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

Abstract

This utility model discloses a semi-automatic dual-triaxial induction welding machine for induction brazing, comprising a dual-output high-frequency power supply, a touch screen, a three-color alarm light, a fume extractor, a coaxial transformer, a three-axis motion module mechanism, a temperature measurement system, a filter, a nitrogen protection system, and an oxygen content detector. This utility model achieves "one machine, two drives" through the dual-output high-frequency power supply, significantly improving welding efficiency; the three-axis motion module mechanism ensures precise heating position adaptation to different product specifications; the fume extractor and filter improve the working environment and ensure stable equipment operation. This utility model can efficiently, stably, and environmentally friendly complete batch brazing operations in fields such as copper-copper and copper-stainless steel, and is particularly suitable for the welding needs of thin-walled products.

Description

Technical Field

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

[0002] With the rapid development of modern industry, especially in the welding of materials such as copper-copper and copper-stainless steel, the requirements for welding efficiency and quality are increasing. Induction brazing, as a highly efficient and precise welding method, has been widely used in industrial production. However, existing induction brazing equipment still has many shortcomings in practical applications. For example, when welding products with large thicknesses, the welding efficiency decreases significantly, making it difficult to meet the needs of high-efficiency production; while for thin-walled products with a wall thickness of less than 0.3 mm, the welding difficulty increases significantly, easily leading to unstable welding quality or even failure. In addition, traditional induction brazing equipment usually adopts a single-station design, and the loading and unloading process cannot be synchronized with the welding process, resulting in limited production efficiency and difficulty in adapting to the needs of large-scale batch production. At the same time, the positioning accuracy of existing equipment during the welding process is low, making it difficult to adapt to the welding requirements of different specifications of products, affecting the consistency and reliability of the welding. Furthermore, the fumes generated during the welding process pollute the working environment, and the lack of effective cooling measures for the heating components of the equipment further limits the continuous and stable operation capability of the equipment. Therefore, there is an urgent need for an induction brazing equipment that can improve welding efficiency, adapt to various product specifications, improve the working environment, and ensure stable operation of the equipment, so as to solve the above-mentioned technical problems and meet the high standards of modern industrial production. Utility Model Content

[0003] 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.

[0004] To achieve the above objectives, this utility model provides the following technical solution: A semi-automatic dual-triaxial induction welding machine for induction brazing includes a dual-output high-frequency power supply, a touch screen, a three-color alarm light, a fume extractor, a coaxial transformer, a three-axis motion module mechanism, a temperature measurement system, a filter, a nitrogen protection system, and an oxygen content detector. Among these: The dual-output high-frequency power supply adopts the FD-MT series digital dual-output induction heating power supply, featuring a "one machine, two drives" design, capable of simultaneously driving two independent coils. The dual-output high-frequency power supply utilizes a resonant circuit design to achieve a power efficiency of over 85%, and outputs a high-frequency current of 10-500kHz, with continuously adjustable frequency and power. Furthermore, 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 adjacent area between the two welding edges, achieving rapid localized heating.

[0005] The touchscreen integrates a control program for setting welding parameters such as heating power and conveying speed, and displays heating temperature and other operating parameters in real time. Furthermore, the three-color alarm light uses different colors to indicate the equipment status: red for fault, yellow for standby, and green for normal operation, facilitating timely response from operators.

[0006] The exhaust fan is connected to the inside of the equipment via pipelines to remove fumes generated during brazing, thus improving the working environment. Specifically, the filter provides circulating purified water to cool and de-heat heat-generating components such as the dual-output high-frequency power supply, coaxial transformer, and welding inductor, ensuring stable equipment operation.

[0007] Furthermore, the three-axis motion module mechanism includes an X-axis module, a Y-axis module, and a Z-axis module. The X-axis module is mounted on the frame and moves horizontally; the Y-axis module is mounted on the output end of the X-axis module and moves perpendicular to the X-axis; the Z-axis module is mounted on the output end of the Y-axis module and moves vertically. Specifically, the output end of the Z-axis module is equipped with a coaxial transformer fixing platform for fixing the coaxial transformer and achieving multi-degree-of-freedom position adjustment through the coordinated movement of the three-axis modules. The three-axis motion module mechanism adjusts the position of the welding inductor according to the product welding position on the welding worktable, ensuring that the heating position accurately adapts to the heating requirements of products of different specifications.

