CN107717163A

CN107717163A - Welding head device, induction brazing system and welding method thereof

Info

Publication number: CN107717163A
Application number: CN201710965093.5A
Authority: CN
Inventors: 殷洪炜; 钟明生; 倪雪辉; 侯纪波; 黄起建; 陈龙龙; 王银春; 覃斌; 柳永刚; 宋汶松; 黄树燕; 邱建华
Original assignee: Gree Electric Appliances Inc of Zhuhai
Current assignee: Gree Electric Appliances Inc of Zhuhai
Priority date: 2017-10-17
Filing date: 2017-10-17
Publication date: 2018-02-23

Abstract

The invention discloses a welding head device, an induction brazing system and a welding method thereof, wherein the device comprises: an induction coil (2) and a magnetic core (3); the induction coil (2) is used for welding a welding spot of a workpiece to be welded in an electrifying and heating manner; the magnetic core (3) is arranged on the induction coil (2) and used for strengthening the magnetic field intensity of a welding seam corresponding to the set welding point at more than two different positions according to the distribution of the welding points of the workpiece to be welded so as to enable the induction coil (2) to weld more than two welding points simultaneously. According to the scheme, the magnetic cores are distributed on the induction coil, so that the magnetic field distribution on the induction coil is changed, the middle magnetic field intensity is enhanced, the welding operation difficulty of a plurality of adjacent welding points is reduced, and the welding efficiency and the welding quality are improved.

Description

Welding head device, induction brazing system and welding method thereof

Technical Field

The invention belongs to the technical field of welding, particularly relates to a welding head device, an induction brazing system and a welding method thereof, and particularly relates to a one-step brazing forming process method for a multi-joint welding spot.

Background

At present, standard parts close to pipe orifices such as a four-way valve and an electronic valve in the refrigeration industry are welded, manual single-point brazing is mainly used in the welding process, and the whole process at least has the following problems to be solved urgently:

⑴, adjacent welding points interfere with each other during welding, so that the welding quality is poor and the welding efficiency is low.

⑵ four-way valve has four welding spots, three of which are combined into a row and have compact structure, the welding operation is difficult because the adjacent welding spots need to be prevented from being influenced with each other, and the welding efficiency is extremely low because each welding spot needs to be welded one by one.

⑶ the flame brazing is greatly influenced by the skill of staff, the production process is uncontrollable, and the welding quality cannot be guaranteed.

In the prior art, the defects of high welding operation difficulty, low welding efficiency, poor welding quality and the like exist.

Disclosure of Invention

The invention aims to provide a welding head device, an induction brazing system and a welding method thereof aiming at the defects, so as to solve the problem that the welding operation difficulty of a plurality of adjacent welding points is large in the prior art and achieve the effect of reducing the welding operation difficulty.

The invention provides a welding head device, comprising: an induction coil and a magnetic core; the induction coil is used for welding a welding spot of a workpiece to be welded in an electrifying and heating mode; the magnetic core is arranged on the induction coil and used for strengthening the magnetic field intensity of the welding seam corresponding to the set welding point at more than two different positions according to the distribution of the welding points of the workpiece to be welded so as to enable the induction coil to weld more than two welding points simultaneously.

Optionally, the structure of the magnetic core includes: at least one of a semi-I-shaped structure and a block-shaped structure; wherein, half I-shaped structure includes: a C-shaped structure; and/or the magnetic core is installed in the induction coil through a preset insulator; and/or, the material of the magnetic core comprises: at least one of silicon steel sheet and ferrite; and/or, a thickness of the magnetic core, comprising: 2.4-2.6 mm.

Optionally, the structure of the induction coil includes: at least one of an open-close structure and a profiling structure; the opening and closing structure is used for opening before welding starts and/or after welding ends so that the workpiece to be welded enters a heating area in the induction coil; and the heating zones are combined into a whole during welding so as to surround the peripheries of more than two welding points; and/or the profiling structure is provided with a structure formed by following the shape of the workpiece to be welded, so that the induction coil with the profiling structure can be used for carrying out adaptive welding on the workpiece to be welded.

Optionally, wherein the induction coil having the opening and closing structure includes: a first half-coil and a second half-coil; the first half coil and the second half coil, when combined together, form a full coil; and/or, the induction coil having the profiling structure, comprising: any one of the parallel four-way valve welding wire ring and the E-shaped four-way valve welding wire ring; the flush four-way valve welding coil is used for welding at least a pipe C, a pipe S and a pipe E which are arranged in flush in the four-way valve at one time; and/or the welding wire ring of the E-shaped four-way valve is used for welding at least the C pipe, the S pipe and the E pipe which are arranged in the shape of the E in the four-way valve in one step.

Optionally, wherein, between the first half coil and the second half coil, the first half coil and the second half coil are symmetrically or asymmetrically arranged; and/or the first half coil and the second half coil have the same structure or different structures.

Optionally, the method further comprises: at least one of a power supply device, a driving device, a positioning tool and a communication device; the power supply device is used for providing induction heating power supply for the induction coil; the induction heating power supply includes: switching on and off a power supply; and/or the driving device is used for providing opening and closing driving for the induction coil so as to open or close the induction coil; and/or providing movement drive for the induction coil so that the induction coil moves when being electrified and heated; and/or the positioning tool is used for positioning the workpiece to be welded; and/or the communication device is used for acquiring the welding parameters of at least one of the welding head device and the induction brazing system to which the welding head device belongs, and outputting, storing and displaying the welding parameters, so as to serve as a basis for optimizing at least one of the welding process and the control parameters of the induction brazing system to which the welding head device belongs.

Optionally, wherein, when the induction coil includes a first half coil and a second half coil, the switching power supply includes: the power supply comprises a power supply body, a connecting bridge and an insulating partition; the single output end of the power supply body is connected with the main body of the connecting bridge, a first bridge arm of the connecting bridge is connected with the first half coil, and a second bridge arm of the connecting bridge is connected with the second half coil; the device comprises a plurality of half coils, a plurality of bridge arms and a plurality of semi-coils, wherein the contact positions between the corresponding bridge arms and the corresponding semi-coils are provided with kerosene liquid seal structures and/or tungsten-copper material structures; the insulation partition is arranged between the first bridge arm and the second bridge arm; alternatively, the switching power supply includes: a power supply main body; a first output end of the power supply main body is connected with the first half coil to form a first output power supply loop; a second output end of the power supply main body is connected with the second half coil to form a second output power supply loop; wherein the first output end and the second output end have the same structure; alternatively, the switching power supply includes: a first power supply and a second power supply; the first power supply is connected with the first half coil, and the second power supply is connected with the second half coil; alternatively, the switching power supply includes: a power supply main body; the first output head of the output end of the power supply main body is connected with the first half coil; the second output head of the output end of the power supply main body is connected with the second half coil; and/or, the actuating device is used for providing the structure of opening and closing drive, and comprises: the device comprises a cylinder, a servo motor and a hydraulic device; the hydraulic device, the servo motor and the air cylinder are sequentially matched and arranged; the cylinder is also matched with a power supply of the induction coil.

Optionally, wherein the switching power supply further includes: a water receiving port; the water receiving port is arranged on at least one of the main body of the connecting bridge, the first bridge arm and the second bridge arm and is used for being connected with a cooling circulation water path when a cooling device of an induction brazing system to which the welding head device belongs comprises the cooling circulation water path so as to cool the induction coil and/or the switching power supply; and/or, the power body, includes: a transformer; the transformer is connected with an alternating current power supply to supply power according to the induction heating requirement of the induction coil; and/or, the drive arrangement provides the drive that opens and shuts for induction coil includes: providing opening and closing drive under the control of a control device of an induction brazing system to which the welding head device belongs; and/or the driving device enables the induction coil to move up and down when being electrified and heated, and the driving device comprises: moving up and down periodically; and/or, the communication device includes: at least one of an RS485 module and an RS232 module.

Optionally, wherein the induction heating distance between the induction coil and the workpiece to be welded comprises: 1-2 mm; and/or, the induction coil, comprising: at least one of a long U-shaped induction coil and a semicircular induction coil; and/or, the workpiece to be welded comprises: a metal workpiece having more than two welding spots; wherein the metal workpiece comprises: at least one of a four-way valve and an electronic valve.

In accordance with another aspect of the present invention, there is provided an induction brazing system, comprising: a control device; further comprising: the above-described bonding head device; the control device is used for controlling the induction coil in the welding head device to move up and down.

Optionally, the control device includes: a robot positioning system and a manipulator assembly; the control end of the robot positioning system is connected with the manipulator component; the manipulator component is connected with the welding head device.

Optionally, the method further comprises: at least one of a heat-insulating device and a cooling device; the heat preservation device is used for preserving heat of the welding spot in the welding process; and/or the cooling device is used for cooling at least one of the induction coil, the magnetic core and the workpiece to be welded after welding is finished.

Optionally, when the welding head device comprises a positioning tool, the positioning tool and the cooling device are integrally arranged; and/or, the cooling device, comprising: and a cooling circulation water path.

