WO2017011930A1 - 一种微张力送丝装置及含有该装置的桥丝自动焊接系统 - Google Patents

一种微张力送丝装置及含有该装置的桥丝自动焊接系统 Download PDF

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Publication number
WO2017011930A1
WO2017011930A1 PCT/CN2015/000555 CN2015000555W WO2017011930A1 WO 2017011930 A1 WO2017011930 A1 WO 2017011930A1 CN 2015000555 W CN2015000555 W CN 2015000555W WO 2017011930 A1 WO2017011930 A1 WO 2017011930A1
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WO
WIPO (PCT)
Prior art keywords
tension
wire
micro
feeding device
bridge
Prior art date
Application number
PCT/CN2015/000555
Other languages
English (en)
French (fr)
Inventor
魏德贤
魏博
Original Assignee
北京航天达盛电子技术有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 北京航天达盛电子技术有限公司 filed Critical 北京航天达盛电子技术有限公司
Publication of WO2017011930A1 publication Critical patent/WO2017011930A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H59/00—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators
    • B65H59/10—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators by devices acting on running material and not associated with supply or take-up devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H59/00—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators
    • B65H59/10—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators by devices acting on running material and not associated with supply or take-up devices
    • B65H59/16—Braked elements rotated by material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F42—AMMUNITION; BLASTING
    • F42B—EXPLOSIVE CHARGES, e.g. FOR BLASTING, FIREWORKS, AMMUNITION
    • F42B3/00—Blasting cartridges, i.e. case and explosive
    • F42B3/10—Initiators therefor
    • F42B3/195—Manufacture
    • F42B3/198—Manufacture of electric initiator heads e.g., testing, machines

Definitions

  • the invention relates to a micro tension wire feeding device and a bridge wire automatic welding system containing the same.
  • the core component of the electric ignition tube is an electrode plug welded with a bridge wire.
  • the ignition components in the electric ignition tube for the airbag, the industrial electric detonator, the military electric ignition device, and the like are all electrode plugs welded with the bridge wire.
  • the electrode plug is connected with an external circuit, and is a core component of components such as a car airbag, an industrial electric detonator, and a military ignition device.
  • the function of the electrode plug is to combine the functions of structural parts, fixed transducing elements, electrical insulation, airtightness, heat sinking, reflection ignition, etc., generally consisting of a bridge wire and two leg wires/electrodes.
  • the bridge wire is a resistance wire welded to the two leg wires/electrodes.
  • the bridge wire instantaneously heats up and heats the heat-sensitive ignition powder wrapped around the bridge wire when the temperature of the bridge wire reaches the point. After the ignition of the gunpowder, the ignition powder is ignited to achieve the function of the component.
  • the car airbag needs to open the airbag within tens of milliseconds in the event of an accident.
  • Material ignition medicine
  • the diameter of the general bridge wire is on the order of several tens of micrometers to ensure that the resistance is large enough to heat up quickly when energized, so that the small bridge ribbon has great welding difficulty.
  • the current production of electric ignition tubes for domestic airbags is only 3-4 million, which is completely unable to meet the market demand.
  • the electrode plug welding wire process of electric ignition tube is also widely used in industrial electric detonators, geological exploration source bombs, flood control and precipitation rockets, aircraft model launches, military rockets, military missiles, artillery shells, fireworks and firecrackers, etc. huge.
  • the process bottleneck of domestic electric ignition tube production is mainly that the bridge wire welding and electrical performance test are basically manual operation, so a technology capable of automatically mechanically welding the bridge wire will be an urgent problem to be solved in the field of electric ignition tube.
  • the bridge wire is generally a wire of the order of several tens of micrometers, such a small wire can only withstand a few grams of weight; if the bridge wire entering the bridge wire welding system is not subjected to tension, it is difficult to bridge the wire and the electrode Alignment welding, if the tension of the bridge wire is too large, it is easy to break the wire.
  • the object of the present invention is to overcome the deficiencies of the prior art and to provide a micro-tension wire feeding device which has a simple structure and a stable tension.
  • the micro-tension wire feeding device can generate the tension that the bridge wire can withstand, ensures the continuous wire of the bridge wire entering the automatic welding system of the bridge wire, and realizes the automatic, efficient and accurate welding electrode plug of the bridge wire automatic welding system.
  • the invention provides a micro tension wire feeding device, the technical proposal of which is:
  • a micro tension wire feeding device comprises a casing, a tension rod, a wire wheel, a clamping member and a tension wheel disposed on the casing, and a damper connected to the tension wheel; one end of the tension rod is connected with the casing The other end is provided with a pulley.
  • the damper is a hysteresis brake or a magnetic damper; the clamping member is a wool felt.
  • the housing is further provided with a magnetic adjustment rotary disc for adjusting the tension, and the magnetic adjustment rotary disc is connected with the magnetic damper.
  • the connecting end of the tension bar and the housing is provided with a rotating wheel, and the rotating wheel is provided with a recessed portion, the shell A broken wire alarm switch is also arranged on the body, and the broken wire alarm switch is provided with a detecting arm, and the detecting arm is in contact with the rotating wheel.
  • the housing is further provided with a back tension adjusting knob for adjusting the tension of the tension bar.
  • One end of the tension rod is hinged to the housing, and the tension rod is provided with a tension spring.
  • One end of the tension spring is connected with the tension rod, and the other end is adjusted with the back tension. Knob connection.
  • the casing is further provided with a wool felt adjusting knob, an anti-slip sheet and an indicator mark for adjusting the clamping force of the wool felt.
  • the micro-tension wire feeding device is supplied with a bridge wire, and the bridge wire sequentially bypasses the clamping member, the tension wheel and the wire-trailing wheel, and finally bypasses the pulley on the tension bar and is connected with the bridge wire welding system.
  • the micro tension wire feeding device can form a tension of 1 g to 10 g in weight to the bridge wire.
  • the invention also provides an automatic welding system for bridge wires, the technical scheme of which is:
  • An automatic welding system for bridge wire comprising a bridge wire positioning device and a micro tension wire feeding device, wherein the micro tension wire feeding device is a micro tension wire feeding device; the micro tension wire feeding device feeds the bridge wire into the bridge wire positioning device .
  • the utility model further comprises a supporting device, a tooling circulation device, a bridge wire welding device, a wire cutting device, a feeding device for feeding the electrode plug base body into the tooling circulation device;
  • the tooling circulation device comprises a circulation track and a pushing device, and the circulation track is provided with the tooling movement guide The slot and the pushing device push the tool to move in the circulating track;
  • the bridge wire positioning device is disposed on the circulating track;
  • the bridge wire welding device and the wire cutting device are disposed on the supporting device or on the circulating track.
  • the micro-tensile wire feeding device of the invention utilizes the principle of magnetisotropic suction, generates damping by magnetic field switching torque change, and has no mechanical friction, so that stable tension can be generated for a long time, and the precision can be effectively ensured. Adjusting the magnetic wheel produces a different amount of torque. When the bridge wire passes around the tension wheel, it needs to overcome the torque generated by the magnetic wheel.