[0008] Furthermore, the coaxial transformer works in conjunction with the welding inductor to convert high-frequency current into an energy form suitable for induction heating. The temperature measurement system monitors the temperature during the welding process to ensure consistent welding quality. Specifically, the nitrogen protection system controls the nitrogen flow rate via a nitrogen flow meter, providing a protective gas environment to prevent oxidation during welding. The oxygen content detector is positioned above the dual-output high-frequency power supply to monitor the oxygen content inside the equipment, ensuring safe operation.

[0009] The operating procedure of the equipment of this utility model is as follows: S1 Equipment Debugging: Secure the compatible product in the tooling fixture, and then fix the tooling fixture on the welding worktable. Set the welding parameters via the touchscreen, start the fume extractor to test the fume extraction effect, and calibrate the status feedback function of the three-color alarm light.

[0010] S2 Induction Brazing Operation: The dual-output high-frequency power supply starts, outputting high-frequency current. This current, transmitted through a coaxial transformer and welding inductor, performs induction heating and brazing on the product. A three-axis motion module adjusts the height of the welding inductor according to preset parameters to ensure effective heating. A fume extractor operates synchronously to remove brazing fumes. A touchscreen displays real-time heating temperature and other parameters, while a three-color alarm light provides feedback on the equipment's operating status.

[0011] S3 Material Unloading and Finishing: After brazing is completed, manual unloading and loading are carried out, while welding work is carried out at another station, and so on in a cycle.

[0012] The key technological innovations of this utility model and their specific implementation methods are as follows: First, the dual-triaxial induction welding technology. The welding machine adopts the FD-MT series digital dual-output induction heating power supply, which simultaneously drives two independent coils through a "one machine, two drives" design, significantly improving production capacity and reducing equipment investment and space occupation. In particular, the dual-output high-frequency power supply improves power efficiency to over 85% through resonant circuit design, reducing energy loss.

[0013] Second, high-efficiency induction heating technology. The high-frequency generator, coaxial transformer, and welding inductor work together, combined with the position adjustment of the three-axis motion module mechanism, to quickly and evenly heat the welded products. The three-axis motion module mechanism achieves precise positioning of the welding inductor in the X, Y, and Z directions through the coordinated movement of the X-axis module, Y-axis module, and Z-axis module, ensuring that the heating position is accurately adapted to the heating requirements of products of different specifications.

[0014] Third, environmentally friendly and durable design. The fume extractor is connected to the internal components of the equipment via pipelines to promptly remove fumes generated during brazing, improving the working environment. The filter provides circulating purified water for cooling the dual-output high-frequency power supply, coaxial transformer, and welding inductor, ensuring stable equipment operation. Specifically, the nitrogen protection system controls nitrogen flow through a nitrogen flow meter, providing a protective gas environment to prevent oxidation during welding. The oxygen content detector is located above the dual-output high-frequency power supply to monitor the internal oxygen content of the equipment, ensuring safe operation.

[0015] Compared with the prior art, the beneficial effects of this utility model are as follows: By employing dual triaxial induction welding technology, a "one machine, two drives" design is achieved, significantly increasing production capacity while reducing equipment investment and space occupation. Through efficient induction heating technology, combined with the position adjustment of the three-axis motion module mechanism, products are heated and welded rapidly and uniformly, shortening the brazing cycle and adapting to mass production needs. Through environmentally friendly and durable design, the exhaust fan effectively removes brazing fumes, and the filter provides cooling water, ensuring stable equipment operation. In summary, this invention achieves efficient, stable, and environmentally friendly induction brazing operations, suitable for mass production needs in fields such as copper-copper and copper-stainless steel.

[0016] 1. Dual Triaxial Induction Welding: The equipment adopts the FD-MT series digital dual-output induction heating power supply, with a revolutionary "one machine, dual drive" design at its core, achieving double the efficiency and direct cost reduction! Its unique dual-output architecture can drive two independent coils simultaneously, significantly improving production capacity and saving equipment investment and space. The other two welding positions can perform high-frequency welding while loading and unloading materials, greatly improving production efficiency. Furthermore, the equipment has a large worktable with pre-drilled threaded holes and positioning pin holes for tooling fixtures, accommodating various product specifications and ensuring high positioning accuracy, guaranteeing accurate brazing and improving the consistency of brazing quality.