In accordance with another aspect of the present invention, there is provided a welding method based on the above induction brazing system, including: welding the welding spot of the workpiece to be welded by the induction coil in an electrifying and heating manner; and according to the distribution and the reinforcement of the welding spots of the workpiece to be welded, setting the magnetic field intensity of the welding spots corresponding to the welding spots at more than two different positions, so that the induction coil can weld more than two welding spots simultaneously.

Optionally, welding the welding point of the workpiece to be welded by the induction coil in an energization heating manner, including: opening before welding starts and/or after welding ends so that the workpiece to be welded enters a heating area in the induction coil; and the heating areas are combined into a whole during welding so as to surround the peripheries of more than two welding points.

Optionally, before the step of welding the welding spot of the workpiece to be welded by causing the induction coil to be heated by energization, the method further includes: providing an induction heating power supply for the induction coil; and/or, providing opening and closing drive for the induction coil so as to open or close the induction coil; and/or, providing moving drive for the induction coil so as to enable the induction coil to move up and down when being electrified and heated; and/or positioning tubing is carried out on at least one of the induction coil, the magnetic core and the workpiece to be welded; and/or during the process of welding the welding point of the workpiece to be welded by enabling the induction coil to be electrified and heated, and/or after the welding is finished, the method further comprises the following steps: insulating the welding spots; and/or cooling at least one of the induction coil, the magnetic core and the workpiece to be welded after welding is finished; and/or acquiring welding parameters of at least one of the welding head device and the induction brazing system to which the welding head device belongs, and performing at least one operation of outputting, storing and displaying on the welding parameters to serve as a basis for optimizing at least one of a welding process and control parameters of the induction brazing system to which the welding head device belongs.

Optionally, when the to-be-welded workpiece includes a four-way valve, welding a weld spot of the to-be-welded workpiece by the induction coil in an energization heating manner, specifically including: 1) after the positioning and piping work of the four-way valve is finished, the induction coil is moved to a welding point of a workpiece to be welded through the control device; 2) controlling a preset connecting rod to extend through an air cylinder in the welding head device to drive the induction coil to be closed; 3) calling a preset welding program to enable the welding point to undergo heating, heat preservation and cooling processes; 4) the connecting rod is retracted through the cylinder, the induction coil is opened, and the control device is reset; and after one welding point of the four-way valve is finished, repeating the steps 1) to 4) to move the induction coil to the next welding point of the workpiece to be welded.

According to the scheme, the magnetic cores are distributed on the induction coil, so that the magnetic field distribution on the induction coil is changed, the middle magnetic field intensity is enhanced, more than two welding spots are welded at the same time, the welding operation difficulty of a plurality of adjacent welding spots is reduced, and the welding efficiency and the welding quality are improved.

Further, according to the scheme of the invention, the induction coil moves up and down periodically during welding heating, so that the heating uniformity is further improved.

Further, according to the scheme of the invention, by adopting the open-close type induction coil structure, the coils are automatically combined into a whole during welding, and the coils are automatically opened after welding, so that the flexibility of induction brazing is enhanced, the application range is enlarged, and meanwhile, the heating uniformity and the welding efficiency are improved.

Furthermore, according to the scheme of the invention, the profiling coil is designed, and the designed profiling coil is used for one-time brazing forming, so that the production efficiency is improved.

Furthermore, according to the scheme of the invention, the positioning tool and the cooling device are combined into a whole, so that the positioning precision is ensured, and the welding appearance is full.

Further, according to the scheme of the invention, welding parameters are output through RS485 communication on equipment, welding information is output and stored, and later-stage tracing and welding optimization are improved.

Therefore, according to the scheme of the invention, the magnetic core is distributed on the induction coil to realize the simultaneous welding of more than two welding spots, so that the problem in the prior art that the welding operation difficulty of a plurality of adjacent welding spots is high (for example, the welding operation difficulty caused by mutual influence among the adjacent welding spots needs to be prevented) is solved, the defects of difficult welding operation, low welding efficiency and poor welding quality in the prior art are overcome, and the beneficial effects of simple welding operation, high welding efficiency and good welding quality are realized.

Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.

The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.

Drawings

FIG. 1 is a schematic structural diagram of an embodiment of a U-shaped induction coil (i.e., U-shaped structure) according to the present invention;

FIG. 2 is a schematic diagram of an embodiment of a closed-loop induction coil (i.e., closed-loop configuration) according to the present invention;

FIG. 3 is a schematic structural diagram of a rotary opening and closing coil (i.e., rotary opening and closing structure) according to an embodiment of the present invention;

FIG. 4 is a schematic structural view of an embodiment of the four-way valve member of the present invention;

FIG. 5 is a schematic structural view of another embodiment of a four-way valve member of the present invention;

FIG. 6 is a front view of one embodiment of a single output connecting bridge configuration of the present invention;

FIG. 7 is a left side view of one embodiment of a single output connecting bridge configuration of the present invention;

FIG. 8 is a front view of one embodiment of a single output connecting bridge configuration of the present invention;

FIG. 9 is a front view of one embodiment of a weld head device of the present invention including an opening and closing coil (i.e., a flush four-way valve weld head coil);

FIG. 10 is a front view of one embodiment of a weld head device of the present invention including an opening and closing coil (i.e., a flush four-way valve weld head coil);

FIG. 11 is a front view of an embodiment of a weld head device of the present invention including a chevron four-way valve weld coil;

FIG. 12 is a front view of an embodiment of a weld head device of the present invention including a chevron four-way valve weld coil;

FIG. 13 is a front view of one embodiment of a four-way valve of the present invention arranged in a chevron configuration;

FIG. 14 is a left side view of one embodiment of a four-way valve of the present invention in a chevron configuration;

FIG. 15 is a front view of one embodiment of a flush four-way valve according to the present invention;

FIG. 16 is a left side view of one embodiment of a flush four-way valve according to the present invention;

FIG. 17 is a front view of one embodiment of a positioning tool of the present invention;

FIG. 18 is a schematic cross-sectional view of B-B of FIG. 17;

FIG. 19 is a left side view of one embodiment of the positioning tool of the present invention;

FIG. 20 is a top view of one embodiment of a positioning tool of the present invention;

FIG. 21 is a perspective view of one embodiment of a positioning tool of the present invention;

FIG. 22 is a schematic structural view of an embodiment of an electronic valve of the present invention;

FIG. 23 is a schematic structural view of an embodiment of an induction brazing system of the present invention;

FIG. 24 is a front view of one embodiment of an arrangement of copper tubes and induction coils of a part of the induction brazing system of the invention;

FIG. 25 is a left side view of one embodiment of an arrangement of copper tubes and induction coils of a part of the induction brazing system of the invention;

FIG. 26 is a top view of one embodiment of an arrangement of copper tubes and induction coils of a part of the induction brazing system of the present invention.

The reference numbers in the embodiments of the present invention are as follows, in combination with the accompanying drawings:

1-a transformer; 2-an induction coil; 3-a magnetic core; 4-a cylinder; 5-a connecting bridge; 6-a water receiving port; 7-insulating partition; 21-half coil; 22-full coil; 23-welding a wire coil of the flush four-way valve; welding a coil for the 24-E-shaped four-way valve; 41-a first cylinder; 42-a second cylinder; 8-positioning the pipe orifice; 9-copper pipe joints; 10-a cylinder and a limiting block; 11-a four-way valve; 12-an inner cavity; 13-a positioning table; a-a welding position; f-liquid level; g-gap.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be clearly and completely described below with reference to the specific embodiments of the present invention and the accompanying drawings. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

According to an embodiment of the present invention, a welding head device is provided, as shown in fig. 1 to 22, which are schematic structural views of an embodiment of the welding head device of the present invention. The welding head device may include: an induction coil 2 and a magnetic core 3.

In an alternative example, the induction coil 2 may be used for welding a welding spot of a workpiece to be welded by means of energization and heating.

Optionally, the structure of the induction coil 2 may include: at least one of an opening and closing structure and a profiling structure.

In an alternative specific example, the opening and closing structure may be used to open before welding starts and/or after welding ends so that the workpiece to be welded enters the heating area in the induction coil 2; and the heating areas are combined into a whole during welding so as to surround the peripheries of more than two welding points.

For example: the induction coil 2 may include: an open-close type induction coil.

For example: the open-close type induction coil is adopted, the open-close type induction coil is automatically combined into a whole during welding, and the open-close type induction coil is automatically opened after welding is finished.

For example: the induction coil can adopt an open-close type induction coil structure, the coils are automatically combined into a whole during welding, the coils are automatically opened after welding, the flexibility of induction brazing is enhanced, the application range is enlarged, and meanwhile, the heating uniformity and the welding efficiency are improved.

Therefore, the induction coil adopting the opening and closing structure can enhance the flexibility of induction brazing, enlarge the application range, and improve the heating uniformity and the welding efficiency.

More optionally, the induction coil 2 having the opening and closing structure may include: a first half-coil and a second half-coil. The first half-coil and the second half-coil, when combined together, form a full coil.

From this, through the structure of opening and shutting that two half coils formed, the convenience that opens and shuts is good, and heating reliability is high.

Wherein, between the first half coil and the second half coil, the first half coil and the second half coil are symmetrically or asymmetrically arranged; and/or the first half coil and the second half coil have the same structure or different structures.