  • the tension rod uses the principle of the lever to reduce the spring force with the slender rod, which plays a balancing role and buffering function, preventing the use of the segment speed too fast, breaking the wire and jumping. Silk, so that the filament is always straight.
  • the bridge wire automatic welding system of the invention solves the process bottleneck of the complete automation of the bridge wire welding, and the production efficiency is more reasonable and more efficient than the similar equipment process route of the individual companies in the United States. It can be widely used in the welding of bridge wires in the fields of automobile airbags, military various ignition devices, industrial electric detonators, geological exploration sources, rockets, aerospace models, and micro gas generators for seat belts.
  • the invention breaks the technical embargo and high-tech blockade of individual companies in the United States, greatly improves our competitiveness, and lays a good foundation for our products to completely replace imports, better meets the needs of the market, and drives the domestic industry. Development has enhanced the international competitiveness of related fields.
  • FIG. 1 is a schematic perspective view of a micro tension wire feeding device according to an embodiment of the present invention.
  • FIG. 2 is a schematic view showing the front structure of a micro tension wire feeding device according to an embodiment of the present invention
  • FIG. 3 is a schematic side view showing a structure of a micro tension wire feeding device according to an embodiment of the present invention.
  • FIG. 4 is a top plan view of a micro tension wire feeding device according to an embodiment of the present invention.
  • FIG. 5 is a cross-sectional structural diagram of a micro tension wire feeding device according to an embodiment of the present invention.
  • FIG. 6 is a schematic diagram of force analysis of a micro tension wire feeding device according to an embodiment of the present invention.
  • FIG. 7 is a top plan view of an automatic welding system for a bridge wire according to an embodiment of the present invention.
  • FIG. 8 is a front elevational view of an automatic welding system for a bridge wire according to an embodiment of the present invention.
  • FIG. 9 is a cross-sectional structural view of an electrode plug of a bridge wire automatic welding system according to an embodiment of the present invention.
  • FIG. 10a is a schematic side view showing the electrode plug electrode surface (B side) of the bridge wire automatic welding system according to an embodiment of the present invention
  • FIG. 10b is a view showing the electrode plug welding surface of the bridge wire automatic welding system according to an embodiment of the present invention (A).
  • FIG. 11 is a perspective view showing the three-dimensional structure of a tooling cycle device for an automatic welding system for a bridge wire according to an embodiment of the present invention
  • FIG. 12 is a top plan view showing a tooling cycle device of an automatic welding system for a bridge wire according to an embodiment of the present invention.
  • FIG. 13 is a schematic diagram of a bridge wire positioning device for a bridge wire automatic welding system according to an embodiment of the present invention.
  • FIG. 14 is a partial schematic view showing a bridge wire and a crochet of a bridge wire positioning device of an automatic welding system for a bridge wire according to an embodiment of the present invention
  • a micro tension wire feeding device provided by the embodiment includes a housing 300 , a tension bar 301 , a wire passing roller 304 , a clamping member and a tension wheel 302 disposed on the housing 300 . And a damper that is drivingly coupled to the tension wheel 302; the damper may be a hysteresis brake or a magnetic damper 315.
  • the damper is a magnetic damper 315 and the clamping member is a wool felt 305.
  • One end of the tension bar 301 is connected to the housing 300, and the other end is provided with a pulley 306.
  • the bridge 96 is oriented as follows: the bridge wire 96 passes through the wool felt 305 and then enters the tension wheel that is drivingly connected to the magnetic damper 315. 302, the bridge wire 96 is wound around the tension wheel 302, the tension wheel 302 is rotatable about the central axis of the magnetic damper 315, and the magnetic damper 315 provides a constant torque to the tension wheel 302 to provide tension to the bridge wire 96, and then The wire wheel 304 is bypassed and finally passed around the pulley 306 fixed to the tension bar 301 and supplied to the bridge wire welding system.
  • the bridge wire 96 is a nickel-chromium resistive alloy wire, and the diameter of the bridge wire 96 is 0.010 mm to 0.050 mm, and preferably the diameter of the bridge wire 96 is 0.020 mm or 0.024 mm or 0.028 mm.
  • the micro-tension wire feeding device can form a tension of 1g to 10g which can be withstood by the bridge wire 96, ensuring that the bridge wire 96 entering the automatic welding system of the bridge wire is continuously wire and easy to be aligned and welded; the automatic welding system of the bridge wire is realized automatically. Efficient and accurate welding electrode plug.
  • the housing 300 of the micro-tensile wire feeder 3 is further provided with a magnetic adjustment dial 303 for adjusting the tension, and the magnetic adjustment dial 303 is coupled to the magnetic damper 315.
  • the end of the tension bar 301 connected to the housing 300 is provided with a rotating wheel 313.
  • the rotating wheel 313 is provided with a recessed portion 314.
  • the housing 300 is further provided with a broken wire alarm switch 307.
  • the broken wire alarm switch 307 is provided with a detecting arm 312.
  • the detecting arm 312 is in contact with the rotating wheel 313; when the wire is broken during use, the tension bar 301 is attached Yang, the recessed portion 314 of the rotating wheel 313 is rotated to the lower end portion of the detecting arm 312, so that the detecting arm 312 cannot be touched to the rotating wheel 313, thereby triggering the wire breaking alarm switch 307 to alarm.
  • the housing 300 is further provided with a back tension adjusting knob 308 for adjusting the tension of the tension bar 301.
  • One end of the tension bar 301 is hinged with the housing 300.
  • the tension bar 301 is provided with a tension spring, and one end of the tension spring is connected with the tension bar 301, and One end is connected to the back tension adjusting knob 308, and the magnitude of the back tension of the tension bar 301 is adjusted by adjusting the position of the tension spring.
  • the casing 300 is further provided with a wool felt adjusting knob 309 for adjusting the clamping force of the wool felt 305, which ensures that the wool felt 305 gives a suitable clamping force to the bridge wire 96.
  • the micro tension wire feeding device is also provided with a fixing seat 310 that fixes the housing 300.
  • the tension wheel 302 is provided with an anti-slip sheet that prevents the bridge wire 96 from slipping.
  • the micro tension wire feeding device is further provided with an indication mark. In normal use, the tension bar 301 is flush with the indicator mark, and if not flush, it can be adjusted by the back tension adjustment knob 308 and the magnetic adjustment knob 303.
  • A is the tension rod pulley end
  • B is the end of the tension rod connected to the housing
  • C is the connection position of the tension spring and the tension rod
  • L AC , L BC respectively indicate the length of AC and BC
  • the tension rod is tensioned spring
  • the length ratio of the length of the joint to the pulley end to the joint of the tension spring to the joint of the housing is 10:1 to 100:1 (L AC : L BC ).
  • the wire feeding device of the embodiment ensures that the bridge wire can realize stable wire feeding under the action of small tension, and meets the requirement of automatic wire feeding.
  • the magnetic damper uses the principle of magnetism to connect the main and passive pair of magnetic pairs through a magnetic contactless connection for torque transmission.
  • the damping torque can be adjusted from zero to the maximum.
  • the magnitude of the damping torque during operation can be kept constant for a long time and does not change with the change of the rotational speed of the primary and passive secondary phases.
