U-shaped wire efficient bending system
The U-shaped wire high-efficiency bending system, which simultaneously bends multiple wires using a hinged die, solves the problems of low production efficiency and poor quality of U-shaped wires in existing technologies, and realizes highly efficient and automated U-shaped wire production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- SHANDONG NEW KEYLEAD POWER TECH CO LTD
- Filing Date
- 2022-12-01
- Publication Date
- 2026-07-14
AI Technical Summary
Existing technologies are difficult to produce U-shaped yarns efficiently, especially in the forming process of yarns with a bending strength of less than 50MPa. There are problems such as low production efficiency and poor forming quality. In particular, the first bend is easily deformed during the second bend, and the existing process has great limitations.
A high-efficiency U-shaped wire bending system was designed, which uses a hinge-type mold to simultaneously bend multiple wires. The U-shaped structure is formed by rotating the hinge mold, and the rotating power mechanism is controlled by a conductive slip ring to achieve automated production.
It enables efficient bending of multiple filaments simultaneously, with a high degree of automation, improved processing efficiency and quality stability, and avoids the problem of unexpected deformation when bending a single filament.
Smart Images
Figure CN118122904B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of wire mesh processing equipment technology, specifically a high-efficiency bending system for U-shaped wires. Background Technology
[0002] U-shaped wires are frequently used in the construction of agricultural plant vine supports and in the binding of steel cages in the construction industry. The most common U-shaped wire in daily life is used in staples.
[0003] When U-shaped wires are used as vertical rib conductors in solar cell grids, the U-shaped wires pass through the middle of the horizontal ribs of the grid. The horizontal ribs are made of lightweight plastic, forming a structurally stable composite grid structure. The bottom bend of the U-shaped wires holds the outermost horizontal rib of the grid, preventing the grid from loosening at its bottom due to the weak bonding force between the vertical and horizontal ribs.
[0004] When the production of grid panels requires the application of a large number of U-shaped wire structures, the existing mature single-wire bending technology is difficult to efficiently supply U-shaped structural wires, making it difficult to meet the needs of industrial production.
[0005] In existing U-shaped wire forming technologies, besides the common single-wire bending method, there are also U-groove slitting or casting processes. For wires with a bending strength below 50 MPa, after the first bend of the U-shape, if production efficiency is increased, unexpected deformation of the first bend can easily occur during the second bend. U-shaped wires formed by the U-groove slitting method often have square end sections, making it difficult to form U-shaped wires with circular end sections. Casting processes are only suitable for wires with larger end sections and a relatively low ratio of wire length to cross-sectional diameter, and the production efficiency of cast U-shaped wires is generally low. Therefore, it is evident that all of the above-mentioned existing processes have certain limitations.
[0006] For wire-formed U-shaped structures with a bending strength of less than 50 MPa, a new process and production equipment need to be designed. Summary of the Invention
[0007] To address the aforementioned technical issues, the applicant designed a "hing-type" synchronous bending mechanism for U-shaped wires with a bending strength of less than 50MPa. Specifically, multiple wires are threaded into pre-set mold core holes, and the mold hinge folds to achieve synchronous bending of a group of wires. The bottom bending part of the U-shaped wire is exposed in the folding rotation axis area of the mold hinge, making it easy for the U-shaped wire to be pulled out from this part for application.
[0008] Based on the above-described production method, this invention provides a high-efficiency bending system for U-shaped wires, the technical solution of which is as follows:
[0009] A high-efficiency U-shaped wire bending system includes a wire feeding device and a wire bending device. The wire feeding device is used to feed the wire, and the wire bending device is used to bend the wire into a U-shaped structure.
[0010] The wire bending device includes a hinge mold, which comprises a fixed mold, a hinge mold shaft, and a rotating mold. The hinge mold shaft is fixedly connected to the rotating mold and is connected to a hinge rotation power mechanism. The hinge rotation power mechanism drives the hinge mold shaft to rotate, thereby causing the rotating mold to rotate relative to the fixed mold, realizing the mold opening and closing actions. The fixed mold and the rotating mold each have a cavity to accommodate a mold core. The mold core is a thin plate structure with multiple through holes evenly distributed on the thin plate. A wire feeding device inserts wire into the through holes of the mold core. During the mold closing action, the included angle between the two mold cores can be rotated from 180° to 0°, and the same wire inserted into the through holes of the two mold cores is bent into a U-shape using the center distance between the through holes.