Therefore, the flexibility and the universality of the induction coil electrifying heating welding can be improved through the half coils in various forms.

More optionally, the induction coil 2 having the opening and closing structure may further include: a rotary connection part or a translational connection part.

In a more optional embodiment, the rotatable connection portion is disposed between a first end of the first half coil and a first end of the second half coil, and can be used to open or close the first half coil and the second half coil by rotation.

In a more specific example, the translational connection portion, which is disposed between the first end of the first half coil and the first end of the second half coil, may be used to enable the first half coil and the second half coil to be opened or combined through translation.

Therefore, the opening and closing mode can be more convenient and flexible through the opening and closing structure in various forms.

In an alternative specific example, the profiling structure has a structure formed to follow the shape of the workpiece to be welded, so that the induction coil 2 having the profiling structure performs the fitting welding on the workpiece to be welded.

For example: for the induction coil, a profiling structure can be designed. Through designing the profile modeling coil, utilize the profile modeling coil one-time brazing shaping of this application design, improve production efficiency.

Therefore, the flexibility of the welding process can be improved by adopting the profiling structure design, and the universality of the welding technology is improved.

More optionally, the induction coil 2 having the profiling structure may include: any one of the flush four-way valve welding wire ring 23 and the chevron four-way valve welding wire ring 24.

In a more alternative embodiment, the flush four-way valve welding coil 23 can be used to weld at least the flush C, S and E tubes of the four-way valve at one time.

In a more alternative embodiment, the welding wire coil 24 for the chevron-shaped four-way valve can be used to weld at least the C-tube, the S-tube and the E-tube of the four-way valve in a chevron shape.

For example: the induction coil may be a flush four-way valve weld coil 23, as can be seen in the examples shown in fig. 9 and 10. The induction coil may also be a chevron four-way valve soldered coil 24, as can be seen in the examples shown in fig. 11 and 12.

For example: four pipe openings of the four-way valve need to be welded, namely E, S, C, D pipes, E, S, C three copper pipes need to be welded at one time, corresponding induction coils need to be designed, and one-time brazing forming is achieved. The method can be divided into a high-low profile structure with a changeable valve ESC nozzle structure and a coil design, and can be seen in the examples shown in figures 13, 14, 15 and 16.

From this, through carrying out the profile modeling design to induction coil for the induction coil that has the profile modeling structure can treat welding workpiece fast and reliably and advance the welding, is favorable to promoting the efficiency of brazing.

Alternatively, the induction heating distance between the induction coil 2 and the workpiece to be welded may include: 1-2 mm.

For example: the optimal distance for induction heating is 1-2mm from the part (i.e., the metal workpiece) to the induction coil.

From this, through the setting to induction heating distance, be favorable to promoting induction heating effect, and then promote the welding effect.

Optionally, the induction coil 2 may include: at least one of a long U-shaped induction coil and a semicircular induction coil.

For example: the design shown in fig. 3 takes into account the heating advantages of the closed loop, and has the flexibility of the U-shaped structure.

For example: the open-close coil structure can solve the problem that a long U-shaped coil heats a copper pipe unevenly. Wherein, the open-close type long U-shaped coil is welded with more than two welding points at the same time. For example: the open-close type long U-shaped copying coil can be used for simultaneously welding three tubes of an ESC on the four-way valve.

From this, through the induction coil of multiform, it is effectual to heat, and welding efficiency is high, still is favorable to promoting the welding flexibility.

Alternatively, the workpiece to be welded may include: a metal workpiece having more than two weld points.

Wherein, the metal workpiece can comprise: at least one of a four-way valve and an electronic valve.

For example: the welding points with adjacent and equal height can be welded at one time, for example, an electronic valve, as shown in the example of fig. 22. In this way, parallel pipe welds in the air conditioner can be welded without being avoided in later designs, and there is no concern that the welds will be affected by each other.

From this, through once only welding to two above solder joints, can promote welding efficiency, and can guarantee the welding effect, it is good to use the convenience, and the reliability is high.

In an alternative example, the magnetic core 3, disposed on the induction coil 2, may be used to strengthen the magnetic field intensity at the weld joint corresponding to two or more different position setting weld points according to the distribution of the weld points of the workpiece to be welded.

For example: and changing the magnetic field intensity in the induction coil 2 after being electrified, and strengthening the magnetic field intensity of the set part according to the requirement, so that the temperature of the welding spots of the workpieces to be welded in the induction coil 2 is raised consistently, and the induction coil 2 can weld more than two welding spots simultaneously. Wherein, add magnetic core 3 in induction coil and can lead to magnetic field intensity to increase, to a plurality of solder joints simultaneous welding in the scheme of this application, can distribute according to the solder joint and strengthen a plurality of different positions and set for the magnetic field intensity of the corresponding welding seam department of solder joint. Under the condition that the temperature of welding points is consistent, the requirement is required under the condition that the specifications of three copper pipes are the same.

For example: the magnetic core 3 may be configured to change a distribution area of a magnetic field on the induction coil 2 after being energized, and strengthen the strength of a middle portion of the magnetic field, so that the induction coil 2 welds two or more welding spots simultaneously.

For example: the magnetic core can be arranged on the coil, the heating area is concentrated or compensated, and the size, thickness and material of the magnetic core are selected for comprehensive design according to the heating loss and the magnetic field concentration area of the magnetic core.

For example: the magnetic cores are distributed on the coils, the magnetic field distribution on the induction coils is changed, and the middle magnetic field intensity is enhanced, so that the phenomenon of temperature rise hysteresis of an S pipe in the four-way valve during induction brazing is avoided, and more than two welding spots are welded simultaneously.

From this, through arranging the magnetic core on induction coil, can change the magnetic field distribution condition on the induction coil after circular telegram to strengthen the magnetic field intensity of mid portion, and then realize welding two above solder joints simultaneously, promote welding efficiency and welding effect.

Alternatively, the structure of the magnetic core 3 may include: at least one of a semi-I-shaped structure and a block-shaped structure; wherein, half I-shaped structure can include: a C-shaped structure (e.g., a structure that may be specifically C-shaped).

Therefore, the magnetic cores with various structures are arranged on the induction coil more conveniently, and the stability and the reliability of the change of the magnetic field distribution are better and higher.

More optionally, the magnetic core 3 is installed in the induction coil 2 through a preset insulator. For example: the magnetic core 3 with the half-I-shaped structure is clamped in the induction coil 2.

For example: the insulator may be an insulating glue. Specifically, the magnetic core 3 may be fixed by using an insulating glue, so as to avoid the temperature rise of the magnetic core caused by the flowing current, because the magnetic core is not in contact with the induction coil 2.

From this, through with the magnetic core card in induction coil for the magnetic core distributes on induction coil stability is good, is favorable to promoting stability and reliability of change to induction coil's behind the circular telegram magnetic field.

Optionally, the material of the magnetic core 3 may include: at least one of silicon steel sheet and ferrite.

For example: the material of the magnetic core 3 may include: at least one of Mn-Zn ferrite, Ni-Zn ferrite, and silicon steel sheet.

For example: after the design outline of the coil is determined, Mn-Zn ferrite, Ni-Zn ferrite, silicon steel sheets and the like can be selected for arranging the magnetic core on the coil.

From this, through the magnetic core of multiple material, be favorable to promoting flexibility and the variety to the magnetic field change on the circular telegram back induction coil.

More optionally, the thickness of the magnetic core 3 may include: 2.4-2.6 mm.

For example: optionally, the thickness of at least one of the Mn — Zn ferrite, the Ni — Zn ferrite, and the silicon steel sheet may include: 2.4-2.6 mm.

For example: silicon steel sheets are distributed on the induction coil and are processed into a half I-shaped structure to be clamped in the coil, wherein the thickness of the silicon steel sheets is 2.4-2.6mm, and the purpose is to reduce magnetic loss.

From this, through the parameter that sets up the magnetic core, can reduce the magnetic loss, and then promote heating effect and welding effect.

In an alternative embodiment, the method may further include: the power supply device and at least one of the driving device, the positioning tool and the communication device.

Therefore, the welding effect of induction brazing can be improved through the adaptive arrangement of the power supply device, the driving device, the positioning tool, the communication device and the like, and the induction brazing welding device is high in reliability and good in safety.

In an alternative example, the power supply device may be used to provide induction heating power to the induction coil 2. The induction heating power supply may include: the power supply is switched on and off.

Alternatively, when the induction coil 2 may include a first half coil and a second half coil, the switching power supply may include: power body, connecting bridge 5 and insulating wall 7.

The single output end of the power supply body is connected with the main body of the connecting bridge 5, a first bridge arm of the connecting bridge 5 is connected with the first half coil, and a second bridge arm of the connecting bridge 5 is connected with the second half coil; and a kerosene liquid seal structure and/or a tungsten-copper material structure are/is arranged at the contact position between the corresponding bridge arm and the corresponding half coil. And the insulation partition 7 is arranged between the first bridge arm and the second bridge arm.

For example: the fourth scheme is a single output end of a power supply, two half coils (for example, half coil 21) of the coil (for example, full coil 22) respectively connected by an intermediate connecting bridge (for example, connecting bridge 5) can still be combined into an induction heating area similar to a closed loop structure, and the schemes shown in fig. 6, 7 and 8 can be seen.