  • the magnetic damper consists of two half pairs, the knot The structure is simple, and the magnetic connection is made during the operation, and the two have no direct contact friction.
  • the gap adjustment ie torque adjustment
  • the gap adjustment is convenient, the installation size is small, the service life is long, and there is no fault.
  • the magnetic damper can be used by: (1) fixing the magnetic pair of the damper to an arbitrary half, and the other half rotating with the wire shaft, and the damper will apply a constant damping torque to the wire shaft. If the half pair is mounted on the sizing guide shaft, the wire and the belt are led out on the sizing guide wheel to cause the wire to have a constant tension. (2) Fixing the magnetic pair of the damper to the power shaft, and fixing the other half on the passive shaft. When the power shaft rotates, a constant rotational torque is obtained on the passive shaft, and the magnetic pair of the damper After the clearance is set, the torque obtained on the passive shaft does not change due to the change in slip caused by the load change.
  • This embodiment also provides a bridge wire welding system for welding a bridge wire to an electrode plug base.
  • an electrode plug to be prepared comprising a core electrode 90, a bridge wire 96, an insulating layer 91 and a plug 92 with a hole, the core electrode 90 being disposed in the hole of the plug 92, the core electrode An insulating layer 91 is disposed between the 90 and the plug 92.
  • the first electrode pin 93 is connected to the plug 92, and the second electrode pin 94 is connected to the core electrode 90.
  • the bridge wire 96 is welded to the core electrode 90 and the plug 92.
  • the plug 92 has two or more solder joints 97; the core electrode 90 is disposed inside the plug 92 with holes, and then the core electrode 90 and the plug 92 are insulated by an insulating material. Since the plug 92 has a large welding area and is easy to weld, it is only necessary to weld the bridge wire 96 to the core electrode 90 during the mechanical welding process.
  • the first electrode needle 93 and/or the second electrode needle 94 are provided with a bent portion 95.
  • the diameter of the curved portion of the bent portion 95 is 0.2-0.6 mm; in this embodiment, it is preferably 0.3-0.5 mm, and specifically 0.45 mm.
  • the bending portion is arranged such that the electrode needle is close to the center of the plug 92 and is easy to handle during mechanical welding.
  • the first electrode pin 93 and the plug 92 are connected by welding, and the second electrode pin 94 and the core electrode 90 are the same wire; the first electrode pin 93 and the second electrode pin 94 have curved bends in the same direction. a folded portion; the electrode needle is plated with copper or gold; the shape of the electrode plug is any one of a circular shape, a square shape, and an elliptical shape; and the shape of the hole of the plug 92 is any one of a circular shape, a square shape, and an elliptical shape;
  • the hole of the plug 92 of the present embodiment is preferably circular; in this embodiment, the plug 92 and the insulating layer 91 are both annular, the annular insulating layer 91 encloses the core electrode 90, and the circular plug 92 encloses the circular ring.
  • the insulating layer 91; the core electrode 90 is an iron-nickel-cobalt alloy material, which is similar to the thermal expansion and contraction coefficient of the bridge wire 96; the insulating layer 91 may be selected from a ceramic material or a thermosetting plastic injection molding material or a high-temperature sintering glass.
  • the glass, the plug 92 is a metal material.
  • the diameter of the electrode plug is 5 to 10 mm, the thickness of the insulating layer 91 between the core electrode 90 and the plug 92 is 0.5 to 1.2 mm, and the diameter of the core electrode 90 is 0.6 to 2 mm.
  • the diameter of the electrode plug is 7.1 mm
  • the insulating layer 91 between the core electrode 90 and the plug 92 is 0.827 mm thick
  • the diameter of the core electrode 90 is 1.026 mm.
  • the bridge wire 96 is a nickel-chromium resistive alloy wire, and the diameter of the bridge wire 96 is 0.020 mm or 0.024 mm or 0.028 mm.
  • the electrode plug of the embodiment can generate heat of more than 1000 degrees Celsius in an instant of 3 milliseconds, and the use performance is superior.
  • a bridge wire welding system provided by the embodiment includes: a tooling circulation device 2 for transmitting an electrode plug base body (electrode plugs of unwelded bridge wires), and feeding the disordered electrode plug base body into the tooling
  • the feeding device 1 of the circulation device is used for conveying the bridge wire and applying a certain tension of the bridge wire to the micro tension wire feeding device 3 (the specific structure is as shown in the above embodiment), and aligning the welding wire of the bridge wire 96 with the electrode plug base body
  • the bridge wire positioning device 4 the bridge wire welding device 5 for welding the bridge wire and the electrode plug base body, the wire cutting device 6 for cutting the bridge wire, the detecting device 7 for detecting whether the electrode plug is qualified for welding, and the supporting device 80
  • the support device 80 is used to support the tooling circulation device 2 or other device components, the micro tension wire feeding device 3 can be mounted on the support device 80; the bridge wire positioning device 4 is disposed on the circulation track 20; the micro tension wire feeding device 3, the bridge The wire bonding device 5 and the
  • the feeding device feeds the electrode plug base into the tooling in the circulation track, and the electrode plug base moves along the tooling in the circulating track, sequentially passes through the bridge wire positioning device, the bridge wire welding device and the wire cutting device; the bridge wire positioning device and the micro
  • the bridge wire connected by the tension wire feeding device is positioned on the core electrode and the plug of the electrode plug base body, and the bridge wire welding device welds the bridge wire on the electrode plug base body, and the welded electrode plug moves to the lower side of the wire cutting device through the circulation track, and cuts
  • the wire device cuts the bridge wire on the welded electrode plug, and the electrode plug enters the detecting device, thus repeating the welding of the next electrode plug base.
  • the bridge wire welding device 5 can select a current hot-melt type welding machine; the feeding device 1 can select a magnetic centrifugal vibration feeding device, which solves the problem that the electrode plug base body is difficult to enter the track; the detecting device 7 can select the resistance type detecting device, The problem of low manual welding efficiency and unstable welding is solved; the electrode plug base body can select the glass sintered electrode plug base body, which breaks the disadvantage that the electrode plug is difficult to adopt mechanical welding.
  • the tooling circulation device provided in this embodiment includes a circulation rail 20, a pushing block 21 and a pushing device 22.
  • the circulating rail 20 is provided with a movement guide groove of the tooling 23.
  • the electrode plug base body is placed in the tooling 23,
  • the pushing block 21 is used to push the tooling 23 to move in a stepwise manner, the pushing device 22 controls the pushing block 21 to move;
  • the pushing device 22 is a pneumatic pushing device, the pneumatic pushing device comprises a cylinder and a cylinder bracket for supporting the cylinder;
  • the circulating track 20 is a shape
  • the chain type circulating track 20, the pushing device 22 is disposed at the four corners of the return rail, and the pushing devices 22 at the four corners can be diagonally linked.
  • the tooling cycle device of the embodiment has a simple structure and is convenient to use, and can carry out the cyclic transfer of the tooling 23, thereby automatically and continuously feeding the electrode plug base body to the welding machine for welding.
