WO2018036208A1 - 金属件与同轴电缆的焊接系统和焊接方法 - Google Patents

金属件与同轴电缆的焊接系统和焊接方法 Download PDF

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Publication number
WO2018036208A1
WO2018036208A1 PCT/CN2017/084170 CN2017084170W WO2018036208A1 WO 2018036208 A1 WO2018036208 A1 WO 2018036208A1 CN 2017084170 W CN2017084170 W CN 2017084170W WO 2018036208 A1 WO2018036208 A1 WO 2018036208A1
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WO
WIPO (PCT)
Prior art keywords
coaxial cable
metal member
cable according
electrode
welding system
Prior art date
Application number
PCT/CN2017/084170
Other languages
English (en)
French (fr)
Inventor
杨志勇
强伟
马红智
刘海滨
朱龙翔
郭林波
韩超
岳德周
Original Assignee
京信通信技术(广州)有限公司
京信通信系统（中国）有限公司
天津京信通信系统有限公司
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.)
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Application filed by 京信通信技术(广州)有限公司, 京信通信系统（中国）有限公司, 天津京信通信系统有限公司 filed Critical 京信通信技术(广州)有限公司
Publication of WO2018036208A1 publication Critical patent/WO2018036208A1/zh

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Classifications

    • 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
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • 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
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0004—Resistance soldering
    • 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
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
    • B23K1/0016—Brazing of electronic components
    • 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
    • B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/04—Heating appliances
    • B23K3/047—Heating appliances electric
    • 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
    • B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/08—Auxiliary devices therefor
    • 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
    • B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/08—Auxiliary devices therefor
    • B23K3/087—Soldering or brazing jigs, fixtures or clamping means
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0214—Resistance welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0235—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections for applying solder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0263—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections for positioning or holding parts during soldering or welding process

Definitions

  • the invention relates to the field of processing of communication devices, in particular to a welding system and a welding method for metal parts and coaxial cables.
  • the base station antenna product in the field of mobile communication has a complicated structure, and the internal structure is mainly composed of sheet metal parts, die-casting parts, PCB circuit boards, coaxial cables, and the like, which are assembled and structural parts of various types and sizes.
  • the welding technology between metal structural devices and coaxial cables is particularly important in the production of antennas.
  • the purpose of soldering is primarily to ensure good electrical continuity of the connection, and secondly to ensure a permanent mechanical connection. Therefore, the consistency of the solder joint between the metal structure device and the coaxial cable, the solder joint penetration and the mechanical strength restrict the electrical parameters and intermodulation indicators of the product.
  • metal structure devices in the field of mobile communication usually need to be electrically connected to a coaxial cable, and are preferably realized by tin alloy-mediated brazing.
  • the tin brazing process of metal structure devices and coaxial cables is often heated by hand soldering iron.
  • the manual soldering iron welding only uses local heating, the solder joints have poor penetration, and the electrical connection continuity cannot be effectively ensured.
  • the welding process is complicated, the processing efficiency is low, the waste water is generated in the welding process, and the waste water is highly polluted, resulting in a high overall processing cost.
  • An object of the present invention is to provide a welding method which can well solve the reliability and conductance of brazing of a metal member and a coaxial cable, and a welding system for realizing the welding method, in order to overcome the deficiencies of the prior art.
  • the first is a welding system of a metal member and a coaxial cable, which comprises a heating device disposed at a processing station for contacting the metal member or the coaxial cable for heating, and is disposed in the heating device.
  • a proximity feeding device for adding solder at the joint of the metal member and the coaxial cable and a moving positioning device for respectively clamping and transferring the metal member and the coaxial cable to the processing station are disposed.
  • the heating device includes a pair of electrodes respectively disposed at two sides of the processing station, an electrode pressing mechanism for driving each of the electrodes to press-contact with the metal member or the coaxial cable, and adjusting the An electrode positioning mechanism for a horizontal distance between a pair of electrodes.
  • the electrode positioning mechanism includes two electrode positioning clips that respectively grip the pair of electrodes, and a horizontal moving rail for sliding the electrode positioning clip.
  • the horizontal moving track is a linear track.
  • the heating device further includes a current controller that controls a value of the current output by the electrode.
  • the heating device further includes a timer that calculates the pressurization time of the electrode.
  • the soldering device includes a solder container, a pressure pump that drives the solder container to extrude the solder, and a cylinder that drives the solder container to reciprocate.
  • the mobile positioning device includes a workpiece holder and a feed mechanism that drives the workpiece holder to move to the processing station.
  • the workpiece holder includes a first positioning clip that clamps the metal member and a second positioning clip that clamps the coaxial cable, and the first positioning clip and the second fixing clip maintain a distance to expose The junction.
  • the first positioning clip is located below the second positioning clip.
  • the feed mechanism includes a guide rail, a motion platform that fixes the workpiece clamp, and a drive assembly that drives the motion platform to travel along the guide rail.
  • the welding system of the metal member and the coaxial cable further includes a cooling device that cools the heated metal member and the coaxial cable; the cooling device is located at a processing station downstream of the processing station.
  • it further includes an electrode cleaning device that performs surface cleaning on the pair of electrodes.
  • it also includes an electrical control device that controls the various devices of the welding system.
  • the metal piece that has been welded is transferred from the processing station.
  • the metal piece and the coaxial cable are driven to reach the processing station when the metal piece and the coaxial cable maintain a preset positional relationship.
