speed stability error is ≤±1%, ensuring the smoothness and consistency of movement during welding, thereby improving welding quality.

[0008] Specifically, this invention employs high-frequency power supply technology, using an IGBT high-frequency inverter as the core component. The output frequency range is 10-500kHz, and both frequency and power are continuously adjustable to meet various welding requirements. Through resonant circuit design, the power supply efficiency is increased to over 85%, significantly reducing energy loss and saving at least one-third energy compared to traditional flame brazing. Utilizing the skin effect and proximity effect of high-frequency current, the current is concentrated on the workpiece surface, forming the highest current density in the weld interface area, achieving "localized rapid heating" and avoiding changes in the properties of the base metal.

[0009] Furthermore, this invention optimizes the geometry and arrangement of the induction coil to constrain the range of the high-frequency magnetic field, ensuring that heat is concentrated only in the weld interface area and preventing heat from diffusing to non-welded areas. The distance between the induction coil and the workpiece can be finely adjusted by a servo mechanism to adapt to workpieces of different thicknesses, further improving heating accuracy.

[0010] In particular, this utility model adopts a dual-station layout design. One three-axis linear module is used in conjunction with an automated production line or robotic arm for automated welding, suitable for large-scale production; the other three-axis linear module faces the opposite direction and is used for manual operation, meeting the welding needs of small batches or special workpieces. The dual-station layout realizes human-machine collaborative operation, avoids equipment idle time, and significantly improves overall work efficiency.

[0011] Furthermore, the safety protection measures of this utility model include safety light curtain protection and a suspended control cabinet design. The safety light curtain is installed at the manual welding station and uses infrared light to detect whether the worker's hand has entered the machine, preventing safety accidents caused by misoperation. The suspended control cabinet integrates the control system, facilitating user operation and maintenance, and at the same time, improving the overall safety of the equipment by centrally managing the start and stop operations of various components.

[0012] Compared with the prior art, the beneficial effects of this utility model are as follows: The precise positioning of the three-axis linear module and the accurate control of the high-frequency power supply enable high-precision control of welding temperature and position. The energy conversion rate of the high-frequency power supply is over 85%, saving at least one-third of the energy compared to flame brazing. No polluting gases are generated during the welding process, avoiding adverse effects on the atmosphere and working environment. The dual-station layout accommodates both automated and manual operation needs, adapting to different production scenarios. The design of the safety light curtain and the suspended control cabinet effectively ensures the safety of operators.

[0013] The application areas of this utility model are mainly concentrated in the field of induction brazing, and it is particularly suitable for local welding of small and delicate products, such as the high silver brazing process of copper to copper, copper to stainless steel and other materials. It is widely used in the electronics, aerospace and automobile manufacturing industries.

[0014] In summary, this invention provides a highly efficient, precise, energy-saving, and safe induction brazing solution through innovative three-axis linear module speed regulation technology, high-frequency power supply technology, and heating zone control technology, combined with a dual-station layout and safety protection measures. The structural design and functional implementation of the welding machine have been thoroughly optimized to ensure excellent performance and technical advantages in practical applications. Attached Figure Description

[0015] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a structural schematic diagram of the sheet metal parts of this utility model, ignoring the latter. Figure 3 This is another structural schematic diagram of the sheet metal parts of this utility model, ignoring certain components.

[0016] Attached image annotations: 1. Suspended control cabinet; 2. Safety light curtain; 3. Three-axis linear module; 4. Sensor; 5. High-frequency machine; 6. Base. Detailed Implementation

[0017] To make the above-mentioned objects, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a full understanding of this utility model. However, this utility model can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed below.

[0018] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly attached to the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. When the number of elements is referred to as "multiple," it can be any number of two or more. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0020] The present invention will now be described in detail with reference to the embodiments shown in the accompanying drawings: A semi-automatic dual-triaxial induction welding machine for induction brazing, combined with Figures 1 to 3 As shown, the equipment mainly consists of a suspended control cabinet 1, a safety light curtain 2, a three-axis linear module 3, a sensor 4, a high-frequency machine 5, and a base 6. The welding machine has a compact and reasonable overall structural design, enabling efficient and precise welding operations. It is suitable for high-silver brazing processes of materials such as copper to copper and copper to stainless steel.