  • the tooling 23 is provided with a recess 24 for marking the mounting direction of the electrode plug and a mounting hole 25 for mounting the electrode plug base.
  • the diameter of the mounting hole 25 is larger than the diameter of the base of the electrode plug;
  • the X direction is the distance of the width of the tooling 23, and the distance of the stepwise movement is the distance of the length of the tooling 23 in the Y direction;
  • the pushing device 22 is further provided with a sensor for detecting the position of the tooling 23;
  • the circulation track 20 is provided with The robot 26 is configured to move the electrode plug base conveyed by the feeding device into the mounting hole of the tooling 23;
  • the circulation rail 20 is provided with a first positioning detecting device 27 and a second positioning detecting device 28, and the first detecting device 27 is used for
  • the position of the tooling 23 on the circular track 20 is positioned to adjust the action of the robot, and the second detecting device 28 is configured to detect whether the electrode plug base in the tooling hole is flat;
  • the circulating track 20 is provided with an infrared detecting device 29 for detecting the cycle.
  • the alarm stops circulating.
  • the working process is that the tooling is sequentially installed in the circulation track, and the robot moves the electrode plug base body sent by the feeding device to the mounting hole on the tooling, and then the pushing device pushes the pushing block to move stepwise, thereby realizing the tooling cycle.
  • the diameter of the mounting hole is slightly larger than the diameter of the electrode plug base. If the welding surface of the electrode plug base is not horizontal, if the electrode plug base is not flat, the electrode plug base can be adjusted by pressing the electrode plug base welding surface or adjusting the swing electrode needle. The welding surface level ensures the welding accuracy.
  • the bridge wire positioning device provided in this embodiment includes a plurality of pressure rollers 40 respectively disposed on two sides of the welding device 5, preferably including more than two crochet pins. 43.
  • a part of the crochet 43 has a hook direction inward, and another part of the crochet 43 has a hook direction outward.
  • the crochet 43 is disposed between the pressure rollers 40, so that the core electrode of the bridge wire and the electrode plug base can be accurately positioned.
  • the bridge wire positioning device further includes a biasing device 42 for applying a force to the pressure roller and a spring 41 for transmitting the force.
  • the spring 41 is disposed between the pressure roller 40 and the force applying device 42 to ensure uniform pressure of the pressure roller 40;
  • the wire positioning device further comprises a positioning pulley 44 for feeding the bridge wire and a wire clamping wheel 45 for clamping the bridge wire, the positioning pulley 44 is for conveying the bridge wire, and the wire clamping wheel 45 is used for clamping the bridge wire when the bridge wire is first stretched. , the bridge wire is positioned on the welding horizontal line.
  • the bridge wire positioning device may further comprise an observation device 47 for observing whether the core wire of the bridge wire and the electrode plug base is aligned, and the observation device 47 may be a magnifying glass.
  • the bridge wire positioning device has the advantages of simple structure and convenient use, and can accurately position the bridge wire of the order of several tens of micrometers in diameter and the millimeter-level core electrode of the electrode plug base body to realize mechanical automatic welding of the bridge wire.
  • the bridge wire When the bridge wire is stretched, the bridge wire is pulled out from the coil, passes through the tension rod on the micro tension wire feeding device, and is turned through the pulley, passing through the crochet (by crochet positioning to ensure the center of the bridge wire is aligned with the electrode plug). Then, the bridge wire is clamped at the wire wheel, and the tensioner tightens the bridge wire, and then the pressure wire wheel presses the bridge wire on the tooling.
  • the movement of the tooling is used to drive the forward movement of the bridge wire.
  • This embodiment also provides a method of using a bridge wire welding system, which is specifically as follows:
  • a bridge wire welding system includes a vibrating plate 10 for automatic loading, a base 11 for fixing the vibrating plate, and a linear feeder 13 for conveying raw materials for gripping the electrode plug a base robot 26, a first positioning detecting device 27 for positioning the tooling, a second positioning detecting device 28 for detecting whether the electrode plug base in the tooling hole is flattened, and a pushing device 22 for pushing the tooling for pulling a micro-tension wire feeding device 3 for a tight bridge wire, a positioning pulley 44, a wire clamping wheel 45 for clamping a bridge wire, a pressure wire wheel 40, a bridge wire welding device 5 for welding a bridge wire, for cutting a bridge wire
  • a console 8 that controls the operation of the automation system.
  • the method of using the bridge wire welding system is as follows:
  • boot check Open the main console 8, check whether the equipment power, air pressure, feeding, etc. are normal.
  • a magnetic centrifugal vibration automatic feeding device is preferred, and an appropriate amount of electrode plug base body is added into the vibrating plate 10, and the electrode plug base body is arranged one by one by the vibrating plate 10, and continuously sent to the linear feeder 13, The electrode plug substrate is then transported to the gripping position of the robot 26 by the loading rail vibration.
  • the shape of the track transfer There are a total of 118 numbered fixtures on the track, the four corners of the track four pneumatic push device 22 diagonally linked to promote the tooling cycle.
  • Electrode plug base transmission When the infrared detecting device detects that the robot gripping position has the electrode plug base body, the robot grabs the electrode plug base body and moves to the upper part of the tooling, and the first positioning detecting device 27 positions the tooling in the rail. The robot puts the electrode plug base into the tooling. The tooling device pushes the tooling to the second positioning detecting device 28, and the second positioning detecting device 28 positions the electrode plug base to ensure that the electrode plug base is at the same level as the tooling, and the tooling is pushed forward.
  • Welding The system starts counting the tooling with the workpiece from the mechanical hand material. When the tooling is pushed to the position of the bridge wire welding device, the system automatically recognizes and starts the welding system. The bridge wire is then welded to the electrode plug substrate by a bridge wire soldering device.
  • the working principle of the welding machine the automatic detection system before welding detects the electrode plug base in the tooling, then clamps the cylinder to clamp the electrode plug base body, the welding head is pressed down, and the welding head and the electrode plug are ensured by the universal joint at the clamp welding head. The base contact surface is completely bonded, and then the current passes through the contact surface of the horn to form an instant thermal fusion to complete the welding.
  • the outlet detection the system counts the tool forward from the resistance detection position, and the non-conforming product is pushed to the non-conforming product outlet 70, which is automatically recognized by the system and then driven by the high-pressure airflow, and the qualified product is pressurized from the qualified product outlet 71 by the high-pressure airflow. Hit out.
  • the discharge pipe connected to the discharge port is equipped with an automatic monitoring device. If the material is not discharged, the system automatically alarms and stops.
  • the electrode plug base is defined as a structural member that is not welded with a bridge wire, and is referred to as an electrode plug (electric ignition device) after being welded with a bridge wire.