For example: aiming at the fourth scheme, one design is that the half coil is in contact with the connecting bridge, and if the contact position is selected from kerosene liquid seal or tungsten copper material, the durability of the coil can be enhanced.

Therefore, the power supply can be used as an open-close power supply through the adaptive arrangement among the power supply body, the connecting bridge and the insulating partition, and the reliability is high; and the contact position of the half coil and the connecting bridge is specially arranged, so that the durability of the coil can be improved.

More optionally, the switching power supply may further include: a water receiving port 6.

The water receiving port 6 is disposed on at least one of the main body of the connecting bridge 5, the first bridge arm, and the second bridge arm, and can be used for connecting with a cooling circulation water path when a cooling device of the induction brazing system to which the welding head device belongs may include the cooling circulation water path, so as to cool the induction coil 2 and/or the switching power supply.

For example: in the solutions shown in fig. 6, 7 and 8, the single output connection bridge structure further includes: a water receiving port 6 and an insulating partition 7.

From this, through the setting of water receiving mouth, can conveniently connect the cooling cycle water route for temperature control is more convenient, also more reliable.

More optionally, the power supply body may include: a transformer 1. The transformer 1 may be used to connect with an ac power source to supply power according to the induction heating requirement of the induction coil 2.

Therefore, the power supply flexibility is higher and the universality is stronger through the adaptive arrangement of the transformer.

Optionally, the switching power supply may further include: a power supply main body. And a first output end of the power supply main body is connected with the first half coil to form a first output power supply loop. And a second output end of the power supply main body is connected with the second half coil to form a second output power supply loop. Wherein the first output terminal and the second output terminal have the same structure.

For example: the scheme is that a power supply main body is designed into two identical output ends, and then a half induction coil is designed into an output power supply loop called a half coil, so that an induction heating area similar to a closed loop structure can be formed by the two output ends.

Optionally, the switching power supply may further include: a first power supply and a second power supply. The first power supply is connected to the first half-coil, and the second power supply is connected to the second half-coil.

For example: and the second scheme is to integrate two power supplies with the same type together and then combine the two half coils into an induction heating area similar to a closed loop structure.

Optionally, the switching power supply may further include: a power supply main body. And the first output head of the output end of the power supply main body is connected with the first half coil. And the second output head of the output end of the power supply main body is connected with the second half coil.

For example: and the third scheme is that one power supply output end is designed into two output heads, so that the two output ends can be combined into an induction heating area similar to a closed loop structure by combining with a half coil.

For example: the coils of the first, second and third schemes do not need to be contacted with each other in the working process, so that the reliability is higher; the coil has various designable shapes, the effect is the same as that of a closed coil, the heating is uniform, the coil can be designed into various profiling shapes, the production requirement is met, and the compatibility is better.

From this, through the power that opens and shuts of multiform, the reliability is high, and is compatible good, is favorable to promoting heating effect and heating efficiency.

In an optional example, the driving device may be configured to provide opening and closing driving for the induction coil 2, so as to open or close the induction coil 2; and/or providing movement drive for the induction coil 2, so that the induction coil 2 moves when being electrified and heated. The movement may be up and down movement, left and right movement, tilting movement, or the like.

For example: the temperature rise of the middle copper pipe is basically matched with the temperature rise of the copper pipes on the two sides, and the middle copper pipe moves up and down during welding heating so as to finish uniform heating.

For example: the robot reciprocates during welding, increases the welding homogeneity.

From this, through make induction coil reciprocate when the welding, can promote heating homogeneity nature, and then promote welding efficiency and welding effect.

Optionally, the driving device may be configured to provide the opening and closing driving structure, and may include: cylinder 4, servo motor, hydraulic means.

The hydraulic device, the servo motor and the air cylinder 4 are sequentially matched and arranged. The cylinder 4 is also matched with the power supply of the induction coil 2.

For example: for the opening and closing operation, a moving element such as a cylinder, a servo motor, or a hydraulic device may be used.

For example: in order to make the heating effect of the open coil shown in fig. 3 substantially the same as that of the closed-loop coil structure, it is easier to automate and the space for opening and closing is smaller than the rotary opening and closing of the open coil shown in fig. 3. In the opening and closing action, moving elements such as an air cylinder, a servo motor, a hydraulic device and the like can be used, the requirement of automatic opening and closing can be met, and the opening and closing are easier to realize.

For example: the automatic opening and closing requirements can be met by using moving elements such as the air cylinder, the servo motor and the hydraulic device in the opening and closing action, the realization is easy, the magnetic core is added on the coil, the material, the magnetic core structure and the magnetic core position are reasonably selected, the welding requirements on the magnetic field are purposefully designed, and the applicability and the production efficiency can be greatly improved.

From this, through cylinder, servo motor and hydraulic means's adaptation setting, be favorable to promoting the degree of automation and the reliability that induction coil opened and shut, and then can promote welding efficiency and welding effect, and avoided the artificial potential safety hazard of controlling and bringing.

More optionally, the driving device provides opening and closing driving for the induction coil 2, and may include: and opening and closing drive is provided under the control of a control device of the induction brazing system to which the welding head device belongs.

Therefore, the automatic folding device can be opened and closed under the control of the control device, the automation degree is higher, and the opening and closing reliability and safety are better.

More alternatively, the driving device for moving the induction coil 2 up and down when the induction coil is heated by electricity may include: moving up and down periodically.

For example: the induction coil can move up and down periodically during welding heating, thereby further improving the heating uniformity.

Therefore, the heating uniformity can be more reliably and stably improved through the periodic movement, and the heating effect is better.

In an optional example, the positioning tool may be used to position the workpiece to be welded. Wherein, the location frock can be treated welding workpiece and fix a position. The piping may be accomplished manually or by a robot.

For example: the profiling coil is positioned in combination with the robot, so that the welding applicability can be greatly improved. The robot moves to the welding position according to the set path for positioning, and the E, S, C pipes are welded simultaneously and then are welded separately by the robot for positioning the D pipes. Therefore, the welding workbench can be designed as a fixed workbench or a rotary table workbench, the welding design difficulty can be greatly reduced, the production universality is improved, and the flexible function of the robot is exerted to the maximum extent. The inlet and outlet space of the induction coil can be reserved in the design process of the four-way valve assembly, so that the design is more standard and reasonable, and the welding efficiency of the assembly is improved.

For example: the positioning tool can position the part (i.e. the workpiece to be welded, see the example shown in fig. 21), then tubing is formed, and the formed part is shown in fig. 4.

From this, through the location of location frock, can promote welded stability and security.

In an optional example, the communication device may be configured to acquire a welding parameter of at least one of the welding head device and the induction brazing system to which the welding head device belongs, and output, store, and display the welding parameter as a basis for optimizing at least one of a welding process and a control parameter of the induction brazing system to which the welding head device belongs.

For example: and optimizing at least one of the welding process of the induction brazing system and the control parameter of the control device according to the welding parameter by the control device of the induction brazing system to which the welding head device belongs.

Optionally, the communication device may include: at least one of an RS485 module and an RS232 module. Of course, the communication device may also include other modules capable of realizing informatization acquisition.

For example: the communication device may include: and an RS485 communication module. In the brazing process, welding parameters can be obtained, the welding parameters are output through RS485 communication on equipment (for example, the equipment can be an induction brazing system or a component in the induction brazing system), welding information is output and stored, and later-stage tracing and welding optimization improvement are achieved.

Therefore, the flexibility and convenience of communication can be improved by various communication modes.

For example: the welding process is innovative, the equipment can monitor and extract welding information, a method is provided for long-term optimization of the process and informatization, a gas pipeline is not used, the layout of a workshop pipeline is reduced, a fire station is eliminated, and the layout of the workshop is simpler.

From this, through communication device's setting, can carry out timely processing and application to the welding parameter, and then optimize, be favorable to further promoting welding efficiency and welding effect, and humanized good.

A large number of experiments verify that the technical scheme of this embodiment is adopted, and through distributing the magnetic core on induction coil, change the magnetic field distribution on the induction coil and strengthen middle magnetic field intensity to realize welding two or more solder joints simultaneously, reduced the welding operation degree of difficulty that several are close to the solder joint, and promoted welding efficiency and welding quality.

According to an embodiment of the invention, there is also provided an induction brazing system corresponding to the weld head device. Referring to fig. 23, a schematic diagram of an embodiment of the system of the present invention is shown. The induction brazing system may include: a control device; the method can also comprise the following steps: a welding head device.

The control device can be used for controlling the induction coil 2 in the welding head device to move up and down.

Optionally, the control device may include: a robot positioning system and a manipulator assembly.

Wherein the control end of the robot positioning system is connected with the manipulator component. The manipulator component is connected with the welding head device.

In an alternative embodiment, the method further comprises: at least one of a heat-insulating device and a cooling device.

In an alternative example, the heat-insulating device can be used for insulating the welding spot in the welding process.

Wherein, the heat preservation can be used for the welding process and is reflected on the welding process.

From this, through heat preservation of heat preservation device, can promote the welding effect, and energy-conserving effectual.