[0011] To improve the efficiency and automation of the bending process, the wire bending device includes a turntable connected to a power unit on a base, which drives the turntable to rotate. Four sets of hinge molds are evenly distributed in a ring around the center of the turntable. The fixed molds are fixed to the turntable surface. The wire bending device has four stations arranged sequentially around the turntable: wire entry, wire bending, mold exit, and mold entry. The wire feeding station is located at the output end of the wire feeding device. Wire is inserted into the through hole of the mold core. The hinge rotation power mechanism acts on the hinge mold shaft, rotating the mold to reduce the angle between the rotating mold and the fixed mold to less than 90°. An auxiliary bending mechanism is provided at the wire bending station. The auxiliary bending mechanism includes a mold closing auxiliary power mechanism, which provides additional torque to the rotating mold, causing the angle between the rotating mold and the fixed mold to be zero. A mold core ejection station is provided with a mold core delivery mechanism, which pushes the mold core out of the hinge mold after mold closing. The hinge rotation power mechanism rotates in the opposite direction, acting on the hinge mold shaft, rotating the mold to reduce the angle between the rotating mold and the fixed mold to 180°. At the mold core feeding station, a pair of new empty mold cores are inserted for the next operation.
[0012] A conductive slip ring is provided at the bottom of the turntable, and the slip ring is supported by its corresponding support frame. The conductive slip ring includes two parallel positive and negative concentric conductive strips. A carbon brush is connected below the hinge rotation power mechanism, passing through the turntable surface. The carbon brush receives electricity from the surface of the conductive slip ring to drive the low-voltage torque motor of the hinge rotation power mechanism. The above structure ensures that when the turntable rotates, the hinge rotation power mechanism can achieve steering control through the polarity arrangement on the conductive slip ring, avoiding the phenomenon of control circuit signal lines of multiple rotation power mechanisms becoming entangled during rotation or mutual interference of wireless control signals.
[0013] Within a 180° arc range below the three stations—the wire entry station, the wire bending station, and the exit core station—the conductive slip ring has two conductive strips with the same polarity. Within a 90° arc range below the exit core station and the entry core station, the polarities of the two parallel concentric conductive strips are interchanged. Within a 90° arc range below the entry core station and the wire entry station, no conductive strip is laid. The positive and negative poles on the corresponding tracks of the conductive slip ring, along with the absence of conductors, control the forward, reverse, and stop movements of the low-voltage torque motor of the hinge rotation power mechanism, thereby controlling the closing and opening actions of the hinge mold.
[0014] The wire feeding station is equipped with a wire cutting mechanism. After the wire feeding action into the die core is completed according to the design requirements, in order to leave a set of wires of the same length in the die core, the wire cutting mechanism is needed to cut the wires.
[0015] The wire cutting mechanism includes a wire cutter. A wire cutter holder is mounted on the upper part of the turntable, and the wire cutter is connected to the wire cutter holder. The wire cutter is connected to a cutting power mechanism and is located at the wire entry station. The cutting power mechanism pushes the wire cutter downward to cut all the wires that have entered the mold core, and then lifts the wire cutter, leaving a set of wires of the same length inside the mold core. After the wires are cut, the wire arranger is pushed away from the turntable a certain distance on the arranger displacement guide rail to facilitate the subsequent rotation of the turntable.
[0016] The upper part of the wire bending device is equipped with a core pressing strip, which is connected to the core pressing power mechanism. The core pressing strip is connected to the frame above the wire entry station, and is positioned above the groove between the fixed mold and the rotating mold at that station. To reduce the displacement of the wire within the core during bending, the core needs to have a groove for bending the wire in the hinge mold rotation area. The core pressing power mechanism drives the core pressing strip, which can just fit into the gap between the two cores, to press down on the two cores. This prevents gaps between the two cores and the hinge mold, and also prevents the wire from getting stuck or protruding at the joint of the two cores. After the wire is in place through the core, the core pressing power mechanism lifts the core pressing strip.
[0017] To ensure complete mold closing between the two mold cores and produce a qualified U-shaped wire, an auxiliary bending mechanism is provided at the wire bending station. This auxiliary bending mechanism includes a mold closing auxiliary power mechanism, which provides additional torque to the rotating mold, ensuring that the angle between the rotating mold and the fixed mold is zero. The mold closing auxiliary power mechanism is mounted on the corresponding frame above the wire bending station. This mechanism provides a large clamping force to ensure the hinge mold at this position fully closes, guaranteeing a U-shaped bending effect.
[0018] The bottom of the hinge mold fixing mold is provided with a mold core push rod. By moving the mold core push rod, the mold core can be pushed out after the hinge mold is closed.
[0019] The mold core delivery mechanism includes a mold core delivery power source and a mold core delivery transmission mechanism. At the mold core delivery station, the mold core delivery power source can drive the mold core push rod to move through the mold core delivery transmission mechanism.
[0020] The lower part of the mold core push rod is provided with a protrusion. When the turntable rotates the hinge mold to the mold core exit position, the protrusion is connected to the mold core delivery transmission mechanism. Thus, the mold core delivery power can drive the mold core push rod to move, thereby driving the mold core to be delivered out of the hinge mold.
