Research On Ignition Loss Of Welding Tips And Thermal Compensation Method During Spot Welding Of Enameled Wire

Spot welding of enameled wire is a welding method that uses resistance heat to remove the insulating layer under the pressure and forms a solid phase connection interface between the exposed wire and the substrate.It can significantly improve the enameled wire connection performance,so in the manufacture of electronic components,electronic equipment,instrumentation,medical equipment and other fields it has broad application prospects.At present,in the continuous welding process of spot welding of enameled wire,due to the resistance changed of the spot welding tips,the resistance heat generation is inconsistent,so the quality of enameled wire is unreliable.Therefore,it is necessary to solve this problem to solve the actual connection matterIn order to solve the problem of unreliable quality of enameled wire.Firstly,the information acquisition system in the spot welding production process was built.The relationship between the dynamic signals of the welding process and the burning behavior of the enameled wire spot welding tips was established.Various factors affecting the resistance change of welding tips were studied through a large number of experiments,and the analysis was obtained under different control modes.The law of the resistance change is extracted,and the reliability of welding quality also put forward by the energy compensation methodThe finite element model of spot welding of enameled wire process simulation was established,and the temperature field distribution of welding tips was studied according to the model.The simulation results are compared with the temperature data which collected by the designed thermocouple temperature measurement test.The results show that the simulation results are reliable.Finally,considering the tip volume changed by the spot welding tips burning,the mathematical model of energy compensation with the increase of welding time with the number of welding points is obtained by simulationThe contrast experiments under constant voltage control and energy compensation control was compared with the built-in DSP controlled enameled wire spot welding control system The results show that the constant voltage control cannot guarantee the consistency of welding quality during the continuous welding process of the spot welding head.Through the improved energy compensation control system,the consistency and reliability of welding quality are significantly increased,which plays a certain reference role for the spot welding of enameled wire.