In an alternative example, the cooling device may be configured to cool at least one of the induction coil 2, the magnetic core 3, and the workpiece to be welded after the welding is finished.

The cooling is mainly performed on welded parts by means of needle welding, the main parts of the welded parts are protected from being damaged due to high welding temperature, and the induction power supply is cooled by the water cooling machine.

From this, through cooling device's cooling, can cool down rapidly after the welding is accomplished, the reliability is high, and the security is strong.

Optionally, the cooling device may include: and a cooling circulation water path.

For example: the structure of the positioning tool and the cooling device can be seen in the examples shown in fig. 17, 18, 19, 20 and 21. In the examples shown in fig. 17, 18, 19, 20 and 21, the positioning tool may further include a positioning nozzle 8; the cooling means may comprise a cooling circulation water circuit, the cooling level of which may be at F; the cylinders may include a first cylinder 41 and a second cylinder 42.

For example: aiming at the induction brazing system, the four-way valve can be subjected to induction brazing by combining a positioning tool and a cooling device.

From this, cool off through the cooling circulation water route, simple structure, the cooling flexibility is good, and energy-conserving effectual.

Optionally, when the welding head device comprises a positioning tool, the positioning tool and the cooling device are integrally arranged.

For example: the positioning tool and the cooling circulation water path are combined into one, the positioning is accurate, and the cooling is effective. For example: the positioning tool and the cooling circulation water path are combined into one, the positioning is accurate, and the cooling is effective.

Wherein, unite two into one location frock and cooling cycle water route, can continuously cool off, welding effect and security are better.

From this, through setting up location frock and cooling device integral type, can promote positioning accuracy, guarantee the cooling effect.

In one embodiment, the induction brazing system may include: an induction coil. The structure of the induction coil will be described in detail with reference to the examples shown in fig. 1, 2 and 3.

The induction brazing of the induction brazing system is realized by utilizing the characteristics that the metal welding workpiece can be heated to the brazing temperature by utilizing the characteristics that the metal welding workpiece is heated to the brazing temperature, and the induction brazing function can be realized. Among them, the induction coil is a key part that generates a magnetic field and is coupled with a workpiece (i.e., a metal workpiece), and thus, the shape and structure of the induction coil play a decisive role in the heating manner and the heating effect. The optimal distance for induction heating is that the distance between the part (i.e. the metal workpiece) and the induction coil is 1-2mm, and for the sake of design beauty and convenient operation, the characteristics of the present application will be described in detail below.

The distance between the part and the induction coil, specifically, the gap G between the copper tube (for example, copper tube connector 9) of the part and the induction coil, can be seen in the examples shown in fig. 24 to 26.

In one example, the induction coil has almost two configurations, one being a closed circular coil, as shown in FIG. 2; the other is an open U-shaped coil as shown in fig. 1.

Wherein, because the U-shaped induction coil has a gap, a magnetic leakage phenomenon exists at the gap, a temperature rise hysteresis phenomenon exists at the position (namely, at the opening of the U-shaped coil or at the gap) in the heating process, and the larger the gap is, the more serious the magnetic leakage is; therefore, the larger the welded diameter, the poorer the welding effect; further, the flux leakage phenomenon of the split coil requires more time to heat to the same temperature, and the welding efficiency is lowered. If the closed-loop coil is used, although the magnetic flux leakage phenomenon can be avoided, the closed-loop coil is poor in flexibility, the two ends of the closed-loop coil are large and the middle of the closed-loop coil is small, or the two ends of the welding seam are of an abnormal structure with a bending structure, and the closed-loop coil is difficult to be sleeved at the welding seam for heating.

Furthermore, the design shown in fig. 3 is produced, the heating advantage of the closed loop is taken into consideration, the flexibility of the U-shaped structure is realized, but the space is required for rotating to open and close, and the automatic opening and closing is difficult to realize; the coil needs to be contacted at the opening and closing position or the rotating position, so that the phenomenon of sparking is easy to occur, the coil is burnt, and the service life of the coil is short.

In an alternative example, in order to make the heating effect of the open coil shown in fig. 3 substantially the same as that of the closed-loop coil structure, it is easier to automate and the space for opening and closing is smaller than the rotary opening and closing of the open coil shown in fig. 3. In the opening and closing action, moving elements such as an air cylinder, a servo motor, a hydraulic device and the like can be used, the requirement of automatic opening and closing can be met, and the opening and closing are easier to realize.

Alternatively, a profiling structure may be designed for the induction coil. Through designing the profile modeling coil, utilize the profile modeling coil one-time brazing shaping of this application design, improve production efficiency.

In an optional example, the induction coil can adopt an open-close type induction coil structure, the coils are automatically combined into a whole during welding, and the coils are automatically opened after the welding is finished, so that the flexibility of induction brazing is enhanced, the application range is enlarged, and meanwhile, the heating uniformity and the welding efficiency are improved.

Therefore, the opening and closing coil structure can solve the problem that the long U-shaped coil heats the copper pipe unevenly. Wherein, the open-close type long U-shaped coil is welded with more than two welding points at the same time. For example: the open-close type long U-shaped copying coil can be used for simultaneously welding three tubes of an ESC on the four-way valve.

Where a long U-shaped coil is provided, a gap or distance of 1-2mm between the induction coil and the part (i.e. the work piece to be welded) is required.

In an alternative embodiment, the induction brazing system may include: an induction coil and a magnetic core. The core design is described in detail below.

According to ohm's law and impedance matching principle, the larger the magnetic core, the thicker the magnetic core, the larger the magnetic field strength under the same alternating current; the thicker the magnetic core, the greater the heating loss; the more the magnetic cores are, the larger the impedance of the coil is, and the impedance matching requirement of induction heating is a quadratic curve with a downward opening, and a value corresponds to the maximum value of output, and then the output is reduced towards both sides, so that the designed coil needs to be matched with an induction power supply, after the design outline of the coil is determined, the magnetic cores are arranged on the coil, and Mn-Zn ferrite, Ni-Zn ferrite, silicon steel sheets and the like can be selected, and the effects are as follows:

the heating time of the induction brazing is short, so that the stability of the silicon steel sheet has little influence on the process; when designing the induction heating range, besides the copying means, the magnetic core can be arranged on the coil, the heating area is concentrated or compensated, and the size, thickness and material of the magnetic core are selected according to the heating loss and the magnetic field concentration area of the magnetic core to carry out comprehensive design.

The intensity distribution of the induced magnetic field generated by the alternating current is such that the intensity distribution becomes stronger as the distance from the alternating current becomes shorter, so that the magnetic field intensity is relatively weaker at a position near the center of the induction coil, and the magnetic core is added to compensate for the magnetic field intensity in this region. The heated region is the region of the part that is heated, here the weld region. And the compensation area is formed by adding a magnetic core at a weak magnetic field part to improve the magnetic field intensity of the magnetic core, when an ESC (electronic stability control) tube of the four-way valve is welded, the S tube is positioned at the center, the magnetic field is weak, the temperature rise is delayed, and in order to promote the welding temperature rise consistency, the magnetic core is added at the center to compensate the magnetic field intensity of the magnetic core.

For example: the coil inner space is designed to be 85mm 25mm 30mm (length, width and height) after the tube end of the ESC copper tube is formed, silicon steel sheets are added at the position of the corresponding ESC tube, the thickness of the silicon steel sheets is 2.5mm, the width of the silicon steel sheets on the corresponding EC tube is 22mm, and the width of the silicon steel sheets on the corresponding S tube is 23 mm; since the center S-tube is at a large average distance from the coil, the magnetic field coupling is small. In order to make up for the defect, the coil magnetic cores are reasonably distributed, according to test verification, if the magnetic cores are all silicon steel sheets (for example, the width of the silicon steel sheet is 22mm) on the corresponding EC tube, the test shows that the heating of the middle S tube lags behind by 2-3S, and the phenomenon that the EC tube is over-burnt and the S tube is not welded well occurs when welding is carried out; this also occurs if the silicon steel sheets on the corresponding S-tubes are used (e.g., the width of the silicon steel sheet is 23 mm). And by adopting the distribution layout in the test, the temperature rise of the middle copper tube is basically matched with the temperature rise conditions of the two copper tubes, and the middle copper tube moves up and down during welding heating so as to finish uniform heating.

Wherein, adopt the distribution overall arrangement in the experiment, the intensification of middle copper pipe is identical basically with the intensification condition of both sides copper pipe, for example: the thickness of the silicon steel sheet at the S tube position is larger than that of the silicon steel sheet at the E, C tube position; the condition that the intermediate magnetic field is weak due to the coil structure is well compensated, and the temperature rise of the three tubes is finally reflected to be consistent.

Optionally, the induction coil is optimized or a magnetic core is added as required to change the magnetic field on the coil after being electrified. For example: silicon steel sheets are distributed on the induction coil and are processed into a half I-shaped structure to be clamped in the coil, wherein the thickness of the silicon steel sheets is 2.4-2.6mm, and the purpose is to reduce magnetic loss.

It is thus clear that heating region homogeneity can be realized about the material of selecting the magnetic core, design magnetic core structure, rational layout magnetic core position in this scheme of adoption technique.