[0021] The mold core delivery mechanism includes a mold core pusher rod, which is rotatably mounted on the corresponding base at the bottom of the turntable and can rotate around its support shaft. The lower end of the mold core pusher rod is connected to the mold core pusher power mechanism, and the upper end is provided with a U-shaped groove. When the turntable rotates the fixed mold to the mold core delivery position, the protrusion of the mold core pusher rod just fits into the groove of the mold core pusher rod.
[0022] The mold core ejection station is equipped with a movable mold core box. One end of the mold core box is open and is used to receive the ejected mold core. The mold core box can accommodate multiple layers of mold cores, which facilitates the transfer of mold cores carrying U-shaped wires in subsequent processes.
[0023] The wire feeding device includes a wire arranger, which includes a wire arranging die. The wire arranging die has multiple through-mouths, through which the wires pass. The through-mouths are arranged in multiple rows and columns. The horn mouths are designed to be large-area inlets with multiple rows and columns. After being deformed and guided within the wire arranging die, the wires are arranged in a neat single row at the outlet. This ensures that the wires are fed into the die core at equal intervals and that the wires are separated as much as possible before entering the wire arranging die, thus avoiding interference and entanglement.
[0024] The output end of the wire feeding die is equipped with a pair of pressure rollers. The cylindrical surface of the pressure rollers is provided with uniformly arranged annular grooves. The grooves are semi-circular. The two semi-circular grooves of the pair of pressure rollers are aligned to form a complete circle. The two pressure rollers move synchronously towards each other and feed the wire into the die core of the wire feeding die station.
[0025] To ensure the turntable does not collide with the wire arranger during rotation, and to allow the wire arranger to be as close to the turntable as possible after the turntable stops rotating, thus reducing the distance between the wire extruded by the pressure roller and the die core through-hole, and improving the success rate of the wire entering the die core through-hole, the wire arrangement die, pressure roller, and pressure roller power mechanism are all mounted on a sliding plate. A wire arranger displacement guide rail is provided on the frame corresponding to the wire arranger. The sliding plate is slidably connected to the wire arranger displacement guide rail, and the sliding plate is connected to the displacement power mechanism.
[0026] The beneficial effects achieved by this invention are:
[0027] This invention can simultaneously bend multiple sets of wires into a U-shape, resulting in high bending efficiency and fully automated operation.
[0028] This invention features a novel and practical structure. Through the structural form of the mold core and hinge mold, wire bending can be completed quickly and efficiently.
[0029] The present invention features an optimized structure, ensuring quality and performance during the processing. Attached Figure Description
[0030] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:
[0031] Figure 1 This is a schematic diagram of the structure of the present invention;
[0032] Figure 2 This is a schematic diagram of the four-station wire bending device of the present invention (first position);
[0033] Figure 3 This is a schematic diagram of the wire bending device of the present invention (second position);
[0034] Figure 4 yes Figure 3 Front view;
[0035] Figure 5 This is a schematic diagram of the mold core structure;
[0036] Figure 6 This is a structural diagram of the mold core and mold core box (with the mold core inserted into the mold core box during operation, the mold part is cut off by rotating the mold).
[0037] Figure 7 This is a schematic diagram of the structure of the push rod for fixing the lower mold core;
[0038] Figure 8 This is a schematic diagram of the structure of a conductive slip ring and a low-voltage torque motor;
[0039] Figure 9 This is a schematic diagram of the filament arranger.
[0040] Figure 10 This is a schematic diagram of the structure of the wire material support.
[0041] In the diagram: 1. Wire feeding device; 1-1. Wire; 1-2. H-beam reel; 1-3. Belt; 1-4. Wire feeding shaft; 1-5. Belt tensioning wheel; 1-6. Wire material support; 1-7. Wire feeding motor;
[0042] 2. Wire arranger; 2-1. Wire laying die; 2-2. Pressure roller wire laying wheel; 2-3. Pressure roller drive gear; 2-4. Pressure roller drive motor; 2-5. Wire cutter; 2-6. Wire cutter drive cylinder; 2-7. Pressing die core cylinder; 2-8. Die core; 2-81. Through hole; 2-82. Wire hooking groove; 2-83. Wire bending groove; 2-84. Die core lip; 2-85. Push core step; 2-86. Die core positioning hole; 2-9. Arranger displacement guide rail; 2-10. Displacement power mechanism;
[0043] 3. Wire bending device; 3-1. Turntable; 3-2. Wire entry station; 3-3. Wire bending station; 3-4. Core exit station; 3-5. Core entry station; 3-6. Core pusher connecting rod; 3-7. Core pusher cylinder; 3-8. Base; 3-9. Support frame; 3-10. Core box; 3-11. Core box clamping cylinder; 3-12. Core loading basket; 3-13. Basket support column; 3-14. Flow strip; 3-15. Low-voltage torque motor; 3-16. Core pressing strip; 3-17. Wire cutter 3-18. Tool holder; 3-19. Mold closing auxiliary cylinder; 3-10. Mold core push rod; 3-191. Protrusion; 3-20. Turntable drive motor; 3-21. Conductive slip ring; 3-211. Positive electrode; 3-212. Negative electrode; 3-213. Cross wire; 3-22. Carbon brush; 3-23. Rotating mold; 3-24. Hinge mold shaft; 3-25. Fixed mold; 3-26. Mold core suction cup; 3-27. Mold core rotation, lifting and translation platform; 3-28. Mold core compartment; 3-29. Mold core positioning rod;
[0044] 4. Mold core turnover device; 4-1. Mold core lifting platform. Detailed Implementation
[0045] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.