Abstract

提供一种微张力送丝装置（3）及含有该装置的桥丝自动焊接系统。微张力送丝装置（3）包括壳体（300），以及设置在壳体（300）上的张力杆（301）、过丝轮（304）、夹紧件（305）和张力轮（302），以及与张力轮（302）传动连接的阻尼器；张力杆（301）的一端与壳体（300）连接，另一端设置有滑轮（306）。桥丝自动焊接系统包括微张力送丝装置（3）、桥丝定位装置（4），微张力送丝装置（3）将桥丝（96）送入桥丝定位装置（4）。

Description

一种微张力送丝装置及含有该装置的桥丝自动焊接系统 技术领域
本发明涉及一种微张力送丝装置及含有该装置的桥丝自动焊接系统。
背景技术
随着汽车工业的飞速发展，汽车安全将提升到更高的层次和水平，给汽车被动安全系统核心初始触发元件的电点火管提出了更高的质量要求。电点火管的核心部件是焊有桥丝的电极塞。安全气囊用电点火管、工业电雷管、军用电点火具等中的发火部件都是焊有桥丝的电极塞。在实际使用中，电极塞与外电路连接，是汽车安全气囊、工业电雷管、军用点火具等构件的核心元器件。电极塞的作用是兼有结构件、固定换能元、电绝缘、气密、热沉、反射点火等功能，一般由桥丝和两条脚线/电极组成。桥丝是一根焊接在两条脚线/电极上的电阻丝，当电流通过后，桥丝瞬间发热，并加热包裹在桥丝周围的对热敏感的点火药，当桥丝的温度达到点火药的着火点后，点火药发火从而实现部件功能。
众所周知，为了降低车祸人员伤亡，汽车安全气囊需要在发生事故时的几十毫秒之内打开气囊，这就要求电极塞上的桥丝焊接良好并能够瞬间点燃包裹在桥丝上的遇热易燃材料(点火药)，一般桥丝的直径是几十微米数量级以确保电阻足够大，通电时能够迅速发热，如此细小的桥丝带来了极大的焊接难度。据不完全统计，目前国内汽车需求的汽车安全气囊用电点火管大概为1亿个左右，由于技术的限制，目前全球只有美国个别公司拥有自动机械焊桥丝生产线，而国内现有的电点火管基本都是手工焊接桥丝，手工焊接桥丝大多采用钎焊工艺，手工焊存在以下不足之处：(1)桥丝电阻阻值离散度受人为因素的影响大；(2)由于残留钎剂的作用，焊接接头中同时存在着介质腐蚀和电化学腐蚀，这两类腐蚀的择优腐蚀部位均是与桥丝接合的部位，故采用这种手工钎焊工艺形成的电雷管引火装置的桥丝阻值在贮存期内会因腐蚀速率不同而无规则地加大，严重时会导致电雷管发火失效；(3)焊接环境中存在氯化锌(ZnCl)或氯化铵 (NH4Cl)有害气体和重金属铅(Pb)等的蒸发，危害环境；(4)焊接作业方式对焊工视力要求高、损伤大，会造成电光性角膜炎等疾病；(5)焊接效率很低，劳动强度大，难以满足市场需求。
受到上述制约，目前国内汽车安全气囊用电点火管生产量大概仅有3-4千万个，完全不能满足市场的需求。而且电点火管的电极塞焊桥丝工艺还广泛应用于工业电雷管、地质勘探震源弹、防雹增雨火箭弹、航模发射、军用火箭弹、军用导弹、炮弹、烟花爆竹等领域，需求十分巨大。国内电点火管生产的工艺瓶颈主要是桥丝焊接和电性能测试目前基本都是人工作业为主，故一种能够自动机械焊接桥丝的技术将是电点火管领域亟需解决的问题。
目前，桥丝一般为几十微米数量级的金属丝，如此细小的金属丝仅仅能够承受几克的重量力；如果进入桥丝焊接系统的桥丝没有受到张力，那么很难把桥丝与电极塞对准焊接，如果桥丝受到的张力过大，那么容易断丝。
发明内容
本发明的目的在于克服现有技术的不足，提供一种结构简单、张力大小稳定的微张力送丝装置。所述微张力送丝装置能够产生桥丝所能够承受的张力，确保进入桥丝自动焊接系统的桥丝不断丝，实现桥丝自动焊接系统自动、高效、准确的焊接电极塞。
本发明提供的一种微张力送丝装置，其技术方案为：
一种微张力送丝装置，包括壳体，设置在壳体上的张力杆、过丝轮、夹紧件和张力轮，以及与张力轮传动连接的阻尼器；张力杆的一端与壳体连接，另一端设置有滑轮。
本发明提供的一种微张力送丝装置，还可以包括以下附属技术方案：：
其中，阻尼器是磁滞制动器或者磁阻尼器；夹紧件是羊毛毡。
其中，壳体上还设置有调节张力大小的磁力调节旋盘，磁力调节旋盘与磁阻尼器连接。
其中，张力杆与壳体的连接端设置有旋转轮，旋转轮上设置有凹陷部，壳 体上还设置有断丝报警开关，断丝报警开关设置有检测臂，检测臂与旋转轮触接。
其中，壳体上还设置有调节张力杆张力的反张力调节旋钮，张力杆的一端与壳体铰接，张力杆上设置有拉簧，拉簧的一端与张力杆连接，另一端与反张力调节旋钮连接。
其中，壳体上还设置有调节羊毛毡夹紧力的羊毛毡调节旋钮、防滑片和指示标志。
其中，所述微张力送丝装置上供给有桥丝，桥丝依次绕过夹紧件、张力轮、过丝轮，最后绕过张力杆上的滑轮后与桥丝焊接系统连接。
其中，微张力送丝装置能够对桥丝形成1g～10g重量大小的张力。
本发明还提供一种桥丝自动焊接系统，其技术方案为：
一种桥丝自动焊接系统，包括桥丝定位装置、微张力送丝装置，微张力送丝装置是上述的一种微张力送丝装置；微张力送丝装置将桥丝送入桥丝定位装置。
其中，还包括支撑装置、工装循环装置、桥丝焊接装置、切丝装置、将电极塞基体送入工装循环装置的送料装置；工装循环装置包括循环轨道和推送装置，循环轨道设置有工装运动导槽，推送装置推动工装在循环轨道内移动；桥丝定位装置设置在循环轨道上；桥丝焊接装置和切丝装置设置在支撑装置上或者循环轨道上。
本发明的实施包括以下技术效果：
本发明的微张力送丝装置利用磁铁异性相吸原理，通过磁场转换扭矩变化产生阻尼，无机械摩擦，因此能长期产生稳定张力，且精度能得到有效保证。调节磁力轮可产生大小不同的扭力。桥丝绕张力轮通过，就需要克服磁力轮产生的扭力，张力杆通过杠杆原理，将弹簧力用细长杆放小，起到平衡作用和缓冲作用，防止使用段速度过快断丝、跳丝，使细丝始终绷直。还能够自由地调整反张力，可以适应方型骨架的绕丝和急剧变化绕丝速度的绕丝，不会产生断 丝。断丝和丝材用完时，由装备的断丝检测装置报警，绕丝机自动停止。羊毛毡可起到夹紧及过滤桥丝的作用，张力轮是产生主张力的部件，张力调节旋盘是调节张力大小的部件。