  • the positional relationship between the metal member and the coaxial cable is maintained by the workpiece holder.
  • the workpiece holder exposes a joint of the metal piece to the coaxial cable to add solder from the exposed location to the joint.
  • the heat required for the contact heating is input to the current contact to be adjacent to the contact surface and the contact surface in the case where the electrode has a pressurized contact with the contact surface of the metal member or the coaxial cable.
  • the region is obtained by generating resistance heat.
  • the temperature generated by the resistance heat is higher as the time of the pressurization contact is longer under a certain current condition and within a certain time range.
  • the electrode is in press contact with the metal member to effect contact heating.
  • the metal member or the coaxial cable is preheated by the electrode before the solder is added at the joint.
  • the step of adding the solder at the joint is performed in synchronization with the step of heating the metal member or the coaxial cable.
  • the electrode requires a step of electrode surface cleaning after one contact heating.
  • it further includes a step of cooling the metal member and the coaxial cable which are welded by contact heating.
  • the cooled finished metal piece and the coaxial cable are transferred from the processing station.
  • the positional transfer of the metal member and the coaxial cable is driven by a numerically controlled feed mechanism.
  • the present invention has the following advantages:
  • the welding system and the welding method of the metal member and the coaxial cable of the present invention by means of the heating method of the electric resistance welding, the contact heating is performed by using a pair of electrodes under pressure contact, so that the heat of the metal part and the coaxial cable is made.
  • the conduction condition is better, the brazed connection structure is more reliable, the conduction rate is higher, and the electrical performance requirements of the mobile communication are met;
  • the welding system and welding method of the metal parts and the coaxial cable of the invention can adopt numerical control to control all the devices, can realize automatic processing, all operating parameters can be controlled, the product quality is higher and more stable, and the electrical properties of the products are consistent. good.
  • Figure 1 is a first welded structure suitable for use in the present invention, showing the case where the metal member provides a flat surface to effect welding.
  • FIG. 2 is a schematic view showing the structure of a welding system of a metal member and a coaxial cable according to the present invention.
  • FIG. 3 is a schematic structural view of a heating device and a partial feeding device in a welding system of a metal member and a coaxial cable according to the present invention.
  • FIG. 4 is a schematic structural view of an electrode control circuit in a welding system of a metal member and a coaxial cable according to the present invention.
  • Fig. 5 is a flow chart showing the welding method of the metal member and the coaxial cable of the present invention.
  • Figure 6 is a second welded structure suitable for use in the present invention, showing the case where the metal member provides a curved groove to effect welding.
  • Figure 7 is a third welded structure suitable for use in the present invention, showing the case where the metal member provides a square groove to achieve welding.
  • the welded structure 1 obtained by welding a metal member and a coaxial cable to each other.
  • the welded structure 1 includes a metal piece 11 that provides a welded base, a coaxial cable 12, and a solder 13 that is filled in the weld bead 14.
  • the metal member 11 provides a flat surface as a soldering surface, and the solder 13 extends from the lower half of the coaxial cable 12 to the metal member 11 due to gravity in a molten state.
  • solder 13 is on the metal member 11 and the coaxial cable 12 is solidified to form a solder joint.
  • the welding system 2 includes a heating device 21, a feeding device 22, a cooling device 23, an electrode cleaning device 24, a moving positioning device 25, and an electrical control device 26.
  • the heating device 21, the brazing device 22, the cooling device 23, and the electrode cleaning device 24 are used to process different processes, respectively.
  • the moving positioning device 25 is used for sequentially transferring the workpiece (the metal member 11 and the coaxial cable 12) to the aforementioned device for processing in different processes, or sequentially transferring the workpiece to different processing stations so that the aforementioned device can be executed.
  • the electrical control device 26 performs numerical control on each device of the welding system 2 to achieve automated processing and production.
  • the heating device 21 includes an upper electrode 211, a lower electrode 212, an electrode pressing mechanism 213, and an electrode positioning mechanism 214, and further includes current control for circuit-controlling the upper electrode 211 and the lower electrode 212. 215 and 216.
  • a heating processing station is formed between the upper electrode 211 and the lower electrode 212, and the metal member 11 and the coaxial cable 12 are heated at the processing station, preferably,
  • the upper electrode 211 and the lower electrode 212 are respectively disposed on both sides of the processing station.
  • the front ends of the upper electrode 211 and the lower electrode 212 are for contacting the object to be heated, and the rear end applies a forward pressure by the electrode pressing mechanism 213 to drive the upper electrode 211 and the lower electrode 212 to the object to be heated. Pressure is generated on the surface to form a pressurized contact.
  • the electrode positioning mechanism 214 includes two electrode positioning clips 2141 respectively sandwiching the upper electrode 211 and the lower electrode 212, and further includes a relative sliding of the electrode positioning clips 2141 to adjust a distance between the two electrodes.
  • Horizontally moving the track 2142; the horizontal moving track 2142 is preferably a linear track passing under the processing station, and the upper electrode 211 and the lower electrode may be adjusted according to the width of the metal member 11 or the coaxial cable 12. The distance between 212.
  • the upper electrode 211 and the lower electrode 212 are controlled by a circuit. Specifically, the output time of the output current and current is controlled by the circuit. Therefore, the circuit further includes a current controller directly connected to the power source. 215 and timer 216.
  • the current controller 215 and the timer 216 are It is easy to implement in the common knowledge in the art, and the implementation manner is various and flexible, and will not be described herein.