[0046] Example:
[0047] like Figure 1 As shown, a high-efficiency U-shaped wire bending system includes a wire feeding device 1, a wire arranger 2, a wire bending device 3, and a die core turnover device 4.
[0048] like Figure 1 , Figure 10The filament feeding device 1 shown includes a filament material rack 1-6, with filaments of the same size and specifications on the same filament material rack 1-6. Multiple parallel feeding shafts 1-4 are arranged on the filament material rack 1-6, and multiple I-beams 1-2 are connected to the feeding shafts 1-4. Fibers 1-1 are wound on the I-beams 1-2. The same filament material rack 1-6 uses I-beams 1-2 of the same specification, and the same size and specifications of filaments are wound on the same winding machine, so that the multiple I-beams are matrix-distributed and controlled by the same filament feeding motor 1-7. When different I-beams 1-2, or when the specifications of the filaments wound on the same I-beam are inconsistent, multiple filament material racks 1-6 need to feed filaments onto the same filament arranger 2 separately.
[0049] The feeding shaft 1-4 is connected to a feeding transmission mechanism, which in turn is connected to a feeding power mechanism. Specifically, the feeding power mechanism includes a feeding motor 1-7, which is connected to a belt 1-3. The belt 1-3 connects to the feeding shaft 1-4 for transmission. A belt tensioning wheel 1-5 is installed on the yarn material support 1-6 to tension the belt. The feeding motor 1-7 simultaneously drives all the yarn rollers 1-2, and the feeding speed of the feeding motor 1-7 is controlled based on the feed speed feedback from the pressure roller drive motor 2-4.
[0050] like Figure 1 , Figure 9 As shown, the wire arranger 2 includes a wire arrangement mold 2-1, which has multiple through-flare openings to introduce vertically matrix-arranged wires 1-1 into the flare openings. The entrance of the flare opening is set with multiple rows and columns of large-area inlet holes. After being deformed and guided inside the wire arrangement mold, the wires are arranged in a neat single row at the exit of the wire arrangement opening, and the wires pass through the through-flare openings.
[0051] The output end of the wire-laying die 2-1 is equipped with a pair of pressure rollers 2-2. The cylindrical surface of each pressure roller 2-2 has evenly arranged annular grooves, which are semi-circular. The two semi-circular grooves of the pair of pressure rollers 2-2 are aligned to form a complete circle. After being laid out by the wire-laying die 2-1, the wire 1-1 enters the pair of semi-circular grooves of the pressure rollers 2-2, where it is tightly pressed. The surface of the pressure rollers 2-2 is made of a material with a higher coefficient of friction than the wire surface material; for example, if the wire is lead, a rubber pressure roller is used.
[0052] Two pressure roller guide wheels 2-2 are connected to the pressure roller power mechanism, causing the two pressure roller guide wheels 2-2 to move synchronously towards each other. The pressure roller guide wheels 2-2 feed the wire into the die core 2-8 at the wire entry die station. The pressure roller power mechanism includes a pressure roller drive motor 2-4, which is a stepper motor or a servo motor. It can control the wire feeding length of the wire 1-1 according to the depth of the through hole in the die core 2-8. The pressure roller drive motor 2-4 is connected to two meshing pressure roller drive gears 2-3. The two pressure roller drive gears 2-3 drive the two pressure roller guide wheels 2-2 to rotate synchronously towards each other.
[0053] To ensure that the turntable 3-1 does not collide with the wire arranger 2 during rotation, and that the wire arranger 2 can be as close as possible to the turntable 3-1 after the turntable 3-1 has rotated to its final position, the distance between the wire extruded by the pressure roller 2-2 and the through hole of the die core 2-8 is reduced, allowing the wire to accurately enter the through hole 2-81 of the die core. The wire arranging die 2-1, the pressure roller 2-2, and the pressure roller power mechanism are all mounted on the sliding plate. The frame corresponding to the wire arranger 2 is equipped with an arranger displacement guide rail 2-9. The sliding plate is slidably connected to the arranger displacement guide rail 2-9, and the sliding plate is connected to the displacement power mechanism 2-10, which is a cylinder.