本发明桥丝自动焊接系统解决了桥丝焊接完全自动化的工艺瓶颈，生产效率比美国个别公司的同类设备工艺路线更合理、效率更高。可广泛用于汽车安全气囊、军用各种点火具、工业电雷管、地质勘探振源弹、增雨防雹火箭、航空航天模型、安全带用微型气体发生器等领域中桥丝的焊接。本发明打破了美国个别公司的技术禁运和高技术封锁，大大提高了我们的竞争力，为我们的产品完全替代进口打下了良好的基础，更好的满足了市场的需求，带动国内行业的发展，增强了相关领域的国际竞争力。
附图说明
图1为本发明实施例的一种微张力送丝装置立体结构示意图
图2为本发明实施例的一种微张力送丝装置正面结构示意图
图3为本发明实施例的一种微张力送丝装置侧面结构示意图
图4为本发明实施例的一种微张力送丝装置俯视结构示意图
图5为本发明实施例的一种微张力送丝装置剖面结构示意图
图6为本发明实施例的一种微张力送丝装置受力分析示意图
图7为本发明实施例一种桥丝自动焊接系统的俯视示意图
图8为本发明实施例一种桥丝自动焊接系统的正面示意图
图9为本发明实施例一种桥丝自动焊接系统的电极塞截面结构示意图
图10a为本发明实施例一种桥丝自动焊接系统的电极塞电极针面(B面)侧视结构示意图；图10b为本发明实施例一种桥丝自动焊接系统的电极塞焊接面(A面)侧视结构示意图
图11为本发明实施例一种桥丝自动焊接系统的工装循环装置立体结构示意图
图12为本发明实施例一种桥丝自动焊接系统的工装循环装置俯视结构示 意图
图13为本发明实施例一种桥丝自动焊接系统的桥丝定位装置示意图
图14为本发明实施例一种桥丝自动焊接系统的桥丝定位装置桥丝与钩针的局部示意图
具体实施方式
下面将结合实施例以及附图对本发明加以详细说明，需要指出的是，所描述的实施例仅旨在便于对本发明的理解，而对其不起任何限定作用。
参见图1至图5，本实施例提供的一种微张力送丝装置，包括壳体300，以及设置在壳体300上的张力杆301、过丝轮304、夹紧件和张力轮302，以及与张力轮302传动连接的阻尼器；阻尼器可以是磁滞制动器或者磁阻尼器315，本实施例中，阻尼器是磁阻尼器315，夹紧件是羊毛毡305。张力杆301的一端与壳体300连接，另一端设置有滑轮306；本实施例中桥丝96的走向如下：桥丝96通过羊毛毡305，然后进入与磁阻尼器315传动连接的张力轮302，桥丝96绕张力轮302缠绕一周，张力轮302可以绕磁阻尼器315的中心轴旋转，磁阻尼器315为张力轮302提供恒定的扭矩，从而为桥丝96提供张力，然后绕过过丝轮304，最后绕过固定在张力杆301上的滑轮306后供给至桥丝焊接系统。桥丝96是镍铬电阻合金丝，桥丝96的直径为0.010mm～0.050mm，优选桥丝96的直径为0.020mm或者0.024mm或者0.028mm。微张力送丝装置能够对桥丝96形成其所能够承受的1g～10g重量大小的张力，确保进入桥丝自动焊接系统的桥丝96不断丝且容易对准焊接；实现桥丝自动焊接系统自动、高效、准确的焊接电极塞。
作为本实施例的进一步优选，微张力送丝装置3的壳体300上还设置有调节张力大小的磁力调节旋盘303，磁力调节旋盘303与磁阻尼器315连接。张力杆301与壳体300连接的端部设置有旋转轮313，旋转轮313上设置有凹陷部314，壳体300上还设置有断丝报警开关307，断丝报警开关307设置有检测臂312，检测臂312与旋转轮313触接；当使用过程中断丝时，张力杆301上 扬，旋转轮313的凹陷部314转动到检测臂312的下端部，致使检测臂312不能触接到旋转轮313，从而触发断丝报警开关307报警。壳体300上还设置有调节张力杆301张力的反张力调节旋钮308，张力杆301的一端与壳体300铰接，张力杆301上设置有拉簧，拉簧的一端与张力杆301连接，另一端与反张力调节旋钮308连接，通过调节拉簧的位置实现调节张力杆301反张力的大小。壳体300上还设置有调节羊毛毡305夹紧力的羊毛毡调节旋钮309，能够确保羊毛毡305给予桥丝96合适的夹紧力。微张力送丝装置还设置有固定壳体300的固定座310。张力轮302设置有防止桥丝96打滑的防滑片。微张力送丝装置还设置有指示标志，正常使用情况下张力杆301与指示标志齐平，如果不齐平，可以通过反张力调节旋钮308和磁力调节旋盘303调节。
参见图6为实施例的一种微张力送丝装置受力分析示意图，其中F1＝F2相当于磁阻尼器产生的力，F3相当于张力杆所受向上的力(反张力)，F4相当于转轴给张力杆末端一个向下的力，G1相当于滑轮自身的重力。
在工作状态中整个系统处于平衡状态(合力为零)并使桥丝拉紧且不断丝，因此整个结构的力矩之和为零，即：
(F1+F2+G1)*LAC+F3*LBC+F4*0＝0
其中，A为张力杆滑轮端，B为张力杆与壳体连接的端部，C为拉簧与张力杆的连接位置，LAC、LBC分别表示AC和BC的长度，张力杆上拉簧连接处到所述滑轮端的长度与拉簧连接处到所述壳体连接处的长度比是10∶1～100∶1(LAC∶LBC)。
本实施例的送丝装置确保了桥丝在小张力作用下得以实现稳定送丝，满足自动送丝的需要。
磁阻尼器是运用磁学原理，把主、被动一对磁性副通过磁力无接触连接，进行力矩传递。调节磁性副之间的气隙大小，可以把阻尼力矩从零调节到最大值。当气隙距离被锁定后，在运转过程中的阻尼力矩大小可保持长期恒定，且不会随主、被动副相的对转速变化而改变。其特点是磁阻尼器由两个半副组成，结 构简单，运转过程中靠磁力连接，两者无直接接触摩擦。间隙调节(即力矩调节)方便，安装尺寸小，使用寿命长，无故障。
磁阻尼器的使用方法有：(一)将阻尼器的磁性副任意之半副固定，另半副随丝盘轴转动，阻尼器将施与丝盘轴恒定的阻尼力矩。如将该半副装在定径导轮轴上，则丝、带在定径导轮上引出时使丝、带有一恒定的张力。(二)将阻尼器的磁性副任意半副固定于动力轴上，在被动轴上固定另半副，动力轴在转动时，在被动轴上获得一恒定的转动力矩，当阻尼器的磁性副间隙被调定后，被动轴上获得的转矩不会因负载变化造成的转差变化而改变。