  • the brazing device 22 acts on a processing station defined by the upper electrode 211 and the lower electrode 212.
  • a solder is added to the joint of the metal member 11 and the coaxial cable 12 from above the processing station.
  • the solder is divided into a solder and a brazing filler metal according to the melting point, wherein the solder has a tin base, a lead base, a zinc base, etc.; the brazing filler metal has an aluminum base, a silver base, a copper base nickel base or the like.
  • the soldering device 22 includes a solder container 211.
  • the soldering device 22 further includes a pressure pump (not shown) that drives the solder container to extrude the solder and drives the A cylinder for reciprocating movement of a solder container (not shown); when a brazing filler metal is used, the ram pump can be replaced with a transport unit per unit volume (or weight).
  • the mobile positioning device 25 includes a workpiece holder and a feed mechanism that drives the workpiece holder to move to the processing station.
  • the workpiece holder based on the structure of the metal member 11 and the coaxial cable 12, the workpiece holder most basically needs to include a first positioning clip for clamping the metal member 11 and a first portion for clamping the coaxial cable 12.
  • a positioning clip preferably, the first positioning clip is below the second positioning clip, more preferably, a distance is maintained between the first positioning clip and the second positioning clip to expose the metal piece 11 and
  • the junction of the coaxial cable 12 is where the weld or weld is to be formed.
  • the metal member 11 and the coaxial cable 12 are fixed to the processing station by the workpiece mechanism after being fixed in the relative position by the workpiece holder.
  • the delivery mechanism includes a guide rail, a motion platform that fixes the workpiece clamp, and a drive assembly that drives the motion platform to travel along the guide rail.
  • the specific implementation of the motion platform and the drive assembly is easily conceivable by those skilled in the art and will not be described in detail herein.
  • the guide rails must pass through the processing station and are interleaved from the linear guides 2142 of the heating device 21, and in another possible embodiment, the guide rails are staggered from above the linear guides 2142.
  • the cooling device 23 is configured to cool the heated metal piece and the coaxial cable and the solder, which substantially accelerates the formation of the welded structure 1, and the cooling device 23 is disposed on the heating device 21 and The downstream processing station of the processing station corresponding to the soldering device 22.
  • the solder is in The rapid cooling process after melting contributes to the formation of a denser structure, and also helps to block the diffusion of the resistance heat, ensuring the aesthetics of the welded structure 1.
  • the cooling device is implemented by providing a cooling medium by cooling, which may be circulating water, circulating air or other medium having a higher specific heat.
  • the electrode cleaning device 24 is for cleaning the surface of the upper electrode 211 and the lower electrode 212 after each heating, in particular, the front ends of the electrodes for direct contact with the object to be heated.
  • the oil resistance and the oxide film increase the contact resistance, resulting in an increase in the total resistance of the welded region, and the effective resistance heat generated is relatively reduced, resulting in a decrease in the strength of the weld or the solder joint, or poor cleaning on the electrode surface.
  • the surface is overheated and splashed, resulting in solder failure.
  • the cleaning process is capable of reducing or even eliminating the above-mentioned adverse effects, and can ensure the consistency of each heating to the greatest extent possible.
  • the processing station corresponding to the electrode cleaning device 24 is preferably downstream of the processing station corresponding to the cooling device 23.
  • the welding system 2 of the metal member and the coaxial cable of the present invention, the heating device 21 and the feeding device 22 are applied to the same processing station, and the moving positioning device 25 is used to transfer the workpiece, and the electric appliance is controlled by the electric device.
  • the automatic control of the device 26 can greatly reduce the labor, effectively improve the production efficiency, reduce the labor cost, realize the automatic processing, control all the operating parameters, the product quality is higher and more stable, and the electrical performance of the product is consistent.
  • the present invention also provides a soldering method for a metal member and a coaxial cable, which includes the following steps:
  • the metal piece and the coaxial cable are transferred to the processing station by the mobile positioning device 25.
  • the metal member 11 and the coaxial cable 12 are fixed on the workpiece holder by manual operation to maintain a preset positional relationship for subsequent welding to form the welded structure 1; then, the clamping is performed
  • a workpiece holder having a metal member 11 and a coaxial cable 12 is fixed to the feeder mechanism, and the workpiece holder is transferred to the processing station by manual pushing or motor driving.
  • the joint of the metal member 11 and the coaxial cable 12 corresponds to the weld bead 14, which is equivalent to the weld bead 14 in the following description.
  • the heat required for the contact heating is input through the input of the electrode (including the upper electrode 211 and the lower electrode 212) in contact with the contact surface of the metal member 11 or the coaxial cable 12. Current is obtained by generating resistive heat in the vicinity of the contact surface and the contact surface. Further, in view of the poor resistance of the coaxial cable 12 to high temperature, the upper electrode 211 and the lower electrode 212 are in press contact with the metal member 11 to achieve contact heating, and the generated resistance heat is generated from The metal piece 11 is delivered to the coaxial cable 12.
  • the metal member 11 In order to ensure the quality of the soldering, before adding the solder to the metal member 11 and the coaxial cable 12, the metal member 11 needs to be preheated so that the overall temperature can quickly reach a preset value in the subsequent heating process (steps) S21).
  • step S22 after the metal member 11 or the coaxial cable 12 is preheated, the step of adding the brazing filler metal to the weld bead 14 during the process of continuing heating the metal member 11 to reach the soldering temperature Simultaneously, the solder is added to be melted while being heated, and the amount of the solder can be adjusted according to the welding condition of the workpiece.