[0021] The welding machine base 6 serves as the basic frame of the equipment, housing a pair of high-frequency inverters 5 to provide high-frequency current to the inductor 4. The high-frequency inverters 5 employ IGBT high-frequency inverter technology, with an output frequency range of 10-500kHz, and continuously adjustable frequency and power to meet various welding requirements. The high-frequency power supply utilizes a resonant circuit design to achieve an efficiency of over 85%, significantly reducing energy loss. The high-frequency current leverages the skin effect and proximity effect to concentrate the current on the workpiece surface, forming the highest current density in the weld interface region, thereby achieving rapid localized heating. This design avoids altering the properties of the base metal while ensuring that heat is concentrated only in the weld interface region, preventing diffusion to non-welded areas.

[0022] A pair of three-axis linear modules 3 are mirror-arranged above the base 6. Each module includes three degrees of freedom: lifting, forward / backward lateral movement, and left / right lateral movement. A sensor 4 is fixed to the output end of each three-axis linear module 3. The sensor 4 heats the welding position through the eddy current effect. The three-axis linear module 3 uses a servo motor as its power source and achieves precise motion control via a PLC or motion controller, with a speed stability error ≤ ±1%, ensuring smooth and consistent motion during welding. The design of the three-axis linear module 3 allows the sensor 4 to flexibly adjust its position in three degrees of freedom, ensuring precise positioning of the welding position and adapting to the welding needs of workpieces of different shapes and sizes.

[0023] The welding machine adopts a dual-station layout design. One three-axis linear module 3, used in conjunction with an automated production line or robotic arm, performs automated welding, suitable for large-scale production. The other three-axis linear module 3, facing the opposite direction, is for manual operation, meeting the welding needs of small batches or special workpieces. This dual-station layout enables human-machine collaborative work, avoids equipment idle time, and significantly improves overall work efficiency. For example, in practical applications, while the automated welding station is performing large-scale welding, workers can simultaneously complete the welding of a small number of special workpieces at the manual welding station, thereby maximizing production efficiency.

[0024] To further enhance the safety of the welding process, a pair of safety light curtains 2 are installed at the manual welding station of the welding machine. These light curtains 2 use infrared detection to check if a worker's hand has entered the machine, preventing accidents caused by misoperation. If a worker's hand is detected entering a dangerous area, the safety light curtains 2 will immediately trigger an emergency stop procedure to protect the operator's safety. In addition, the welding machine is equipped with a suspended control cabinet 1, which integrates the control system to uniformly manage the start and stop operations of the three-axis linear module 3, the high-frequency generator 5, and the sensors 4. The suspended control cabinet 1 is designed for ease of operation and maintenance, while also improving the overall safety of the equipment by centrally managing the start and stop operations of each component.

[0025] The welding machine operates as follows: S1 First, the high-frequency generator 5 is started via the suspended control cabinet 1, and the high-frequency generator 5 outputs high-frequency current to the inductor 4. S2 After the inductor 4 is powered on, it generates a high-frequency magnetic field, which uses the eddy current effect to locally heat the welding position. S3 The three-axis linear module 3 precisely adjusts the position of the inductor 4 according to the preset program or manual instructions to ensure accurate welding position. S4 During the welding process, the high-frequency power supply monitors the changes in current and frequency in real time and dynamically adjusts the output parameters according to actual needs to ensure precise control of welding temperature. S5 If it is an automated welding station, the workpiece is transported and positioned by a robot or automated production line; if it is a manual welding station, the workpiece is positioned and welded by a worker. S6 After welding is completed, the high-frequency generator 5 stops outputting current, and the three-axis linear module 3 resets, ready for the next welding task.