In an alternative example, since the S-tube in the four-way valve is a copper tube located in the middle of the induction coil, the temperature rise hysteresis may occur due to less magnetic field coupling. Therefore, in the embodiment, the magnetic cores are distributed on the coils, the magnetic field distribution on the induction coils is changed, and the middle magnetic field intensity is enhanced, so that the temperature rise hysteresis phenomenon of an S pipe in the four-way valve during induction brazing is avoided, and more than two welding spots are welded simultaneously.

For example: two tubes of the electronic valve can be welded at the same time by distributing the magnetic core on the coil, and three tubes (for example, a C tube, an S tube and an E tube) of the four-way valve can be welded at the same time. The structure of the electronic valve can refer to the example shown in fig. 22, and the structure of the four-way valve can refer to the examples shown in fig. 4, fig. 5, fig. 13, fig. 14, fig. 15 and fig. 16.

Further, the induction coil can move up and down periodically during welding heating, thereby further improving heating uniformity.

In an alternative embodiment, the induction welding system may further comprise: induction coil, magnetic core and induction welding power. The induction power supply (for example, an induction welding power supply) may be an on-off power supply. The switching power scheme is explained in detail below.

In an alternative example, since most induction welding power supplies are single power supplies, the coil must form a loop, so that:

optionally, one power supply main body is designed to have two identical output ends, and then a half of the induction coil is designed to be an output power supply loop, which is called a half coil, so that the two output ends can form an induction heating area similar to a closed loop structure.

Optionally, the second scheme is to integrate two power supplies with the same model together, and then combine the two half coils into an induction heating area similar to a closed loop structure.

Optionally, the third solution is to design one power output terminal as two output terminals, so that the two output terminals in combination with the half coil can also be combined into an induction heating area similar to a closed loop structure.

Alternatively, the fourth scheme is a single output end of a power supply, and two half coils (for example, half coil 21) of the coil (for example, full coil 22) respectively connected by using an intermediate connecting bridge (for example, connecting bridge 5) can still be combined into an induction heating area similar to a closed loop structure, as shown in the schemes of fig. 6, 7 and 8. In the solutions shown in fig. 6, 7 and 8, the single output connection bridge structure further includes: a water receiving port 6 and an insulating partition 7.

Wherein, the water receiving port can indicate the quick-operation joint in water route, the convenient connecting water pipe of ability. The junction is isolated, and because of the special structure of the induction coil, current needs to flow through the whole loop of the coil, and at the place where the coils are close to each other, an insulating material needs to be used for isolating the two, so as to avoid short circuit.

Specifically, the coils of the first, second and third schemes do not need to be contacted with each other in the working process, so that the reliability is higher; the coil has various designable shapes, the effect is the same as that of a closed coil, the heating is uniform, the coil can be designed into various profiling shapes, the production requirement is met, and the compatibility is better.

Compared with the schemes shown in fig. 6, 7 and 8, the first, second and third schemes are that the half coils are an independent power supply loop, and the two half coils are combined into an integral induction heating source (for example, the two half coils can be combined into a full coil), and the heating effect is the same as that of a closed loop structure. The same way as the scheme shown in fig. 6, 7 and 8 realizes automation, and because the two half coils are not contacted with each other, the service life is longer, and the two half coils can be designed into various copying structures according to requirements.

For example: the shape of the induction coil can be designed into a required profiling structure according to requirements, and the profiling coil is obtained.

Specifically, the fourth scheme is that the half coil is contacted with the connecting bridge, so that the service life is influenced, and the reliability is slightly poor.

More optionally, according to the fourth aspect, in the first design, the half coil is in contact with the connecting bridge, and when the half coil is energized, the half coil is also easily ignited, and the contact abrasion and the like are likely to occur, so that the half coil has a short service life and is slightly poor in reliability, and if the contact position is selected from kerosene liquid seal or tungsten copper material, the durability of the half coil can be enhanced.

More specifically, the first scheme and the third scheme are respectively to change the structures of the host and the output transformer, so that the design and manufacturing cost is low; and the second scheme has high cost.

Optionally, the automatic opening and closing requirements can be met by using moving elements such as a cylinder, a servo motor and a hydraulic device in the opening and closing actions, the realization is easy, the magnetic core is added on the coil, the material, the magnetic core structure and the magnetic core position are reasonably selected, the welding requirements on the magnetic field are purposefully designed, and the applicability and the production efficiency can be greatly improved.

Wherein, the cylinder, the servo motor and the hydraulic device only provide the power of advancing and retreating, and any one of the actions of realizing opening and closing can be selected.

In an alternative embodiment, the induction brazing system may include: induction coil, magnetic core, induction brazing power, location frock and cooling device. The following is a detailed description of the preferred embodiment.

In an optional example, the switching power supply (i.e. the induction brazing power supply) uses the scheme one, namely the power supply main body is designed into two identical output ends, and then half of the induction coil is designed into an output power supply loop; silicon steel sheet is selected to the magnetic core, opens and shuts and selects the cylinder for use, and whole induction power supply's output coil is integrated on industrial robot.

Alternatively, the welding process of the induction brazing system can be described with respect to a four-way valve structure.

Specifically, four pipe openings of the four-way valve need to be welded, namely E, S, C, D pipes, E, S, C three copper pipes need to be welded at one time, corresponding induction coils need to be designed, and one-time brazing forming is achieved. The method can be divided into a high-low profile structure with a changeable valve ESC nozzle structure and a coil design, and can be seen in the examples shown in figures 13, 14, 15 and 16.

In an alternative example, the positioning tool and the cooling device may be configured as shown in fig. 17, 18, 19, 20 and 21. In the examples shown in fig. 17, 18, 19, 20 and 21, the positioning tool may further include a positioning nozzle 8; the cooling means may comprise a cooling circulation water circuit, the cooling level of which may be at F; the cylinders may include a first cylinder 41 and a second cylinder 42.

Optionally, for the induction brazing system, the four-way valve can be subjected to induction brazing by combining a positioning tool and a cooling device. Wherein, the process of carrying out the induction brazing to the cross valve can include:

(1) two cylinders are controlled to extend out through an air valve, so that the movement of a positioning block tool for limiting the pipe orifice is realized, and the cavity is exposed.

Wherein, the air valve, the two air cylinders, the limiting pipe orifice, the positioning block tool and the cavity in the step (1) can be seen in an example shown in fig. 21. The gas valve may be a switch-like component. In the cylinder and the stopper that links with it, square structure is the cylinder, and the stopper is "U" shape notch. The four-way valve is provided with a D pipe extending independently and three parallel ESC pipes.

(2) The four-way valve is placed on the positioning table in the inner cavity, and the D pipe extends out independently, so that the workpiece has a fool-proof function.

(3) And closing the air valve, moving the positioning slide block of the limiting pipe opening at the moment, closing the cavity, and calibrating and positioning the E, S, C, D pipe.

(4) The cavity sub-unit connection has the water pipe, pumps water in the cavity below, and when the surface of water exceeded the liquid level, unnecessary water flowed away, and the valve body (the valve body of cross valve) just submerged the valve body (promptly) to the water level this moment, and the valve body temperature maintains the normal atmospheric temperature basically when guaranteeing the welding, is unlikely to scald the plastics slider in the valve body.

(5) Then the valve body (namely the valve body of the four-way valve) and the copper pipe are matched and connected on the pipe orifice according to the design diagram, and the positioning and piping work is completed.

The inner cavity and the positioning table in the step (2), the positioning slide block in the step (3), the positioning slide block and the water pipe and the valve body in the step (4) are connected with the air cylinder in a linkage mode, and the example shown in the figure 18 can be seen. Because the cavity of the positioning tool is large, a quick connector water receiving pipe is welded at the position communicated with the interior of the cavity; the valve body is a four-way valve, and a small sliding block (plastic piece) for controlling the flow direction of the working medium is arranged in the four-way valve due to the steering effect of the four-way valve, so that the sliding block is prevented from being damaged by welding temperature, and the valve body needs to be cooled.

Through the steps (1) to (5) above, the brazed four-way valve can be seen in the examples shown in fig. 4 and 5.

In an optional example, the positioning tool and the cooling device can be combined into a whole, so that the positioning precision is ensured, and the welding appearance is full.

Optionally, the positioning tool and the cooling circulation water path are combined into one, the positioning is accurate, and the cooling is effective. For example: the positioning tool and the cooling circulation water path are combined into one, the positioning is accurate, and the cooling is effective.

In an alternative embodiment, the induction brazing system may further include: the robot can refer to the example shown in fig. 23. The following describes a welding process using the induction brazing system in detail with reference to a robot. In the example shown in fig. 23, the induction brazing system may include: transformer 1, induction coil 2, magnetic core 3 and cylinder 4.

Wherein, the profiling coil is positioned in combination with the robot, so that the welding applicability can be greatly improved. The robot moves to the welding position according to the set path for positioning, and the E, S, C pipes are welded simultaneously and then are welded separately by the robot for positioning the D pipes. Therefore, the welding workbench can be designed as a fixed workbench or a rotary table workbench, the welding design difficulty can be greatly reduced, the production universality is improved, and the flexible function of the robot is exerted to the maximum extent. The inlet and outlet space of the induction coil can be reserved in the design process of the four-way valve assembly, so that the design is more standard and reasonable, and the welding efficiency of the assembly is improved.