  • the feeding mechanism needs to transfer the metal member 11 and the coaxial cable 12 to the next processing station to perform the following steps:
  • S32 performing electrode surface cleaning on the upper electrode 211 and the lower electrode 212 after one contact heating; preferably, the upper electrode 211 and the lower electrode 212 are cooled to normal temperature before surface cleaning;
  • the positional transfer of the metal member 11 and the coaxial cable 12 is driven by a numerically controlled feed mechanism.
  • the welding method of the metal member and the coaxial cable of the invention only heats the metal member, avoiding The electrical properties of the heat-affected coaxial cable; the welding process does not produce a large amount of waste water and waste gas, the processing site is clean and tidy, reducing the cost of wastewater waste gas treatment and maintenance processing environment.
  • the welded structure 1 is roughly divided into three implementations based on the condition of the welded surface provided by the metal member 11:
  • FIG. 1 The implementation shown in FIG. 1 has been described in detail in the foregoing embodiment 1, and is not repeated.
  • a soldering surface on the surface of the metal member 11 is disposed in a recess 111 in which the coaxial cable 12 can be accommodated. After the recess 111 receives the coaxial cable 12, there is a gap between the bottom of the recess 111 and the coaxial cable 12.
  • the welded surface has a curved surface
  • the slit also has a curved surface.
  • the solder 13 melted after heating is automatically filled into the slit to form a welded structure 1 as shown in FIG.
  • the welding surface is composed of a plurality of planes, and an accommodation space having an angle is formed between the plurality of planes (corresponding to the gap)
  • the solder 13 melted after heating is automatically filled into the accommodating space to form the welded structure 1 as shown in FIG.
  • the welding method is applied to the above three welding surfaces, indicating that the welding method is not limited by the shape of the workpiece, and in the case of various welding surface shapes, the welding of the workpiece conforms to the mobile communication. Electrical requirements.