[0054] like Figures 1 to 5 As shown, the wire bending device includes a turntable 3-1. The circular turntable 3-1 is connected to a turntable power unit on the base 3-8. The turntable power unit includes a turntable drive motor 3-20, which drives the turntable 3-1 to rotate. Four sets of hinge molds are evenly distributed in a ring around the center of the turntable on the turntable 3-1. Each hinge mold includes a fixed mold 3-25, a hinge mold shaft 3-24, and a rotating mold 3-23. The fixed mold 3-25 is fixed to the surface of the turntable 3-1. The hinge mold shaft 3-24 is fixedly connected to the rotating mold 3-23 and is connected to a hinge rotation power mechanism. The hinge rotation power mechanism includes a low-voltage torque motor 3-15, which drives the hinge mold shaft 3-24 to rotate, thereby driving the rotating mold 3-23 to rotate, performing mold closing and opening actions. The fixed mold 3-25 and the rotating mold 3-23 each have a cavity that can just accommodate one mold core.
[0055] like Figure 5As shown, the mold core 2-8 is a thin plate structure. Multiple through holes 2-81 are evenly distributed on the thin plate of the mold core 2-8. The wire passes through the through holes 2-81. The inner diameter of the through holes 2-81 is slightly larger than the diameter of the wire to be passed through, generally controlled to be 1.05 to 1.5 times the wire diameter. The outer side of the mold core 2-8 is provided with a mold core lip 2-84, a mold core positioning hole 2-86, and a core pusher step 2-85, facilitating precise positioning of the mold core 2-8 by tooling fixtures during turnover. To reduce the displacement of the wire 1-1 within the mold core 2-8 during bending, the mold core 2-8 has a bending groove 2-83 for bending the wire and a hooking groove 2-82 in the area corresponding to the hinge mold shaft, leaving space for the subsequent U-shaped wire pull-out device to be inserted.
[0056] like Figure 2 , Figure 3 , Figure 4 , Figure 8 As shown, the wire bending device is provided with wire entry station 3-2, wire bending station 3-3, die exit station 3-4 and die entry station 3-5 in sequence, which are evenly distributed around the center of the turntable at 90° intervals.
[0057] A conductive slip ring 3-21 is provided at the lower part of the turntable 3-1. The conductor slip ring 3-21 is supported by its corresponding support frame 3-9, and the lower part of the support frame 3-9 is fixedly connected to the base 3-8. The conductive slip ring 3-21 includes two parallel concentric conductive strips with positive and negative poles, namely positive pole 3-211 and negative pole 3-212, and corresponding cross conductors 3-213 are provided. Within a 180° arc range below the three stations from the wire entry station 3-2, the wire bending station 3-3 to the core exit station 3-4, the two conductive strips have the same polarity; within a 90° arc range below the core exit station 3-4 to the core entry station 3-5, the polarities of the two parallel concentric conductive strips are interchanged; within a 90° arc range below the core entry station 3-5 to the wire entry station 3-2, no conductive strip is laid. The low-voltage torque motor 3-15 is connected to a carbon brush 3-22 below. The carbon brush 3-22 receives electricity from the surface of the conductive slip ring 3-21 to drive the low-voltage torque motor 3-15 of the hinge rotation power mechanism. The low-voltage torque motor 3-15 is controlled to rotate forward, reverse, and stop by contacting the positive pole 3-211 and negative pole 3-212 on the corresponding track of the conductive slip ring 3-21, and by not contacting any conductor. This controls the closing and opening actions of the hinge mold.
[0058] The following is a detailed explanation of the structure of the four stations: wire entry station 3-2, wire bending station 3-3, core exit station 3-4, and core entry station 3-5:
[0059] 1. Wire insertion station 3-2;
[0060] The wire feeding station 3-2 is located at the output end of the wire feeding device, where the wire 1-1 is squeezed into the die core 2-8 by the pressure roller 2-2. To reduce the distance between the pressure roller 2-2 and the die core 2-8, the edge of the fixed hinge die is designed as a straight edge.
[0061] At this workstation, a wire cutter holder 3-17 is installed on the upper part of the wire bending device. A wire cutter 2-5 is connected to the wire cutter holder 3-17, and the wire cutter 2-5 is connected to a cutting power mechanism, which includes a wire cutter drive cylinder 2-6. After the wire feeding action into the mold core 2-8 is completed according to the design requirements, the wire cutter drive cylinder 2-6 pushes the wire cutter 2-5 downward to cut all the wires that have entered the mold core 2-8, and then lifts the wire cutter 2-5, so that a set of wires of the same length remains in the mold core.