[0017] 2. High-efficiency induction heating: The high-frequency machine, coaxial transformer, and welding inductor work together, combined with the position adjustment of the three-axis motion module mechanism, to quickly and evenly induction heat the welded products, significantly improving heating efficiency and shortening the brazing cycle, making it suitable for mass production.

[0018] 3. Environmental protection and durability: The exhaust fan effectively removes brazing fumes and dust, improving the working environment; the filter provides circulating pure water to the dual-output high-frequency power supply, coaxial transformer, welding inductor and other heat-generating components for cooling, so as to ensure that induction brazing can operate normally, stably and continuously. Attached Figure Description

[0019] Figure 1 This is one of the frontal perspective views of this utility model; Figure 2 This is one of the perspective views of the rear view of this utility model; Figure 3 This is one of the three-dimensional perspectives of the dual three-axis module mechanism of this utility model; Reference numerals in the attached diagram: 1. Dual-output high-frequency power supply; 2. Touch screen; 3. Three-color alarm light; 4. Smoke exhaust fan; 5. Coaxial transformer; 6. Three-axis module; 7. Temperature measurement system; 8. Filter; 9. Nitrogen flow meter; 10. Oxygen content detector; 11. X-axis module of the three-axis module; 12. Y-axis module of the three-axis module; 13. Z-axis module of the three-axis module; 14. Sensor; 15. Coaxial transformer mounting platform. Detailed Implementation

[0020] The present invention will now be described in detail with reference to the embodiments shown in the accompanying drawings: like Figure 1-3 As shown in the figure, this embodiment provides a semi-automatic dual-triaxial induction welding machine for induction brazing, the structure and function of which are illustrated in the attached figure. Figure 1 To be continued Figure 3A detailed description is provided. The equipment includes a frame and several core components mounted on it, such as a dual-output high-frequency power supply 1, a touchscreen 2, a three-color alarm light 3, a smoke exhaust fan 4, a coaxial transformer 5, a triaxial module 6, a temperature measurement system 7, a filter 8, a nitrogen flow meter 9, and an oxygen content detector 10. These components work together to achieve efficient, stable, and environmentally friendly induction brazing operations.

[0021] S1 Equipment Overall Architecture and Component Location Relationships The frame serves as the basic support structure for the equipment, housing a dual-output high-frequency power supply 1. Above it are a pair of oxygen content detectors 10, used to monitor the internal oxygen content in real time to ensure safe operation. A nitrogen flow meter 9 is installed on one side of the frame to control nitrogen flow and provide a protective gas environment to prevent oxidation during welding. Simultaneously, a pair of three-axis modules 6 are installed inside the frame, each driving one of the two independent welding stations. The three-axis modules 6 include an X-axis module 11, a Y-axis module 12, and a Z-axis module 13. The X-axis module 11 is mounted on the frame and moves horizontally; the Y-axis module 12 is mounted at the output end of the X-axis module 11 and moves perpendicular to the X-axis; the Z-axis module 13 is mounted at the output end of the Y-axis module 12 and moves vertically. A coaxial transformer fixing platform 15 is installed at the output end of the Z-axis module 13 to fix the coaxial transformer 5 and to achieve multi-degree-of-freedom position adjustment through the coordinated movement of the three-axis modules. A temperature measurement system 7 is also mounted on the coaxial transformer mounting platform 15 to monitor temperature changes in real time during the welding process. In addition, a three-color alarm light 3 and a fume extractor 4 are arranged on the top of the frame to provide feedback on equipment status and to remove fumes generated during brazing, respectively. A touchscreen 2 is located on one side of the frame for operation control and parameter setting, while a filter 8 is located near the bottom of the frame to provide circulating purified water for cooling the dual-output high-frequency power supply 1, coaxial transformer 5, and welding inductor 14, among other heat-generating components.

[0022] S2 Dual-Output High-Frequency Power Supply and Induction Heating System The dual-output high-frequency power supply 1 adopts the FD-MT series digital dual-output induction heating power supply, featuring a "one machine, two drives" design, capable of simultaneously driving two independent coils. This power supply utilizes a resonant circuit design to achieve an efficiency of over 85%, outputting a high-frequency current of 10-500kHz, with continuously adjustable frequency and power. The high-frequency current leverages the skin effect and proximity effect, concentrating the current on the workpiece surface and creating the highest current density in the adjacent areas of the two welding edges, thus achieving rapid localized heating. After conversion by the coaxial transformer 5, the high-frequency current is used by the welding inductor 14 to perform induction brazing on the products on the welding worktable. The coaxial transformer 5 is fixed on the coaxial transformer fixing platform 15, and its position is adjusted by the XYZ movement of the three-axis module 6 to adapt to the heating requirements of different product specifications. The welding inductor 14 achieves precise positioning based on the adjustment of the three-axis module 6, ensuring accurate heating. The temperature measurement system 7 monitors temperature changes in real time during the welding process and feeds the data back to the touchscreen 2, facilitating operator adjustments to welding parameters.