  • the welding system and the welding method of the metal parts and the coaxial cable of the invention can well solve the reliability and the conduction rate of the brazing of the metal parts and the coaxial cable, and can improve the production efficiency and reduce the production cost.

Abstract

一种金属件（11）与同轴电缆（12）的焊接系统（2），其包括设置在加工工位处对所述金属件（11）或同轴电缆（12）进行接触以进行加热的加热装置（21）、设置在所述加热装置（21）邻近的用于在所述金属件（11）与同轴电缆（12）连接处添加钎料（13）的送钎装置（22）以及将所述金属件（11）和同轴电缆（12）分别进行夹持并移送到所述加工工位的移动定位装置（25）。还涉及一种金属件（11）与同轴电缆（12）的焊接方法。该系统和方法能很好提高金属件与同轴电缆钎焊的可靠性和导通率，并且能提高生产效率，降低生产成本。

Description

金属件与同轴电缆的焊接系统和焊接方法 技术领域
本发明涉及通信器件加工领域，尤其涉及一种金属件与同轴电缆的焊接系统和焊接方法。
背景技术
移动通信领域的基站天线产品结构复杂，内部结构主要由钣金件、压铸件、PCB电路板、同轴电缆等包含多种类型、多中规格的零部件组装及结构件焊接而成。金属结构器件与同轴电缆之间的焊接技术在天线生产中尤为重要，其焊接的目的首要是要保证良好的电气连续连接导通，其次是要保证持久的机械连接。因此金属结构器件与同轴电缆之间的焊点的锡量一致性、焊点的融透性和力学强度制约着产品电器参数及互调指标。目前移动通信领域金属结构器件通常需要与同轴电缆进行电性连接，首选通过锡合金介导的钎焊实现。金属结构器件与同轴电缆的锡钎焊过程多采用手工烙铁加热焊接，手工烙铁焊接只是采用局部加热的方式，焊点的融透性较差，并且不能有效保证电气连接的导通性。
进一步地，由于传统焊接技术手动操作的特性，导致焊接工序复杂，加工效率低下，焊接过程产生废水废气，且废水废气污染性较高，因而导致整个加工成本较高。
焊接工艺参数量化管控，是实现产品一致性的重大前提。
发明内容
本发明的目的是为克服现有技术的不足，提供一种能很好解决金属件与同轴电缆钎焊的可靠性和导通率的焊接方法，以及实现该焊接方法的焊接系统。
为达到以上技术目的，本发明采用的技术方案如下：
首先是一种金属件与同轴电缆的焊接系统，其包括设置在加工工位处对所述金属件或同轴电缆进行接触以进行加热的加热装置、设置在所述加热装 置邻近的用于在所述金属件与同轴电缆连接处添加钎料的送钎装置以及将所述金属件和同轴电缆分别进行夹持并移送到所述加工工位的移动定位装置。
具体地，所述加热装置包括一对分别设置在所述加工工位两侧的电极、驱动每个所述电极与所述金属件或同轴电缆加压接触的电极加压机构以及调节所述一对电极之间的水平距离的电极定位机构。
更具体地，所述电极定位机构包括两个分别夹持所述一对电极的电极定位夹、以及供所述电极定位夹滑动的水平移动轨道。
优选地，所述水平移动轨道为直线轨道。
更优选地，该加热装置还包括控制所述电极所输出的电流值的电流控制器。
可选择地，该加热装置还包括计算所述电极加压时间的计时器。
进一步地，所述送钎装置包括钎料容器、驱动所述钎料容器挤出钎料的压料泵和驱动所述钎料容器往返移动的气缸。
更进一步地，所述移动定位装置包括工件夹具和驱动所述工件夹具移动到所述加工工位的送件机构。
具体地，所述工件夹具包括夹持所述金属件的第一定位夹和夹持所述同轴电缆的第二定位夹，所述第一定位夹和第二定夹之间保持距离以暴露所述连接处。
优选地，所述第一定位夹位于所述第二定位夹的下方。
更具体地，所述送件机构包括导轨、固定所述工件夹具的运动平台、驱动所述运动平台沿所述导轨行走的驱动组件。
所述的金属件与同轴电缆的焊接系统还包括对被加热的所述金属件与同轴电缆进行冷却的冷却装置；所述冷却装置位于所述加工工位的下游的加工工位。
进一步地，其还包括对所述一对电极进行表面清理的电极清理装置。
更进一步地，其还包括对所述焊接系统各个装置进行控制的电气控制装置。
其次是一种金属件与同轴电缆的焊接方法，其包括以下步骤：
准备所述金属件与同轴电缆并移送到加工工位；
在所述加工工位对所述金属件与同轴电缆的连接处添加钎料并且对所述 金属件或同轴电缆进行接触加热以实现焊接；
将已完成焊接的所述金属件从所述加工工位上转移。
进一步地，所述准备步骤中，在所述金属件与同轴电缆维持预设的位置关系的情况下驱动所述金属件与同轴电缆到达所述加工工位。
优选地，所述金属件与同轴电缆之间的位置关系通过工件夹具来维持。
更优选地，所述工件夹具暴露所述金属件与同轴电缆的连接处，以便从所述暴露的位置向所述连接处添加钎料。
进一步地，所述接触加热的所需的热量在所述电极与所述金属件或同轴电缆的接触面存在加压接触的情况下通过输入电流以在所述接触面及该接触面的邻近区域产生电阻热而获得。
具体地，在一定的电流条件下和一定的时间范围内，随着所述加压接触的时间越长，所述电阻热所产生的温度越高。
优选地，所述电极与金属件进行加压接触以实现接触加热。
进一步地，在所述连接处添加钎料之前，利用所述电极对所述金属件或同轴电缆进行预热。
更进一步地，对所述金属件或同轴电缆进行预热后，在所述连接处添加钎料的工序与对所述金属件或同轴电缆进行接触加热的工序同步进行。
优选地，所述电极在一次所述接触加热之后需要进行电极表面清理的步骤。
更优选地，还包括将通过接触加热完成焊接的所述金属件与同轴电缆进行冷却的步骤。
进一步优选地，所述冷却后的完成焊接的所述金属件与同轴电缆从所述加工工位上转移。
较优地，所述金属件与同轴电缆的位置转移通过数控的送件机构驱动。
与现有技术相比较，本发明具有如下优势：