[0062] The upper part of the wire bending device is provided with a core pressing strip 3-16, which is connected to a core pressing power mechanism. The core pressing power mechanism includes a core pressing cylinder 2-7. The core pressing strip 3-16 is connected to the frame corresponding to the upper part of the wire entry station, and is correspondingly set on the upper part of the groove between the fixed mold 3-25 and the rotating mold 3-23 at this station. In order to reduce the displacement of the wire 1-1 in the core 2-8 during the bending process, the core 2-8 needs to have a bending groove 2-83 for bending the wire in the hinge mold rotation area. The core pressing cylinder 2-7 drives the core pressing strip 3-16, which can just fit into the gap of the bending groove 2-83 between the two cores, to press down the two cores 2-8. This is to prevent gaps between the two cores 2-8 and the hinge mold, and to prevent the wire 1-1 from getting stuck or protruding at the gap where the two cores 2-8 are joined. After the wire is threaded into the die core, the die core pressing cylinder 2-7 drives the die core pressing strip 3-16 to lift.
[0063] II. Wire bending station 3-3;
[0064] After the wire is inserted into the mold, the turntable drive motor 3-20 is started, and the turntable 3-1 rotates. The power carbon brush 3-22 of the low-voltage torque motor 3-15 installed on the rotating shaft of the hinge mold at each position contacts the conductive slip ring 3-21 of the double rail. The motor rotates in the forward direction (in the reverse direction to distinguish the opening of the hinge mold) between the wire insertion station 3-2 and the mold core exit station 3-4. The hinge mold closes. After the four-position turntable 3-1 rotates 90°, it moves to the hinge mold at the wire bending station 3-3. According to the bending strength of the wire, a suitable torque motor is selected so that the included angle between the two hinge pieces needs to be rotated from 180° to within 90°.
[0065] Due to the bending strength of the wire, it is difficult to hinge the two mold cores 2-8 to a zero-degree angle using only the low-voltage torque motor 3-15. Therefore, an auxiliary bending mechanism is provided at the wire bending station. This auxiliary bending mechanism includes a mold closing auxiliary power mechanism, which includes a mold closing auxiliary cylinder 3-18. This cylinder provides a large arm torque for mold closing, causing the hinge mold at this position to fully close, with the included angle between the two mold cores 2-8 reaching zero degrees. The mold closing auxiliary power mechanism is mounted on the corresponding frame above the wire bending station and outputs downward pressure.
[0066] III. Demolding core station 3-4:
[0067] like Figure 2 , Figure 3 , Figure 4 , Figure 6 , Figure 7 As shown, after mold closing, the wires inside the two mold cores 2-8 are bent into a "U" shape. At the mold core exit station 3-4, the mold core 2-8 is sent out to the mold core box 3-10 through the mold core delivery mechanism. The mold core delivery mechanism includes a mold core push rod 3-6. When the turntable 3-1 is confined by space, the mold core push rod 3-6 is rotatably mounted on the corresponding base 3-8 at the lower part of the turntable and can rotate around its support shaft. The lower end of the mold core push rod 3-6 is connected to the mold core push power mechanism, which includes a mold core push cylinder 3-7. A U-shaped groove is opened at the upper end of the mold core push rod 3-6.
[0068] like Figure 6 , Figure 7 As shown, a core push rod 3-19 is provided at the bottom of the hinge mold fixing mold 3-25. After the hinge mold is closed, the core push rod 3-19 can push out the core 2-8. Specifically, part of the core push rod 3-19 is located at the lower part of the fixing mold 3-25 and can slide along the sliding rod at the bottom of the fixing mold; the other part of the core push rod 3-19 is located in the cavity of the fixing mold 3-25 and is used to push the core 2-8. The core 2-8 is provided with a core push step 2-85 structure, which makes it easy for the core push rod 3-19 to be locked, thereby pushing the core 2-8. In addition, a protrusion 3-191 is provided at the lower part of the mold core push rod 3-19. When the turntable 3-1 rotates to the mold core exit station 3-5, the protrusion 3-191 just fits into the groove of the mold core push rod 3-6, thereby connecting the mold core push rod 3-6 and the mold core push rod 3-19. At this time, the mold core push cylinder 3-7 drives the mold core push rod 3-6 to rotate around the support shaft, and the upper end of the mold core push rod 3-6 drives the mold core push rod 3-19 to move, thereby pushing out the mold core 2-8 and sending it to the mold core box 3-10. The mold core push cylinder 3-7 reverses its action to reset the mold core push rod 3-19 so that the mold core placed at the mold core entry station does not conflict with the mold core push rod 3-19.
