漆包线电阻热压焊电极位移控制系统

Electrode Displacement Control System for Enameled Wire Resistance Hot Pressure Bonding

多股漆包线与端子电阻热压焊过程中,随着焊接次数增加或焊接节拍变化,在电极上产生的热积累不同,传统的恒流控制方法难以保证接头加热的一致性。研制了一种电阻热压焊电极位移控制系统,在焊接过程中,利用光栅式位移传感器对电极位移进行实时检测,并建立模糊PID控制器实时调控焊接电流,使实际位移曲线跟踪目标位移曲线,通过控制接头热变形的方法控制接头加热的一致性。试验结果表明,与恒流控制方法相比,该方法可以实现对端子热输入的有效控制,焊接过程热输入稳定,在特定端子50次焊接试验中,焊后端子厚度误差减小了84.97%,接头的一致性有明显改善。而得益于一致性的提高,其良品率提高了13.64%。

In the process of multi-strand enameled wire and copper terminal resistance hot pressure bonding,as the number of welding increases or the welding beat changes,the heat accumulation on the electrode is different.The traditional constant-current control method is difficult to ensure the consistency of the joint heating.A new developed electrode displacement control system for resistance hot pressure bonding was introduced.During the welding process,the grating displacement sensor was used to detect the electrode displacement adaptively,and a fuzzy PID controller was established to control the welding current in real time,so that the actual displacement curve could track the target displacement curve.By controlling the thermal deformation of the joint,the consistency of the joint heating was controlled.The test results show that compared with the constant-current control method,this method can effectively control the heat input of the copper terminal,and the heat input of the welding process is stable.In 50 welding tests of a specific terminal,the thickness error of the copper terminal after welding is reduced by 84.97%,and the consistency of the joint is significantly improved.Due to the improvement of consistency,its fine goods rate has increased by 13.64%.