[0026] Specific applications of welding machines include the localized welding of small, precision products made of materials such as copper to copper or copper to stainless steel in industries such as electronics, aerospace, and automotive manufacturing. For example, in the electronics industry, welding machines can be used to weld the connection points of small electronic components, ensuring welding quality without altering the metallic properties of the base material; in the aerospace field, welding machines can be used to weld precision parts, meeting the requirements of high strength and high reliability; and in automotive manufacturing, welding machines can be used to weld engine parts, ensuring the strength and durability of the welded area.

[0027] The welding machine's induction coil design has been optimized to constrain the range of the high-frequency magnetic field, ensuring that heat is concentrated only in the weld interface area. The distance between the induction coil and the workpiece can be finely adjusted via a servo mechanism to adapt to workpieces of different thicknesses, further improving heating accuracy. For example, when welding thicker workpieces, the distance between the induction coil and the workpiece can be appropriately increased to avoid overheating; while when welding thinner workpieces, the distance can be decreased to ensure sufficient heat input. This flexible adjustment method allows the welding machine to adapt to the needs of various workpiece thicknesses, improving the applicability and flexibility of welding.

[0028] The welding machine boasts an energy conversion rate exceeding 85%, saving at least one-third more energy compared to traditional flame brazing. No polluting gases are generated during the welding process, avoiding adverse effects on the atmosphere and the working environment. Furthermore, the welding machine's dual-station layout accommodates both automated and manual operation needs, adapting to different production scenarios. For example, on large-scale production lines, automated welding stations can efficiently complete large-volume welding tasks; while in R&D or maintenance scenarios, manual welding stations can meet the welding needs of small batches or special workpieces.

[0029] In summary, this invention provides a highly efficient, precise, energy-saving, and safe induction brazing solution through innovative three-axis linear module speed regulation technology, high-frequency power supply technology, and heating zone control technology, combined with a dual-station layout and safety protection measures. The welding machine's structural design and functional implementation have been thoroughly optimized to ensure excellent performance and technical advantages in practical applications.

[0030] The technical features of the above embodiments can be combined arbitrarily. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as the combination of these technical features does not contradict each other, it should be considered within the scope of this specification. For those skilled in the art, several modifications and improvements can be made without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A semi-automatic dual-triaxial induction welding machine for induction brazing, comprising a base (6), a high-frequency generator (5), a three-axis linear module (3), an inductor (4), a suspended control cabinet (1), and a safety light curtain (2), characterized in that: The base (6) serves as the basic frame of the equipment, and the high-frequency machine (5) is placed inside. The three-axis linear module (3) is arranged in a mirror above the base (6). Each module includes lifting, forward and backward lateral movement and left and right lateral movement functions, and the output end is fixed with a sensor (4). The suspended control cabinet (1) integrates the control system and manages the start and stop operations of the three-axis linear module (3), the high-frequency machine (5) and the sensor (4) in a unified manner. The safety light curtain (2) is arranged at the manual welding station to detect the position of the worker's hand.

2. The semi-automatic dual-triaxial induction welding machine according to claim 1, characterized in that: The three-axis linear module (3) uses a servo motor as the power source and achieves precise control of the three degrees of freedom of lifting, forward and backward movement and left and right movement through a PLC or motion controller.

3. The semi-automatic dual-triaxial induction welding machine according to claim 2, characterized in that: The output of the three-axis linear module (3) is adjusted by a servo mechanism to fine-tune the distance between the sensor (4) and the workpiece, thus adapting to workpieces of different thicknesses.

4. The semi-automatic dual-triaxial induction welding machine according to claim 1, characterized in that: The high-frequency machine (5) adopts IGBT high-frequency inverter technology, and its frequency and power are continuously adjustable.

5. The semi-automatic dual-triaxial induction welding machine according to claim 1, characterized in that: The welding machine adopts a dual-station layout design. One of the three-axis linear modules (3) is used in conjunction with an automatic production line or robot for automated welding, while the other three-axis linear module (3) faces the opposite direction for manual operation.

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