[0069] The mold core box 3-10 is open at one end. The mold core 2-8 pushed out by the mold core push rod 3-19 enters the mold core box 3-10 under the guidance of the wedge-shaped mold core lip 2-84. Multiple layers of mold cores 2-8 can be installed in the mold core box 3-10, so that multiple mold cores 2-8 can be transferred to the subsequent welding station at the same time. The middle part of the turntable 3-1 has a concave structure. The bottom of the concave surface is fixed to the turntable drive motor 3-20. The internal space of the concave surface is designed to accommodate the mold core box 3-10, which facilitates the placement of the mold core 2-8 into the mold core box 3-10 by a flat pushing method.
[0070] The turntable 3-1 has a recessed structure in the middle, which also houses a core-filling basket 3-12 and a basket support column 3-13. The core-filling basket 3-12 has a slotted bottom to facilitate the subsequent transfer of the mold core box 3-10. To reduce the torque on the mold core lifting platform 4-1 during the process of squeezing the mold core 2-8 into the mold core box 3-10, a support column 3-13 is provided on the back of the core-filling basket 3-12. The support column rotates with the turntable, and after each 90-degree rotation, one side of the support column supports the squeezing force of the mold core entering the box. After the mold core box 3-10 is inserted into the core-filling basket 3-12, the mold core box clamping cylinder 3-11 ensures that the mold core box is locked inside the core-filling basket 3-12, preventing shaking and displacement. To reduce the friction between the concave surface of the four-station turntable and the basket support column 3-13 when the core-loading basket 3-12 enters and exits, flow strips 3-14 composed of rows of bullseye balls are provided at four positions directly opposite the wire entry station 3-2 to the core entry station 3-5. The above describes the transfer structure of the core box 3-10.
[0071] IV. Mold core insertion station 3-5:
[0072] After the mold core 2-8 is pushed out of the previous station, the empty hinge mold rotates to this position and the hinge mold reverses and opens to 180°. Driven by the mold core rotation lifting and translation platform 3-27, the mold core suction cup 3-26 picks up a piece of mold core 2-8 fitted on the mold core positioning rod 3-29 from the mold core chamber 3-28 and puts it into the mold cavity of the rotating mold 3-23 or the fixed mold 3-25, so that the folding groove 2-83 of the mold core 2-8 is placed in the center and facing upward. Then, driven by the mold core rotation lifting and translation platform 3-27, the mold core suction cup 3-26 picks up another piece of mold core 2-8 from the mold core chamber 3-28 and puts it into another fixed mold 3-25 or the rotating mold 3-23, so that the folding groove 2-83 of the mold core 2-8 is placed in the center and facing upward. The suction cup inserts a pair of symmetrically placed mold cores 2-8 in this position twice and continues to repeat the above bending process.
[0073] The frame in this invention refers to each fixed frame used to support the various components, which can be set in different positions and at different heights as needed.
[0074] In this invention, the operation of each power component is basically controlled by the control system, thus achieving automation.
[0075] The U-shaped wires processed by this invention can be used as longitudinal wires of the solar panel grid, connected with transverse wires, to manufacture the solar panel grid.
Claims
1. A high-efficiency bending system for U-shaped wires, characterized in that, The device includes a wire feeding device and a wire bending device (3). The wire bending device (3) includes a hinge mold, which includes a fixed mold (3-25), a hinge mold shaft (3-24), and a rotating mold (3-23). The hinge mold shaft (3-24) is fixedly connected to the rotating mold (3-23). The hinge mold shaft (3-24) is connected to the hinge rotation power mechanism. The fixed mold (3-25) and the rotating mold (3-23) are respectively provided with cavities to accommodate a mold core (2-8). The mold core (2-8) is a thin plate structure. The thin plate of the mold core (2-8) is evenly provided with multiple through holes (2-81). The wire feeding device inserts the wire (1-1) into the through holes (2-81) of the mold core. The wire bending device (3) includes a turntable (3-1), which is connected to a turntable power device on a base (3-8). Four sets of hinge molds are evenly distributed in a ring around the center of the turntable (3-1). A fixed mold (3-25) is fixed to the turntable (3-1) platform. The wire bending device (3) has four stations arranged sequentially around the turntable (3-1): wire entry, wire bending, mold exit, and mold entry. The wire entry station (3-2) is located at the output end of the wire feeding device. Wire (1-1) is inserted into the mold core through hole (2-81). The hinge rotation power mechanism acts on the hinge mold shaft (3-24), rotating the mold (3-23) and the fixed mold (3-25). 5) The included angle between them is less than 90°; An auxiliary bending mechanism is provided at the wire bending station (3-3). The auxiliary bending mechanism includes a mold closing auxiliary power mechanism, which provides additional torque to the rotating mold (3-23), so that the included angle between the rotating mold (3-23) and the fixed mold (3-25) is zero; A mold core delivery mechanism is provided at the mold core exit station (3-4). The mold core delivery mechanism is used to push the mold core (2-8) after mold closing out from the hinge mold; The hinge rotation power mechanism rotates in the opposite direction to the hinge mold shaft (3-24), and the included angle between the rotating mold (3-23) and the fixed mold (3-25) is 180°. When it reaches the mold core entry station (3-5), a pair of new empty mold cores (2-8) are put in.