(1)本发明的金属件与同轴电缆的焊接系统和焊接方法，借鉴电阻焊的加热方式，采用一对电极在加压接触的情况下进行接触加热，使金属件和同轴电缆的热导通情况更良好，使钎焊连接结构更可靠、导通率更高，符合移动通信的电气性能要求；
(2)本发明的金属件与同轴电缆的焊接系统和焊接方法，区别于电 阻焊的焊点形成方式，仅对金属件进行加热，避免过热影响同轴电缆的电气性能；
(3)本发明的金属件与同轴电缆的焊接系统和焊接方法，焊接过程操作简单，可以大大减少人工劳动，有效提高了生产效率，降低了劳动成本；
(4)本发明的金属件与同轴电缆的焊接系统和焊接方法，焊接过程没有产生大量废水废气，加工现场干净整洁，降低了废水废气处理和维护加工环境的成本；
(5)本发明的金属件与同轴电缆的焊接系统和焊接方法，可采用数控控制所有装置，能够实现自动化加工，所有操作参数可控，产品质量更高更稳定，产品的电性能一致性良好。
附图说明
图1为适用于本发明的第一种焊接结构，示出了金属件提供平面以实现焊接的情况。
图2为本发明金属件与同轴电缆的焊接系统的组织结构示意图。
图3为本发明金属件与同轴电缆的焊接系统中的加热装置、部分送钎装置的结构示意图。
图4为本发明的金属件与同轴电缆的焊接系统中电极控制电路的结构示意图。
图5为本发明的金属件与同轴电缆的焊接方法的流程示意图。
图6为适用于本发明的第二种焊接结构，示出了金属件提供曲面凹槽以实现焊接的情况。
图7为适用于本发明的第三种焊接结构，示出了金属件提供方槽凹槽以实现焊接的情况。
具体实施方式
以下结合附图和具体实施方式对本发明作进一步详细描述。
实施例一
焊接系统
参考图1，示出了金属件与同轴电缆相互焊接所要得到的焊接结构1， 所述焊接结构1包括提供焊接基体的金属件11、同轴电缆12以及填充在焊缝14中的焊料13。图1所示的实施例中，所述金属件11提供了一个平面作为焊接面，焊料13在熔融状态下由于重力的作用从所述同轴电缆12的下半部分延伸到所述金属件11的表面，并且从所述同轴电缆12的正下方向两侧扩散，直到熔融的焊料13基于自身材料特性以及冷却效应不再扩散，最后所述焊料13在所述金属件11和同轴电缆12之间凝固形成焊点。
参考图2，其示出了一种金属件与同轴电缆的焊接系统2，该焊接系统2用于形成所述焊接结构1。具体地，所述焊接系统2包括加热装置21、送钎装置22、冷却装置23、电极清理装置24、移动定位装置25和电气控制装置26。所述加热装置21、送钎装置22、冷却装置23和电极清理装置24分别用于处理不同的工序。所述移动定位装置25用于将工件(金属件11和同轴电缆12)依次移送到前述的装置中进行不同工序的加工，或者将工件依次移送到不同的加工工位以便前述的装置能够执行相应的工序。所述电气控制装置26对该焊接系统2的各个装置进行数控控制，以实现自动化加工生产。
参考图3和图4，所述加热装置21包括上电极211、下电极212、电极加压机构213、电极定位机构214，还包括对所述上电极211和下电极212进行电路控制的电流控制器215和216。
如图3所示，所述上电极211和下电极212之间形成加热的加工工位，所述金属件11和同轴电缆12将在所述加工工位上被加热，优选地，所述上电极211和下电极212分别设置在所述加工工位的两侧。所述上电极211和下电极212的前端用于与被加热的物体接触，后端通过所述电极加压机构213施加向前的压力，驱动所述上电极211和下电极212在被加热物体表面产生压力，以形成加压接触。所述电极定位机构214包括两个分别夹持所述上电极211和下电极212的电极定位夹2141，还包括供所述电极定位夹2141相对滑动以调整所述两个电极之间的距离的水平移动轨道2142；所述水平移动轨道2142优选为从所述加工工位的下方经过的直线轨道，可以根据所述金属件11或同轴电缆12的宽度来调整所述上电极211和下电极212之间的距离。
如图4所示，所述上电极211和下电极212由电路控制，具体地，由该电路控制所输出的电流和电流的输出时间，因此，该电路还包括与电源直接连通的电流控制器215和计时器216。所述电流控制器215和计时器216在 本领域的公知常识中容易实现，并且实现方式多样灵活，在此不进行赘述。
当所述上电极211和下电极212与被加热物体接触后形成闭合回路，并且在接触面存在加压接触的情况下通过输入电流以在所述接触面及该接触面的邻近区域产生电阻热。经试验发现，在一定的电流条件下和一定的时间范围内，随着所述加压接触的时间越长，所述电阻热所产生的温度越高，当所产生的电阻热足够高的情况下可以用于焊接加热。
继续参考图3，所述送钎装置22作用于由所述上电极211和下电极212所限定的加工工位。优选从所述加工工位上方对所述金属件11和同轴电缆12的连接处添加钎料。钎料按熔点高低分为软钎料和硬钎料，其中，所述软钎料有锡基、铅基、锌基等；硬钎料有铝基、银基、铜基镍基等。所述送钎装置22包括钎料容器211，当使用软钎料的时候，该送钎装置22还包括驱动所述钎料容器挤出钎料的压料泵(未图示)和驱动所述钎料容器往返移动的气缸(未图示)；当使用硬钎料的时候，所述压料泵可以替换为运送单位体积(或重量)的运料夹。
所述移动定位装置25包括工件夹具和驱动所述工件夹具移动到所述加工工位的送件机构。本实施例中，基于所述金属件11和同轴电缆12的结构，所述工件夹具最基本需要包括夹持所述金属件11的第一定位夹和夹持所述同轴电缆12的第二定位夹，优选地，所述第一定位夹在所述第二定位夹的下方，更优选地，所述第一定位夹和第二定位夹之间保持距离以暴露所述金属件11和同轴电缆12的连接处，即暴露拟形成焊缝或焊点的位置。所述金属件11和同轴电缆12被所述工件夹具固定好相对位置后通过送件机构移送到所述加工工位。在一种可能的实施方式中，所述送件机构包括导轨、固定所述工件夹具的运动平台、驱动所述运动平台沿导轨行走的驱动组件。所述运动平台和驱动组件具体的实现方式是本领域技术人员容易想到的，在此不进行详述。所述导轨必定经过所述加工工位，并且从与所述加热装置21的直线导轨2142相交错，在另一种可能的实施方式中，所述导轨从所述直线导轨2142的上方交错经过。