Wherein the induction coil may be a flush four-way valve welding coil 23, as shown in the examples of fig. 9 and 10. The induction coil may also be a chevron four-way valve soldered coil 24, as can be seen in the examples shown in fig. 11 and 12.

Optionally, the robot moves up and down during welding, and welding uniformity is improved.

Therefore, the robot positioning in the scheme can solve the difficult problem of automatic positioning and the problem of fixed-point or turntable universality of the workbench, thereby shortening the positioning time, improving the universality and improving the welding efficiency.

In an alternative example, the induction brazing system can also realize weld expansion.

Alternatively, the welding points with adjacent and equal height can be welded at one time, such as an electronic valve, as shown in fig. 22. In this way, the parallel pipeline welding points in the air conditioner can be welded without avoiding in the later design, and the welding process is not affected by each other, and the specific welding process can comprise:

1) a part (e.g.: electronic valve) and then the pipeline is assembled one by one according to the instruction of the assembly design drawing.

2) And moving the induction coil to a position needing welding through a robot positioning system.

3) The cylinder on the induction coil controls the extension of the connecting rod to drive the induction coil to be closed.

4) At this point, the welding program is called and the weld will undergo heating, holding and cooling processes.

5) And the cylinder on the induction coil retracts the connecting rod, the induction coil is opened, and the robot is reset.

6) And (5) repeating the steps 2) to 5) again in the whole system, completing welding of the welding points on the assembly in sequence, and repeating the whole welding action.

Therefore, the new brazing process can greatly exert the advantages of induction brazing, can replace flame brazing and is superior to the flame brazing.

In an alternative embodiment, the induction brazing system may further include: a communication device.

Optionally, the communication device may include: and an RS485 communication module. In the brazing process, welding parameters can be obtained, the welding parameters are output through RS485 communication on equipment (for example, the equipment can be an induction brazing system or a component in the induction brazing system), welding information is output and stored, and later-stage tracing and welding optimization improvement are achieved.

Therefore, the welding process is innovative, the equipment can monitor and extract welding information, a method is provided for long-term optimization of the process and informatization, a gas pipeline is not used, the layout of workshop pipelines is reduced, a firing station is eliminated, and the layout of a workshop is simpler.

Since the processing and functions implemented by the system of this embodiment substantially correspond to the embodiments, principles and examples of the apparatus shown in fig. 1 to 22, reference may be made to the related descriptions in the foregoing embodiments without specific details in the description of this embodiment, which is not described herein again.

A large number of tests prove that the technical scheme of the invention further improves the heating uniformity by the up-and-down periodic movement of the induction coil during welding heating.

There is also provided, in accordance with an embodiment of the present invention, a method of welding for an induction brazing system corresponding to the induction brazing system. The welding method of the induction brazing system can be based on the welding method of the induction brazing system.

Specifically, the welding method may include: welding the welding spot of the workpiece to be welded by the induction coil 2 in an electrifying and heating manner; and strengthening the magnetic field intensity of the welding seam corresponding to the set welding point at more than two different positions according to the distribution of the welding points of the workpiece to be welded so as to enable the induction coil 2 to weld more than two welding points simultaneously.

Optionally, when the workpiece to be welded may include a four-way valve, during the welding of the welding point of the workpiece to be welded by causing the induction coil 2 to be heated by energization and/or after the welding is finished, causing the induction coil 2 to be heated by energization and welded, which may specifically include:

1) after the positioning and piping work of the four-way valve is finished, the induction coil 2 is moved to the welding point of the workpiece to be welded through the control device.

2) And the cylinder in the welding head device is used for controlling a preset connecting rod to extend to drive the induction coil 2 to be closed.

3) And calling a preset welding program to enable the welding point to undergo heating, heat preservation and cooling processes.

4) The connecting rod is retracted through the cylinder, the induction coil 2 is opened, and the control device is reset.

Optionally, the welding point of the workpiece to be welded is welded by the induction coil 2 in an energization heating manner, and the method specifically may further include: and after one welding point of the four-way valve is finished, repeating the steps 1) to 4) to move the induction coil 2 to the next welding point of the workpiece to be welded.

In an alternative example, causing the induction coil 2 to perform welding on a welding spot of a workpiece to be welded in an electrically heated manner may include: before welding begins and/or after welding ends, opening the workpiece to be welded to enter a heating area in the induction coil 2; and the heating areas are combined into a whole during welding so as to surround the peripheries of more than two welding points.

In an alternative embodiment, before the welding spot of the workpiece to be welded by the induction coil 2 in the manner of heating by energization, the method may further include: an induction heating power supply is provided for the induction coil 2.

In an alternative embodiment, before the welding spot of the workpiece to be welded by the induction coil 2 in the manner of heating by energization, the method may further include: providing opening and closing drive for the induction coil 2 to open or close the induction coil 2; and/or providing moving drive for the induction coil 2, so that the induction coil 2 moves up and down when being electrified and heated.

In an alternative embodiment, before the welding spot of the workpiece to be welded by the induction coil 2 in the manner of heating by energization, the method may further include: and positioning and piping at least one of the induction coil 2, the magnetic core 3 and the workpiece to be welded.

In an alternative example, when the to-be-welded workpiece may include a four-way valve, the positioning and piping at least one of the induction coil 2, the magnetic core 3, and the to-be-welded workpiece may include:

(1) the two cylinders are controlled to extend out through a preset air valve, so that the positioning block tool at the position limiting pipe orifice of the positioning tool moves, and the inner cavity of the positioning tool is exposed.

(2) And placing the four-way valve on a positioning table in the inner cavity, and enabling a D pipe of the four-way valve to extend out independently.

(3) And closing the air valve, moving the positioning slide block at the limiting pipe orifice at the moment, closing the inner cavity, and calibrating and positioning the E pipe, the S pipe, the C pipe and the D pipe of the four-way valve.

(4) And pumping water into the inner cavity through a water pipe connected with the lower part of the inner cavity, and when the water level exceeds a set liquid level, the redundant water flows away, and at the moment, the water level just submerges the valve body of the four-way valve.

(5) And then the valve body is matched and connected with the copper pipe according to a set mode so as to complete the positioning and piping work of the four-way valve.

In an optional embodiment, during the welding of the welding spot of the workpiece to be welded by the induction coil 2 in an electrically heating manner, and/or after the welding is finished, the method may further include: and preserving the heat of the welding spots.

In an optional embodiment, during the welding of the welding spot of the workpiece to be welded by the induction coil 2 in an electrically heating manner, and/or after the welding is finished, the method may further include: and after welding is finished, cooling at least one of the induction coil 2, the magnetic core 3 and the workpiece to be welded.

In an optional embodiment, during the welding of the welding spot of the workpiece to be welded by the induction coil 2 in an electrically heating manner, and/or after the welding is finished, the method may further include: and acquiring welding parameters of at least one of the welding head device and the induction brazing system to which the welding head device belongs, and performing at least one of output, storage and display on the welding parameters to serve as a basis for optimizing at least one of a welding process and control parameters of the induction brazing system to which the welding head device belongs.

Since the processing and functions implemented by the method of the present embodiment substantially correspond to the embodiment, the principle and the example of the system shown in fig. 23, the description of the present embodiment is not detailed, and reference may be made to the related description in the foregoing embodiments, which is not described herein again.

A large number of tests prove that by adopting the technical scheme of the invention and adopting the open-close type induction coil structure, the coils are automatically combined into a whole during welding, and the coils are automatically opened after welding, so that the flexibility of induction brazing is enhanced, the application range is enlarged, and meanwhile, the heating uniformity and the welding efficiency are improved.

In summary, it is readily understood by those skilled in the art that the advantageous modes described above can be freely combined and superimposed without conflict.

The above description is only an example of the present invention, and is not intended to limit the present invention, and it is obvious to those skilled in the art that various modifications and variations can be made in the present invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the claims of the present invention.

Claims

1. A weld head device, comprising: an induction coil (2) and a magnetic core (3); wherein,

the induction coil (2) is used for welding a welding spot of a workpiece to be welded in an electrifying and heating mode;

the magnetic core (3) is arranged on the induction coil (2) and used for strengthening the magnetic field intensity of a welding seam corresponding to the set welding point at more than two different positions according to the distribution of the welding points of the workpiece to be welded so as to enable the induction coil (2) to weld more than two welding points simultaneously.

2. The apparatus of claim 1, wherein,

the structure of the magnetic core (3) comprises: at least one of a semi-I-shaped structure and a block-shaped structure; wherein, half I-shaped structure includes: a C-shaped structure;

and/or the presence of a gas in the gas,

the magnetic core (3) is installed in the induction coil (2) through a preset insulator;

and/or the presence of a gas in the gas,

the material of magnetic core (3) includes: at least one of silicon steel sheet and ferrite;

and/or the presence of a gas in the gas,

-the thickness of the magnetic core (3) comprising: 2.4-2.6 mm.