2. The U-shaped wire high-efficiency bending system according to claim 1, characterized in that, A conductive slip ring (3-21) is provided at the lower part of the turntable (3-1). The conductive slip ring (3-21) is supported by its corresponding support frame (3-9). The conductive slip ring (3-21) includes two parallel positive and negative concentric conductive strips. A carbon brush (3-22) is connected below the hinge rotation power mechanism and passes through the table surface of the turntable (3-1). The carbon brush (3-22) receives electricity from the surface of the conductive slip ring (3-21). Within a 180° arc range below the three stations of wire entry mold station (3-2), wire bending station (3-3) to mold core exit station (3-4), the two conductive strips have the same polarity. Within a 90° arc range below the mold core exit station (3-4) to mold core entry station (3-5), the polarities of the two parallel concentric conductive strips are interchanged.
3. The U-shaped wire high-efficiency bending system according to claim 1, characterized in that, The wire entry station (3-2) is equipped with a wire cutting mechanism, which includes a wire cutter. A wire cutter holder (3-17) is provided on the upper part of the turntable. A wire cutter (2-5) is connected to the wire cutter holder (3-17). The wire cutter (2-5) is connected to a cutting power mechanism. The wire cutter (2-5) is located at the wire entry station (3-2).
4. The U-shaped wire high-efficiency bending system according to claim 1, characterized in that, The upper part of the wire bending device is provided with a core pressing strip (3-16), which is connected to the core pressing power mechanism. The core pressing strip (3-16) is connected to the frame corresponding to the upper part of the wire entry station (3-2), and is correspondingly set on the upper part of the groove between the fixed mold (3-25) and the rotating mold (3-23) at this station.
5. The U-shaped wire high-efficiency bending system according to claim 1, characterized in that, The bottom of the hinge mold fixing mold is provided with a mold core push rod (3-19). By moving the mold core push rod (3-19), the mold core (2-8) can be pushed out after the hinge mold is closed.
6. The U-shaped wire high-efficiency bending system according to claim 5, characterized in that, The mold core delivery mechanism includes a mold core delivery power and a mold core delivery transmission mechanism. At the mold core delivery station (3-4), the mold core delivery power can drive the mold core push rod (3-19) to move through the mold core delivery transmission mechanism. The lower part of the mold core push rod (3-19) is provided with a protrusion (3-191). When the turntable (3-1) rotates to the mold core delivery station (3-4), its protrusion (3-191) is just connected to the mold core delivery transmission mechanism.
7. The U-shaped wire high-efficiency bending system according to claim 6, characterized in that, The mold core delivery mechanism includes a mold core pusher rod (3-6), which is rotatably mounted on the base (3-8) corresponding to the lower part of the turntable (3-1) and can rotate around its support shaft. The lower end of the mold core pusher rod (3-6) is connected to the mold core pusher power mechanism, and the upper end is provided with a U-shaped groove. When the turntable (3-1) rotates the hinge mold to the mold core delivery station (3-4), the protrusion (3-191) of the mold core pusher rod (3-19) just fits into the groove of the mold core pusher rod (3-6).
8. The U-shaped wire high-efficiency bending system according to claim 1, characterized in that, The mold core ejection station (3-4) can be moved into the mold core box (3-10). One end of the mold core box (3-10) is open and is used to receive the ejected mold core (2-8).
9. The U-shaped wire high-efficiency bending system according to claim 1, characterized in that, The wire feeding device includes a wire arranger (2), which includes a wire arrangement mold (2-1). The wire arrangement mold (2-1) has multiple through-mouths, through which the wire (1-1) passes. The output end of the wire arrangement mold (2-1) is provided with a pair of pressure roller wire arrangement wheels (2-2). The cylindrical surface of the pressure roller wire arrangement wheel (2-2) has uniformly arranged annular grooves. The grooves are semi-circular grooves. The two semi-circular grooves of the pair of pressure roller wire arrangement wheels (2-2) are aligned to form a complete circle. The two pressure roller wire arrangement wheels (2-2) move synchronously towards each other and feed the wire into the mold core (2-8) of the wire entry mold station (3-2).
10. The U-shaped wire high-efficiency bending system according to claim 9, characterized in that, The wire arranging mold (2-1), the pressure roller wire arranging wheel (2-2) and the pressure roller power mechanism are all set on the sliding plate. The frame corresponding to the wire arranger (2) is provided with an arranger displacement guide rail (2-9). The sliding plate is slidably connected to the arranger displacement guide rail (2-9). The sliding plate is connected to the displacement power mechanism (2-10).