所述冷却装置23用于对加热后的所述金属件与同轴电缆以及钎料进行冷却，其实质是加速所述焊接结构1的形成，该冷却装置23设置在所述加热装置21和送钎装置22所对应的所述加工工位的下游加工工位。所述钎料在 熔融之后进行快速冷却的过程中有助于形成较致密的结构，也有利于阻断所述电阻热的扩散，保证所述焊接结构1的美观。所述冷却装置通过冷却提供冷却介质实现，所述冷却介质可以是循环水、循环空气或其他比热较高的介质。
所述电极清理装置24用于对每一次加热后的所述上电极211和下电极212的表面进行清理，特别是对这两个电极用于与被加热物直接接触的前端。电极表面清理不良时，油污和氧化膜等使接触电阻增大，导致焊接区域的总电阻增大，所产生的有效电阻热相对减少，致使焊缝或焊点强度降低，或者在电极表面清理不良的情况下焊缝或焊点的局部接触表面过热和喷溅，导致焊接失败。清理工序是能够减少甚至消除上述不良影响的，能最大可能地保证每一次加热的一致性。所述电极清理装置24所对应的加工工位优选在所述冷却装置23所对应的加工工位的下游。
本发明的金属件与同轴电缆的焊接系统2，其所述加热装置21和送钎装置22作用于同一个加工工位，并且使用所述移动定位装置25进行移送工件，采用所述电器控制装置26实现自动化控制，可以大大减少人工劳动，有效提高了生产效率，降低了劳动成本；能够实现自动化加工，所有操作参数可控，产品质量更高更稳定，产品的电性能一致性良好。
实施例二
焊接方法
参考图5，本发明还提供了一种金属件与同轴电缆的焊接方法，其包括以下步骤：
S1：准备所述金属件与同轴电缆并移送到加工工位；
具体地，通过所述移动定位装置25将所述金属件与同轴电缆移送到所述加工工位。首先，通过人工操作，将所述金属件11和同轴电缆12固定在所述工件夹具上，以维持预设的位置关系，便于后续焊接形成所述焊接结构1；然后，将所述夹持有金属件11和同轴电缆12的工件夹具固定在所述送件机构上，通过人工推动或者电机驱动，将所述工件夹具移送到所述加工工位上。
本领域技术人员应当理解，在自动化生产成熟的情况下，上述需要人工执行的工序可由机器替代。
S2：在所述加工工位对所述金属件与同轴电缆的连接处添加钎料并且对所述金属件或同轴电缆进行接触加热以实现焊接；
所述金属件11与同轴电缆12的连接处即相当于所述焊缝14，下文的描述中将所述连接处等同于所述焊缝14。
如上所述，所述接触加热的所需的热量在所述电极(包括上电极211和下电极212)与所述金属件11或同轴电缆12的接触面存在加压接触的情况下通过输入电流以在所述接触面及该接触面的邻近区域产生电阻热而获得。进一步地，考虑到所述同轴电缆12对高温的耐受能力较差，所述上电极211和下电极212与所述金属件11进行加压接触以实现接触加热，所产生的电阻热从所述金属件11传递到所述同轴电缆12。
为了保证焊接质量，在对所述金属件11和同轴电缆12添加钎料之前，需要对所述金属件11进行预热，以便在后续的加热过程使整体温度可以快速达到预设值(步骤S21)。
下一步(步骤S22)，对所述金属件11或同轴电缆12进行预热后，在对所述金属件11继续加热以达到焊接温度的过程，在所述焊缝14添加钎料的工序同步进行，加热的同时将即时添加的所述钎料进行熔融，所述钎料的添加量可以根据工件的焊接情况适时调整。
S3:将已完成焊接的所述金属件从所述加工工位上转移；
在所述进行加热和送钎的加工工位完成当前工序之后，所述送件机构需要将所述金属件11和同轴电缆12移送到下一个加工工位以执行以下步骤：
S31:将通过接触加热完成焊接的所述金属件11与同轴电缆12进行冷却；
S32：将经过一次接触加热之后的上电极211和下电极212进行电极表面清理；优选地，所述上电极211和下电极212冷却至常温后再进行表面清理；
S33:将冷却后所形成所述焊接结构1从所有加工工位上转移，并卸出工件夹具。
以上各个工序和步骤中，所述金属件11与同轴电缆12的位置转移通过数控的送件机构驱动。
本发明的金属件与同轴电缆的焊接方法，仅对金属件进行加热，避免过 热影响同轴电缆的电气性能；焊接过程没有产生大量废水废气，加工现场干净整洁，降低了废水废气处理和维护加工环境的成本。
实施例三
金属件的焊接面的情况
参考图1、图6和图7，所述焊接结构1基于所述金属件11所提供的焊接面的情况大概分为三种实现方式：
如图1所示的实现方式已在前述的实施例一经过详细描述，不再重复。
如图6和图7所示，为了便于所述金属件11和同轴电缆12之间的定位，位于所述金属件11表面的焊接面会设置在可容纳所述同轴电缆12的凹槽111中，所述凹槽111容置所述同轴电缆12后，所述凹槽111的底部与同轴电缆12之间存在缝隙。
当所述凹槽111的底部是曲面时，所述焊接面具有曲面，所述缝隙也具有曲面。加热后熔融的所述钎料13自动填充到所述缝隙中，形成如图6所示的焊接结构1。当所述凹槽111为方槽，其底部为平面时，所述焊接面由多个平面相接组成，并且所述多个平面之间形成具有夹角的容置空间(相当于所述缝隙)，加热后熔融的所述钎料13自动填充到所述容置空间中，形成如图7所示的焊接结构1。
经过试验，采用所述焊接方法均适用上述三种焊接面的情况，表明所述焊接方法不受工件的外形限制，在存在各种焊接面形状的情况下，都使工件的焊接符合移动通信的电气要求。
