Progressive die and stamping method for new energy vehicle connector stamping

Abstract

The application relates to the technical field of bending forming, and discloses a progressive die and a stamping forming method for stamping forming of a new energy vehicle connector, the progressive die is composed of an upper die and a lower die, the upper die is composed of an upper cover plate, an upper die seat, an upper backing plate, an upper clamping plate, a stop plate and an upper stripper plate from top to bottom, the lower die is composed of a concave die plate, a lower backing plate, a lower die seat and a lower backing foot from top to bottom, the concave die plate is provided with a blind hole for a bending process, the upper die is provided with a bending punch for bending in correspondence, and a roller is rotatably arranged on the bending punch. The stamping forming method is used for Z-shaped bending of a square block with a circular hole at the end of the length direction of the unfolded drawing of the new energy vehicle connector, V-shaped bending is first carried out on two V-shaped bends connected in a head-to-tail mode in the length direction to form preliminary bending of the end V-shaped bend and the end penultimate V-shaped bend, the preliminary bending is continuously bent to form the end penultimate V-shaped bend, then the end penultimate V-shaped bend is shaped, and the starting end and both sides in the length direction are cut off. The precision requirement of the new energy vehicle connector is met.

Description

Technical Field

[0001] This invention relates to the field of bending forming technology, specifically to a progressive die and a stamping forming method for stamping connectors in new energy vehicles. Background Technology

[0002] In his paper "Design of Progressive Die for Locking Sleeve of Electrical Connector," published in Volume 45, Issue 7 of *Mold Industry* in 2019, Tang Yuguang stated that layout design is crucial to progressive die design. The overall structure of the die is conceived during the layout stage, so the rationality of the layout design determines the quality of the overall die structure. The difficulty lies in two aspects: firstly, the locking sleeve requires high dimensional accuracy; secondly, and more importantly, the part has U-shaped bends at both ends and a square bend in the middle, similar to a USB port. The square cavity is only 2.1mm × 1.55mm in size, with limited space, and the maximum opening distance after the square is closed is ≤0.2mm, posing challenges to the design of the bending die. Connectors for new energy vehicles have even higher precision requirements, with tolerances around 1 micrometer; high requirements are also placed on positioning accuracy and hole smoothness; however, their dimensions are larger than the aforementioned existing technologies. The design challenges lie not only in the high precision requirements but also in other aspects such as the absence of creases at the bends and minimizing material stress release. Summary of the Invention

[0003] The purpose of this invention is to overcome the defects in the existing technology and provide a progressive die for stamping connectors for new energy vehicles. Through the design of the step sequence and the structural design of the progressive die, the precision requirements of connectors for new energy vehicles can be met. Pre-bending can reduce the stress release of the material and also help to improve the final product precision. The rolling bending method eliminates creases and helps to improve the final product precision.

[0004] To achieve the above objectives, the technical solution of the present invention is to design a progressive die for stamping connectors of new energy vehicles, which consists of an upper die and a lower die. The upper die, from top to bottom, consists of an upper cover plate, an upper die base, an upper pad plate, an upper clamping plate, a stop plate, and an upper stripper plate; the lower die, from top to bottom, consists of a concave die plate, a lower pad plate, a lower die base, and a lower pad foot. The concave die is provided with blind holes for the pre-bending process, and the upper die is provided with corresponding pre-bending punches for pre-bending. The concave die has blind holes for bending, and the upper die has corresponding bending punches for bending; rollers are rotatably mounted on the bending punch. A placement plate is fixedly installed extending outward from one of the side end faces of the upper ejector plate and the lower die base. A gap-blocking structure is provided on the placement plate of the upper ejector plate to block the gap between the upper and lower dies of the progressive die during equipment operation, preventing them from entering to pick up or place parts and remove residual material. Pre-bending reduces material stress and helps improve the final product accuracy; rolling bending eliminates creases, further contributing to improved final product accuracy.

[0005] A further technical solution involves a groove on the lower mold base to accommodate a spring used in the shaping process. A top plate is fixedly connected to the top of the spring, and a top post is fixedly connected to the top plate. The lower mold base has a through hole for the top post to pass through and guide it. There are two top posts, each with a shaping slider fixedly mounted on it. The two shaping sliders are symmetrically arranged about the rotation axis of the spring. The shaping sliders are slidably mounted on wedges, which are mounted on the concave mold plate. When the shaping sliders are not pressed, their upper surfaces extend beyond the upper surface of the concave mold plate. The shaping sliders are used for shaping after bending to improve accuracy and ensure positioning accuracy.