本实施例还提供了一种桥丝焊接系统，用于把桥丝焊接在电极塞基体上。参见图9、图10a、图10b，显示了欲制备的电极塞，包括芯电极90、桥丝96、绝缘层91和带孔的塞子92，芯电极90设置在塞子92的孔中，芯电极90和塞子92之间设置有绝缘层91，塞子92上连接有第一电极针93，芯电极90上连接有第二电极针94；桥丝96与芯电极90和塞子92焊接，桥丝96与塞子92具有两个以上焊点97；把芯电极90设置在带孔的塞子92里边，然后通过绝缘材料把芯电极90和塞子92绝缘。由于塞子92具有较大的焊接面积而容易焊接，因此在机械焊接过程中只需把桥丝96对准芯电极90焊接即可。第一电极针93和/或第二电极针94设置有弯折部95，弯折部95弧线的直径为0.2～0.6mm；本实施例优选0.3～0.5mm，具体可选为0.45mm，弯折部的设置使电极针靠近塞子92的中心，机械焊接过程中方便操作。本实施例中第一电极针93与塞子92的连接方式是焊接，第二电极针94与芯电极90为同一根导线；第一电极针93和第二电极针94具有向同一方向弯曲的弯折部；电极针上镀有铜或金；电极塞的形状为圆形、方形、椭圆形中的任一种，塞子92的孔的形状为圆形、方形、椭圆形中的任一种；本实施例塞子92的孔优选圆形；本实施例中塞子92和绝缘层91都为圆环形，圆环形绝缘层91包裹着芯电极90，圆环形的塞子92包裹着圆环形的绝缘层91；芯电极90是铁镍钴合金材料，与桥丝96的热胀冷缩系数相近；绝缘层91可选择是陶瓷材料或者热固性塑料注塑材料或高温烧结玻 璃，塞子92是金属材料。电极塞的直径为5～10mm，芯电极90与塞子92之间的绝缘层91厚0.5～1.2mm，芯电极90的直径是0.6～2mm。本实施例优选，电极塞的直径为7.1mm，芯电极90与塞子92之间的绝缘层91厚0.827mm，芯电极90的直径是1.026mm。桥丝96是镍铬电阻合金丝，桥丝96的直径为0.020mm或者0.024mm或者0.028mm。本实施例电极塞能够在3毫秒瞬间发热达到1000多摄氏度，使用性能优越。
参见图7和图8，本实施例提供的一种桥丝焊接系统，包括：传送电极塞基体(未焊接桥丝的电极塞)的工装循环装置2，将无序的电极塞基体送入工装循环装置的送料装置1，用于传送桥丝并施予桥丝一定张力的微张力送丝装置3(具体结构如上述实施例所示)，将桥丝96与电极塞基体的焊点对准的桥丝定位装置4，将桥丝与电极塞基体焊接的桥丝焊接装置5，用于切断桥丝的切丝装置6，用于检测电极塞是否焊接合格的检测装置7，以及支撑装置80；支撑装置80用于支撑工装循环装置2或者其它装置部件，微张力送丝装置3可以安装在支撑装置80上；桥丝定位装置4设置在循环轨道20上；微张力送丝装置3、桥丝焊接装置5和切丝装置6设置在支撑装置80或者循环轨道20上；微张力送丝装置3能够产生1g～10g重量大小的张力；优选2g重量大小的张力。送料装置把电极塞基体送入循环轨道中的工装上，电极塞基体随着工装在循环轨道内移动，顺序经过桥丝定位装置、桥丝焊接装置和切丝装置；桥丝定位装置把与微张力送丝装置连接的桥丝定位在电极塞基体的芯电极和塞子上，桥丝焊接装置把桥丝焊接在电极塞基体上，焊接完成的电极塞经循环轨道移动到切丝装置下方，切丝装置把焊接完成的电极塞上的桥丝切断，电极塞进入检测装置，如此重复进行下一个电极塞基体的焊接。本实施例中桥丝焊接装置5可以选择电流热熔型焊机；送料装置1可以选择磁力离心振动送料装置，解决了电极塞基体难以进入轨道的问题；检测装置7可以选择电阻式检测装置，解决了人工焊接效率低、焊接不稳定的问题；电极塞基体可以选择玻璃烧结电极塞基体，打破以往电极塞难以采用机械焊接的弊端。
参见图11和图12，本实施例提供的工装循环装置包括循环轨道20、推动块21和推送装置22，循环轨道20中设置有工装23的运动导槽，电极塞基体放置在工装23内，推动块21用于推动工装23步进式移动，推送装置22控制推动块21移动；推送装置22是气动推送装置，气动推送装置包括气缸和用于支撑气缸的气缸支架；循环轨道20是回形链条式循环轨道20，推送装置22设置在回形轨道的四个角上，四个角上的推送装置22能够对角联动。本实施例的工装循环装置结构简单、使用方便，能够使工装23循环传送，从而自动连续地把电极塞基体送到焊机处焊接。作为本实施例优选，工装23设置有用于标志电极塞的安装方向的凹槽24和安装电极塞基体的安装孔25，安装孔25的直径大于电极塞基体的直径；步进式移动的距离在X方向上是工装23宽度的距离，步进式移动的距离在Y方向上是工装23长度的距离；推送装置22上还设置有传感器，用于检测工装23的位置；循环轨道20上设置有机械手26，用于把送料装置输送过来的电极塞基体移动到工装23的安装孔中；循环轨道20上设置有第一定位检测装置27和第二定位检测装置28，第一检测装置27用于定位循环轨道20上的工装23的位置从而调整机械手的动作，第二检测装置28用于检测工装孔中的电极塞基体是否放平；循环轨道20上设置有红外检测装置29，用于检测循环工装23的安装孔内是否为空，如果安装孔内还具有电极塞，则报警停止循环。其工作流程是，在循环轨道中顺序安装工装，机械手把送料装置送来的电极塞基体移动到工装上的安装孔中，然后推送装置推动推动块步进式移动，从而实现工装循环。安装孔的直径略大于电极塞基体的直径，如果电极塞基体的焊接面不水平，如果电极塞基体不平，可以通过下压电极塞基体焊接面或者调节摆动电极针的方式来调节电极塞基体的焊接面水平，保证焊接精度。
参见图13和图14，本实施例提供的桥丝定位装置包括多个压丝轮40，多个压丝轮40分别设置在焊接装置5的两侧，优选地，还包括两个以上的钩针43，其中一部分钩针43的弯钩方向向里，另外一部分钩针43的弯钩方向向外，钩针43设置在压丝轮40之间，能够实现桥丝与电极塞基体的芯电极精确定位。 桥丝定位装置还包括给压丝轮施力的施力装置42和传递力的弹簧41，弹簧41设置在压丝轮40与施力装置42之间，确保压丝轮40的压力均匀；桥丝定位装置还包括穿送桥丝的定位滑轮44和夹紧桥丝的夹丝轮45，定位滑轮44用于传送桥丝，夹丝轮45用于在最初张拉桥丝时夹紧桥丝，实现桥丝定位于焊接水平线上。桥丝定位装置还可以包括观测桥丝与电极塞基体的芯电极是否对正的观测装置47，观测装置47可以是放大镜。
本实施例提供的桥丝定位装置，结构简单、使用方便，能够将直径为几十微米数量级的桥丝与电极塞基体的毫米级的芯电极准确定位，实现机械自动焊接桥丝。最初张拉桥丝时，桥丝从线圈上拉出，穿过微张力送丝装置上的张力杆，经滑轮变向，穿过钩针(通过钩针定位来保证桥丝与电极塞中心对齐)，再至夹丝轮处将桥丝夹紧，张力器将桥丝拉紧拉直，然后压丝轮将桥丝压紧在工装上。连续焊接过程中通过工装的移动来带动桥丝的向前移动。