[0023] Working principle and adjustment method of S3 three-axis motion module mechanism The three-axis motion module 6 is the core moving component of the equipment, responsible for adjusting the position of the welding inductor 14. The X-axis module 11 moves horizontally, the Y-axis module 12 moves perpendicular to the X-axis, and the Z-axis module 13 moves vertically. Through the coordinated movement in these three directions, the welding inductor 14 can achieve precise positioning in three-dimensional space. For example, when welding copper-copper or copper-stainless steel products, the operator can input the product dimensions and welding position parameters through the touch screen 2. The three-axis module 6 automatically adjusts the height and angle of the welding inductor 14 according to the preset parameters, ensuring that the energy of induction heating is concentrated in the welding area. This multi-degree-of-freedom adjustment method not only improves welding efficiency but also significantly enhances the consistency of welding quality. In addition, the output end of the three-axis module 6 is equipped with a coaxial transformer fixing platform 15, which is used to fix the coaxial transformer 5 and achieve multi-degree-of-freedom position adjustment through the coordinated movement of the three-axis module.

[0024] Operating mechanism of S4 exhaust and cooling system The fume extractor 4 is connected to the internal components of the equipment via pipelines to promptly remove fumes generated during brazing, improving the working environment. The fume extractor 4 starts operating synchronously with the welding process. When the welding inductor 14 begins heating, the fume extractor 4 immediately removes the generated fumes, ensuring a clean and pollution-free welding area. The filter 8 provides circulating purified water for cooling the dual-output high-frequency power supply 1, coaxial transformer 5, and welding inductor 14, among other heat-generating components. The cooling water circulates through pipelines, absorbing heat generated by the heat-generating components before entering the filter 8 for purification, and then returning to the heat-generating components to complete the cooling cycle. This cooling method ensures stable performance of the equipment during long-term operation, preventing malfunctions or damage caused by overheating.

[0025] Functional Implementation of S5 Control and Monitoring System The touchscreen 2 integrates a control program for setting welding parameters such as heating power and conveyor speed, and displays the heating temperature and other operating parameters in real time. After the operator inputs the specifications and welding requirements of the product to be welded via the touchscreen 2, the equipment automatically adjusts the position of the three-axis module 6 and the output power of the dual-output high-frequency power supply 1 to meet the welding needs. The three-color alarm light 3 uses different colors to indicate the equipment status: red for fault, yellow for standby, and green for normal operation, facilitating timely operator response. For example, when an abnormality occurs during equipment operation, the three-color alarm light 3 immediately switches to red, and the touchscreen 2 displays specific fault information, reminding the operator to inspect and repair it.

[0026] The function of the S6 nitrogen protection system and oxygen content detector The nitrogen protection system controls the nitrogen flow rate via nitrogen flow meter 9, providing a protective gas environment for the welding area and preventing oxidation during welding. Nitrogen flow meter 9 can adjust the nitrogen flow rate according to the material and thickness of the welded product, ensuring that the protective gas covers the entire welding area. An oxygen content detector 10 is positioned above the dual-output high-frequency power supply 1 to monitor the oxygen content inside the equipment in real time. When the oxygen content exceeds a set threshold, the oxygen content detector 10 issues an alarm signal, reminding the operator to check the operating status of the nitrogen protection system to ensure the safety and stability of the welding process.