3. The device according to claim 1 or 2, characterized in that the structure of the induction coil (2) comprises: at least one of an open-close structure and a profiling structure; wherein,

the opening and closing structure is used for opening before welding starts and/or after welding ends so that the workpiece to be welded enters a heating area in the induction coil (2); and the heating zones are combined into a whole during welding so as to surround the peripheries of more than two welding points;

and/or the presence of a gas in the gas,

the profiling structure is formed by following the shape of the workpiece to be welded, so that the induction coil (2) with the profiling structure can be used for carrying out adaptive welding on the workpiece to be welded.

4. The apparatus of claim 3, wherein,

the induction coil (2) having the opening and closing structure includes: a first half-coil and a second half-coil; the first half coil and the second half coil, when combined together, form a full coil;

and/or the presence of a gas in the gas,

the induction coil (2) having the profiling structure, comprising: any one of a flush four-way valve welding wire ring (23) and a chevron four-way valve welding wire ring (24); wherein,

the flush four-way valve welding coil (23) is used for welding at least the C pipe, the S pipe and the E pipe which are arranged in flush in the four-way valve at one time; and/or the presence of a gas in the gas,

the welding wire coil (24) of the E-shaped four-way valve is used for welding at least C tubes, S tubes and E tubes which are arranged in the E shape in the four-way valve in a one-time mode.

5. The apparatus of claim 4, wherein,

the first half coil and the second half coil are symmetrically or asymmetrically arranged;

and/or the presence of a gas in the gas,

the first half coil and the second half coil have the same structure or different structures.

6. The apparatus of any of claims 1-5, further comprising: at least one of a power supply device, a driving device, a positioning tool and a communication device; wherein,

the power supply device is used for providing an induction heating power supply for the induction coil (2); the induction heating power supply includes: switching on and off a power supply;

and/or the presence of a gas in the gas,

the driving device is used for providing opening and closing driving for the induction coil (2) so as to open or close the induction coil (2); and/or providing movement drive for the induction coil (2) so that the induction coil (2) moves when being electrified and heated;

and/or the presence of a gas in the gas,

the positioning tool is used for positioning the workpiece to be welded;

and/or the presence of a gas in the gas,

the communication device is used for acquiring the welding parameters of at least one of the welding head device and the induction brazing system to which the welding head device belongs, and performing at least one of output, storage and display on the welding parameters, so as to serve as a basis for optimizing at least one of the welding process and the control parameters of the induction brazing system to which the welding head device belongs.

7. The apparatus of claim 6, wherein,

when the induction coil (2) comprises a first half-coil and a second half-coil,

the switching power supply comprises: the power supply comprises a power supply body, a connecting bridge (5) and an insulating partition (7); wherein,

the single output end of the power supply body is connected with the main body of the connecting bridge (5), a first bridge arm of the connecting bridge (5) is connected with the first half coil, and a second bridge arm of the connecting bridge (5) is connected with the second half coil; the device comprises a plurality of half coils, a plurality of bridge arms and a plurality of semi-coils, wherein the contact positions between the corresponding bridge arms and the corresponding semi-coils are provided with kerosene liquid seal structures and/or tungsten-copper material structures;

the insulation partition (7) is arranged between the first bridge arm and the second bridge arm;

or,

the switching power supply comprises: a power supply main body; a first output end of the power supply main body is connected with the first half coil to form a first output power supply loop; a second output end of the power supply main body is connected with the second half coil to form a second output power supply loop; wherein the first output end and the second output end have the same structure;

or,

the switching power supply comprises: a first power supply and a second power supply; the first power supply is connected with the first half coil, and the second power supply is connected with the second half coil;

or,

the switching power supply comprises: a power supply main body; the first output head of the output end of the power supply main body is connected with the first half coil; the second output head of the output end of the power supply main body is connected with the second half coil;

and/or the presence of a gas in the gas,

the driving device is used for providing the structure for opening and closing driving, and comprises: the device comprises a cylinder (4), a servo motor and a hydraulic device; wherein,

the hydraulic device, the servo motor and the cylinder (4) are sequentially matched and arranged; the air cylinder (4) is also matched with a power supply of the induction coil (2).

8. The apparatus of claim 7, wherein,

the switching power supply further comprises: a water receiving port (6);

the water receiving port (6) is arranged on at least one of the main body of the connecting bridge (5), the first bridge arm and the second bridge arm and is used for being connected with a cooling circulation water path when a cooling device of an induction brazing system to which the welding head device belongs comprises the cooling circulation water path so as to cool the induction coil (2) and/or the switching power supply;

and/or the presence of a gas in the gas,

the power supply body includes: a transformer (1); the transformer (1) is connected with an alternating current power supply to supply power according to the induction heating requirement of the induction coil (2);

and/or the presence of a gas in the gas,

the drive arrangement provides the drive that opens and shuts for induction coil (2), includes: providing opening and closing drive under the control of a control device of an induction brazing system to which the welding head device belongs;

and/or the presence of a gas in the gas,

the driving device enables the induction coil (2) to move up and down when being electrified and heated, and comprises: moving up and down periodically;

and/or the presence of a gas in the gas,

the communication device comprises: at least one of an RS485 module and an RS232 module.

9. The apparatus according to one of claims 1 to 8, wherein,

an induction heating distance between the induction coil (2) and the workpiece to be welded, comprising: 1-2 mm;

and/or the presence of a gas in the gas,

the induction coil (2) comprising: at least one of a long U-shaped induction coil and a semicircular induction coil;

and/or the presence of a gas in the gas,

the workpiece to be welded includes: a metal workpiece having more than two welding spots;

wherein the metal workpiece comprises: at least one of a four-way valve and an electronic valve.

10. An induction brazing system, comprising: a control device;

further comprising: the weld head device of any one of claims 1-9; wherein,

the control device is used for controlling the induction coil (2) in the welding head device to move.

11. The system of claim 10, wherein the control device comprises: a robot positioning system and a manipulator assembly; wherein,

the control end of the robot positioning system is connected with the manipulator component;

the manipulator component is connected with the welding head device.

12. The system of claim 10 or 11, further comprising: at least one of a heat-insulating device and a cooling device; wherein,

the heat preservation device is used for preserving heat of the welding spot in the welding process;

and/or the presence of a gas in the gas,

and the cooling device is used for cooling at least one of the induction coil (2), the magnetic core (3) and the workpiece to be welded after welding is finished.

13. A welding method based on the induction brazing system according to any one of claims 10 to 12, comprising:

welding the welding spot of the workpiece to be welded by the induction coil (2) in an electrifying and heating manner;

and according to the distribution and the reinforcement of the welding spots of the workpiece to be welded, setting the magnetic field intensity of the welding spots corresponding to the welding spots at more than two different positions so as to enable the induction coil (2) to weld more than two welding spots simultaneously.

14. The method according to claim 13, characterized in that causing the induction coil (2) to weld a weld spot of a workpiece to be welded in an electrically heated manner comprises:

before welding begins and/or after welding ends, opening the workpiece to be welded so that the workpiece to be welded enters a heating area in the induction coil (2); and the number of the first and second groups,

the welding points are combined into a whole during welding, so that the heating area surrounds the periphery of more than two welding points.

15. The method according to claim 13 or 14,

before the induction coil (2) is used for welding a welding point of a workpiece to be welded in an electrifying and heating mode, the method further comprises the following steps:

providing an induction heating power supply for the induction coil (2);

and/or the presence of a gas in the gas,

providing opening and closing drive for the induction coil (2) so as to open or close the induction coil (2); and/or providing moving drive for the induction coil (2) so as to enable the induction coil (2) to move up and down when being electrified and heated;

and/or the presence of a gas in the gas,

positioning tubing is carried out on at least one of the induction coil (2), the magnetic core (3) and the workpiece to be welded;

and/or the presence of a gas in the gas,

during and/or after welding of the welding point of the workpiece to be welded by the induction coil (2) in an electrifying and heating manner, the method further comprises the following steps:

insulating the welding spots;

and/or the presence of a gas in the gas,

after welding is finished, at least one of the induction coil (2), the magnetic core (3) and the workpiece to be welded is cooled;

and/or the presence of a gas in the gas,

and acquiring welding parameters of at least one of the welding head device and the induction brazing system to which the welding head device belongs, and performing at least one of output, storage and display on the welding parameters to serve as a basis for optimizing at least one of a welding process and control parameters of the induction brazing system to which the welding head device belongs.

16. The method according to claim 15, wherein when the workpiece to be welded comprises a four-way valve, the induction coil (2) is used for welding the welding point of the workpiece to be welded in an electrifying and heating mode, and the method specifically comprises the following steps:

1) after the positioning and piping work of the four-way valve is finished, the induction coil (2) is moved to a welding point of a workpiece to be welded through the control device;

2) the cylinder in the welding head device is used for controlling a preset connecting rod to extend to drive the induction coil (2) to be closed;

3) calling a preset welding program to enable the welding point to undergo heating, heat preservation and cooling processes;

4) the connecting rod is retracted through the cylinder, the induction coil (2) is opened, and the control device is reset;

make induction coil (2) treat the solder joint of welding the work piece with the mode of ohmic heating and weld, specifically still include:

and after one welding point of the four-way valve is finished, repeating the steps 1) to 4) to move the induction coil (2) to the next welding point of the workpiece to be welded.