本实施例还提供了一种桥丝焊接系统的使用方法，具体如下：
参见图7和图8的一种桥丝焊接系统，包括用于自动上料的振动盘10，用于固定振动盘的底座11，用于传送原料的直线送料器13，用于抓取电极塞基体的机械手26，用于定位工装的第一定位检测装置27，用于检测工装孔中的电极塞基体是否放平的第二定位检测装置28，用于推送工装的推送装置22，用于拉紧桥丝的微张力送丝装置3，定位滑轮44，用于夹紧桥丝的夹丝轮45，压丝轮40，用于焊接桥丝的桥丝焊接装置5，用于切断桥丝的切丝装置6，用于检测电极塞上的桥丝是否焊接成功的检测装置7，不合格品出口70，合格品出口71，用于检测工装孔中是否为空的红外检测器29，用于控制自动化系统运转的主控台8。
桥丝焊接系统的使用方法如下：
1)、开机检查：打开主控台8，检查设备电源、气压、供料等是否正常。
2)、桥丝安装与定位：将直径为0.028mm的桥丝从微张力送丝装置3穿过(张力约为2克)，微张力送丝装置优选磁力型张力器，桥丝96绕过定位滑轮 44后经过压丝轮40的下方，穿过桥丝定位装置将其定位(确保桥丝与直径为1mm左右的电极塞基体芯电极对正)，并在夹丝轮45处夹紧。
3)、上料：本实施例优选磁力离心振动自动上料装置，在振动盘10内加入适量的电极塞基体，由振动盘10将电极塞基体逐个排列整齐，连续送至直线送料器13，再通过上料轨道震动将电极塞基体输送至机械手26抓取位置。
4)、回形轨道传送：轨道上共有118个被编号的工装夹具，轨道四角4个气动推送装置22对角连动，推动工装循环运行。
5)、电极塞基体传送：经红外检测装置检测到机械手抓取位置有电极塞基体时，由机械手抓取电极塞基体移至工装上方，同时由第一定位检测装置27将轨道内的工装定位，机械手将电极塞基体放入工装。由推送装置推送工装至第二定位检测装置28操作位，再由第二定位检测装置28将电极塞基体定位，确保电极塞基体与工装处于同一水平，工装继续被推送前移。
6)、自动送丝：桥丝被压丝轮40压紧在工装上，通过推送装置22推动工装前移，工装带动桥丝前移，实现自动送丝。
7)、焊接：系统从机械手上料开始对装有工件的工装计数，当工装推送至桥丝焊接装置位置时，系统自动识别并启动焊接系统。然后由桥丝焊接装置将桥丝焊接在电极塞基体上。焊机工作原理：焊接前自动检测系统检测到工装内的电极塞基体，之后夹紧气缸夹紧电极塞基体，焊头下压，通过夹焊头处的万向节来确保焊头与电极塞基体接触面完全贴合，之后电流从焊头的接触面通过，形成瞬间的热熔接，完成焊接。
8)、断丝检测及报警：每次焊接完成后，压丝轮40微抬，微张力送丝装置3对桥丝全程受力进行监测，若有断丝现象，微张力送丝装置的张力杆失力上扬，触发报警系统，自动焊机停止运行。
9)、切丝、电阻检测：焊接完成后由切丝装置6将电极塞两端的桥丝切断，通过检测装置7检测工装内电极塞的电阻值是否合格(合格电阻值范围1.8-2.0Ω)。
10)、出料口检测：系统从电阻检测位置对工装前移进行计数，不合格品推送至不合格品出口70由系统自动识别后被高压气流打出，合格品从合格品出口71被高压气流打出。出料口连接的出料管道装有自动监测装置，若有料未卸出则系统自动报警并停机。
11)、最后通过推送装置22将空工装推送至初始位置，如此往复。
电极塞基体定义为未焊接有桥丝的结构件，焊接有桥丝后称为电极塞(电发火件)。
最后应当说明的是，以上实施例仅用以说明本发明的技术方案，而非对本发明保护范围的限制，尽管参照较佳实施例对本发明作了详细地说明，本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本发明技术方案的实质和范围。

Claims (10)

  1. 一种微张力送丝装置，其特征在于：包括壳体，设置在所述壳体上的张力杆、过丝轮、夹紧件和张力轮，以及与所述张力轮传动连接的阻尼器；所述张力杆的一端与所述壳体连接，另一端设置有滑轮。
  2. 根据权利要求1所述的一种微张力送丝装置，其特征在于：所述阻尼器是磁滞制动器或者磁阻尼器；所述夹紧件是羊毛毡。
  3. 根据权利要求2所述的一种微张力送丝装置，其特征在于：所述壳体上还设置有调节张力大小的磁力调节旋盘，所述磁力调节旋盘与所述磁阻尼器连接。
  4. 根据权利要求1所述的一种微张力送丝装置，其特征在于：所述张力杆与所述壳体的连接端设置有旋转轮，所述旋转轮上设置有凹陷部；所述壳体上还设置有断丝报警开关，所述断丝报警开关设置有检测臂，所述检测臂与旋转轮触接。
  5. 根据权利要求1所述的一种微张力送丝装置，其特征在于：所述壳体上还设置有调节张力杆张力的反张力调节旋钮，所述张力杆的一端与所述壳体铰接，所述张力杆上设置有拉簧，所述拉簧的一端与所述张力杆连接，另一端与所述反张力调节旋钮连接。
  6. 根据权利要求2所述的一种微张力送丝装置，其特征在于：所述壳体上还设置有调节羊毛毡夹紧力的羊毛毡调节旋钮、防滑片和指示标志。
  7. 根据权利要求1所述的一种微张力送丝装置，其特征在于：所述微张力送丝装置上供给有桥丝，桥丝依次绕过夹紧件、张力轮、过丝轮，最后绕过张力杆上的滑轮后与桥丝焊接系统连接。
  8. 根据权利要求1～7任一所述的一种微张力送丝装置，其特征在于：所述微张力送丝装置能够对桥丝形成1g～10g重量大小的张力。
  9. 一种桥丝自动焊接系统，包括桥丝定位装置、微张力送丝装置，其特征在于：所述微张力送丝装置是权利要求1～8任一所述的微张力送丝装置；所 述微张力送丝装置将桥丝送入桥丝定位装置。
  10. 根据权利要求9所述的一种桥丝自动焊接系统，其特征在于：还包括支撑装置、工装循环装置、桥丝焊接装置、切丝装置、将电极塞基体送入工装循环装置的送料装置；所述工装循环装置包括循环轨道和推送装置，所述循环轨道设置有工装运动导槽，所述推送装置推动工装在循环轨道内移动；所述桥丝定位装置设置在所述循环轨道上；所述桥丝焊接装置和所述切丝装置设置在所述支撑装置上或者所述循环轨道上。
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