[0027] S7 Equipment Operation Process and Practical Application Scenarios During the equipment debugging phase, operators fix the compatible product in the tooling fixture and then fix the tooling fixture on the welding workbench. Welding parameters, such as the output power of the dual-output high-frequency power supply 1 and the position of the three-axis module 6, are set via the touchscreen 2 to match the specifications of the product to be welded. The exhaust fan 4 is started to test the fume extraction effect and calibrate the status feedback function of the three-color alarm light 3. During the induction brazing operation phase, the dual-output high-frequency power supply 1 is started, outputting high-frequency current, which is used for induction heating brazing of the product via the coaxial transformer 5 and the welding inductor 14. The three-axis module 6 adjusts the height and angle of the welding inductor 14 according to preset parameters to ensure heating effect. The exhaust fan 4 operates synchronously to remove brazing fumes. The touchscreen 2 displays parameters such as heating temperature in real time, and the three-color alarm light 3 provides feedback on the equipment's operating status. In the unloading and finishing phase, after brazing is completed, manual unloading and loading are performed, while another workstation performs welding work, and this cycle repeats. For example, in practical applications of copper-copper welding, the equipment significantly improves welding efficiency through dual triaxial induction welding technology, while shortening the brazing cycle through efficient induction heating technology, thus meeting the needs of mass production.

[0028] In summary, this utility model achieves efficient, stable, and environmentally friendly induction brazing operations through dual triaxial induction welding technology, high-efficiency induction heating technology, and environmentally friendly and durable design, and is suitable for mass production needs in fields such as copper-copper and copper-stainless steel.

[0029] 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, characterized in that: The system includes a dual-output high-frequency power supply (1), a touch screen (2), a three-color alarm light (3), a smoke exhaust fan (4), a coaxial transformer (5), a three-axis module (6), a temperature measurement system (7), a filter (8), a nitrogen flow meter (9), and an oxygen content detector (10), among which: The dual-output high-frequency power supply (1) adopts the FD-MT series digital dual-output induction heating power supply, which has a dual-drive design and can drive two independent coils to work simultaneously; the touch screen (2) integrates the control program, which is used to set welding parameters and display operating parameters in real time; the three-color alarm light (3) provides feedback on the equipment status through different colored lights; the exhaust fan (4) is connected to the inside of the equipment through pipelines to exhaust the fumes generated during the brazing process; the coaxial transformer (5) works in conjunction with the welding inductor to convert the high-frequency current into an energy form suitable for induction heating; the three-axis module (6) includes three axes The X-axis module (11), the Y-axis module (12), and the Z-axis module (13) of the three-axis module are used to adjust the position of the welding inductor; the temperature measurement system (7) monitors the temperature during the welding process; the filter (8) provides circulating pure water for cooling the dual-output high-frequency power supply (1), the coaxial transformer (5), and the welding inductor; the nitrogen flow meter (9) controls the nitrogen flow and provides a protective gas environment to prevent oxidation during the welding process; the oxygen content detector (10) is arranged above the dual-output high-frequency power supply (1) to monitor the oxygen content inside the equipment.

2. The semi-automatic dual-three-axis induction welding machine as described in claim 1, characterized in that: The dual-output high-frequency power supply (1) improves the power efficiency to over 85% through resonant circuit design and outputs high-frequency current of 10-500kHz, with frequency and power continuously adjustable.

3. The semi-automatic dual-three-axis induction welding machine as described in claim 2, characterized in that: High-frequency current utilizes the skin effect and proximity effect to concentrate the current on the surface of the workpiece and form the highest current density in the area adjacent to the two welding edges.

4. The semi-automatic dual-three-axis induction welding machine as described in claim 1, characterized in that: The output end of the Z-axis module (13) of the three-axis module (6) is provided with a coaxial transformer fixing platform (15) for fixing the coaxial transformer (5) and realizing multi-degree-of-freedom position adjustment through the cooperation of the three-axis module (6).

5. The semi-automatic dual-three-axis induction welding machine as described in claim 1, characterized in that: The exhaust fan (4) is connected to the inside of the equipment through a pipeline to promptly remove the smoke and dust generated during the brazing process. The filter (8) provides circulating pure water for cooling the dual-output high-frequency power supply (1), coaxial transformer (5), and welding inductor.

6. The semi-automatic dual-three-axis induction welding machine as described in claim 1, characterized in that: The nitrogen flow meter (9) controls the nitrogen flow rate and provides a protective gas environment to prevent oxidation during welding. The oxygen content detector (10) is arranged above the dual-output high-frequency power supply (1) to monitor the oxygen content inside the equipment.

7. The semi-automatic dual-three-axis induction welding machine as described in claim 1, characterized in that: The three-color alarm light (3) uses different colored lights to reflect the status of the equipment. Red indicates a fault, yellow indicates standby, and green indicates normal operation.

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