综上所述，本发明金属件与同轴电缆的焊接系统和焊接方法能很好解决金属件与同轴电缆钎焊的可靠性和导通率，并且能提高生产效率，降低生产成本。
上述实施例为本发明较佳的实施方式，但并不仅仅受上述实施例的限制，其他的任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化，均应为等效的置换方式，均包含在本发明的保护范围之内。

Claims (27)

  1. 一种金属件与同轴电缆的焊接系统，其特征在于：其包括设置在加工工位处对所述金属件或同轴电缆进行接触以进行加热的加热装置、设置在所述加热装置邻近的用于在所述金属件与同轴电缆连接处添加钎料的送钎装置以及将所述金属件和同轴电缆分别进行夹持并移送到所述加工工位的移动定位装置。
  2. 如权利要求1所述的金属件与同轴电缆的焊接系统，其特征在于，所述加热装置包括一对分别设置在所述加工工位两侧的电极、驱动每个所述电极与所述金属件或同轴电缆加压接触的电极加压机构以及调节所述一对电极之间的水平距离的电极定位机构。
  3. 如权利要求2所述的金属件与同轴电缆的焊接系统，其特征在于，所述电极定位机构包括两个分别夹持所述一对电极的电极定位夹、以及供所述电极定位夹滑动的水平移动轨道。
  4. 如权利要求3所述的金属件与同轴电缆的焊接系统，其特征在于，所述水平移动轨道为直线轨道。
  5. 如权利要求2所述的金属件与同轴电缆的焊接系统，其特征在于，该加热装置还包括控制所述电极所输出的电流值的电流控制器。
  6. 如权利要求2所述的金属件与同轴电缆的焊接系统，其特征在于，该加热装置还包括计算所述电极加压时间的计时器。
  7. 如权利要求1所述的金属件与同轴电缆的焊接系统，其特征在于，所述送钎装置包括钎料容器、驱动所述钎料容器挤出钎料的压料泵和驱动所述钎料容器往返移动的气缸。
  8. 如权利要求1所述的金属件与同轴电缆的焊接系统，其特征在于，所述移动定位装置包括工件夹具和驱动所述工件夹具移动到所述加工工位的送件机构。
  9. 如权利要求8所述的金属件与同轴电缆的焊接系统，其特征在于，所述工件夹具包括夹持所述金属件的第一定位夹和夹持所述同轴电缆的第二定位夹，所述第一定位夹和第二定夹之间保持距离以暴露所述连接处。
  10. 如权利要求9所述的的金属件与同轴电缆的焊接系统，其特征在于， 所述第一定位夹位于所述第二定位夹的下方。
  11. 如权利要求8所述的金属件与同轴电缆的焊接系统，其特征在于，所述送件机构包括导轨、固定所述工件夹具的运动平台、驱动所述运动平台沿所述导轨行走的驱动组件。
  12. 如权利要求1所述的金属件与同轴电缆的焊接系统，其特征在于，其还包括对被加热的所述金属件与同轴电缆进行冷却的冷却装置；所述冷却装置位于所述加工工位的下游的加工工位。
  13. 如权利要求1所述的金属件与同轴电缆的焊接系统，其特征在于，其还包括对所述一对电极进行表面清理的电极清理装置。
  14. 如权利要求1所述的金属件与同轴电缆的焊接系统，其特征在于，其还包括对所述焊接系统各个装置进行控制的电气控制装置。
  15. 一种金属件与同轴电缆的焊接方法，其特征在于，其包括以下步骤：
    准备所述金属件与同轴电缆并移送到加工工位；
    在所述加工工位对所述金属件与同轴电缆的连接处添加钎料并且对所述金属件或同轴电缆进行接触加热以实现焊接；
    将已完成焊接的所述金属件从所述加工工位上转移。
  16. 如权利要求15所述的金属件与同轴电缆的焊接方法，其特征在于，所述准备步骤中，在所述金属件与同轴电缆维持预设的位置关系的情况下驱动所述金属件与同轴电缆到达所述加工工位。
  17. 如权利要求16所述的金属件与同轴电缆的焊接方法，其特征在于，所述金属件与同轴电缆之间的位置关系通过工件夹具来维持。
  18. 如权利要求17所述的金属件与同轴电缆的焊接方法，其特征在于，所述工件夹具暴露所述金属件与同轴电缆的连接处，以便从所述暴露的位置向所述连接处添加钎料。
  19. 如权利要求15所述的金属件与同轴电缆的焊接方法，其特征在于，所述接触加热的所需的热量在所述电极与所述金属件或同轴电缆的接触面存在加压接触的情况下通过输入电流以在所述接触面及该接触面的邻近区域产生电阻热而获得。
  20. 如权利要求19所述的金属件与同轴电缆的焊接方法，其特征在于，在一定的电流条件下和一定的时间范围内，随着所述加压接触的时间越长， 所述电阻热所产生的温度越高。
  21. 如权利要求19所述的金属件与同轴电缆的焊接方法，其特征在于，所述电极与金属件进行加压接触以实现接触加热。
  22. 如权利要求15所述的金属件与同轴电缆的焊接方法，其特征在于，在所述连接处添加钎料之前，利用所述电极对所述金属件或同轴电缆进行预热。
  23. 如权利要求22所述的金属件与同轴电缆的焊接方法，其特征在于，对所述金属件或同轴电缆进行预热后，在所述连接处添加钎料的工序与对所述金属件或同轴电缆进行接触加热的工序同步进行。
  24. 如权利要求22所述的金属件与同轴电缆的焊接方法，其特征在于，所述电极在一次所述接触加热之后需要进行电极表面清理的步骤。
  25. 如权利要求15所述的金属件与同轴电缆的焊接方法，其特征在于，还包括将通过接触加热完成焊接的所述金属件与同轴电缆进行冷却的步骤。
  26. 如权利要求25所述的金属件与同轴电缆的焊接方法，其特征在于，所述冷却后的完成焊接的所述金属件与同轴电缆从所述加工工位上转移。
  27. 如权利要求15所述的金属件与同轴电缆的焊接方法，其特征在于，所述金属件与同轴电缆的位置转移通过数控的送件机构驱动。
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