[0006] A further technical solution is that the pre-bending punch has a beveled surface at a 45° angle to the vertical side of the pre-bending punch; the pre-bending punch extends beyond the lower end face of the upper stripper plate. Pre-bending is used to first bend the Z-shaped bend (i.e., the 90° bend at the square with the round hole at the end of the unfolded diagram of the new energy vehicle connector) by 45°. This 45° pre-bending is achieved by the pre-bending punch extruding the material strip during progressive die operation, avoiding the large material release stress that would result from a direct 90° bend, thus preventing the accuracy requirements from being met.

[0007] A further technical solution involves the bending punch head extending beyond the lower end face of the upper stripper plate. The bending punch head has a curved surface that conforms to the smooth transition surface of the Z-shaped bend in the new energy vehicle connector. The roller is tangent to the curved surface. The aforementioned punch head also has a superior arc groove connected to the curved surface for the roller to roll relative to the bending punch. Although the roller is tangent to the curved surface, for the 45° bend portion of the strip, the roller is the first point of contact. Therefore, during the stamping process, rolling bending (i.e., bending from 45° to 90°) is achieved, and the superior arc groove effectively enables the roller to roll relative to the bending punch.

[0008] A further technical solution involves providing a pair of mirror-aligned blind holes on the concave template for simultaneous pre-bending on the strip, and a pair of mirror-aligned pre-bending punches on the upper clamping plate, stop plate, and upper stripper plate for pre-bending. This configuration allows for the formation of two mirror-aligned pre-bends during a single pre-bend, which are then mirror-aligned and simultaneously bent in subsequent bending processes to ultimately cut off sequentially, producing two new energy vehicle connectors of opposite orientations.

[0009] A further technical solution is that the pre-bending punch is configured to penetrate the upper clamping plate, the stop plate, and the upper release plate, and the upper end face of the pre-bending punch is flush with the upper end face of the upper clamping plate; the bending punch is configured to penetrate the upper clamping plate, the stop plate, and the upper release plate, and the upper end face of the bending punch is flush with the upper end face of the upper clamping plate; the spring is a rectangular helical spring SWH20-50.

[0010] The present invention also provides a stamping forming method, which employs the progressive die for stamping forming of new energy vehicle connectors, including a layout design method for new energy vehicle connectors, the specific steps of which are as follows: S1: Perform a Z-shaped bend on the square block with a round hole at the end of the length direction of the unfolded diagram of the new energy vehicle connector; S2: For two V-shaped bends that are connected end to end in the length direction, a V-bend is first made to form the initial bend of the end V-shaped bend and the second to last V-shaped bend at the end. S3: Continue bending the initial bend formed in step S2 to form the penultimate V-shaped bend at the end, and then shape it; S4: Cutting off the starting end and both sides along the length. This process combines two bends (i.e., two V-shaped bends connected end-to-end) into a single operation (this refers to the initial bend to form the final V-shaped bend and the penultimate V-shaped bend; it doesn't directly form two V-shaped bends, but rather one and the other as initial bends), improving efficiency. Combined with pre-bending and simultaneous bending of two parts during the bend (i.e., mirror bending), this supports the final stamping speed of 80 strokes / min.

[0011] A further technical solution includes the following sequential steps: punching, punching, punching, idle step, trimming, idle step, punching, thinning, flattening, idle step, precision cutting, punching, punching, head chamfering, trimming, idle step, precision punching, burr removal, idle step, idle step, pre-bending, idle step, idle step, bending, idle step, shaping, idle step, idle step, idle step, trimming, V-bending, bending, shaping, shaping, shaping, shaping, cutting and unloading. An idle step process is set as a preparatory process to facilitate subsequent adjustments based on the progressive die's stamping performance. For bending, a pre-bending process is also included to reduce material stress release; the stamping speed of this progressive die can reach 80 times / min (significantly improving efficiency compared to the dozen or so times / minute of existing technologies); this progressive die uses a rolling bending method, eliminating creases. Through the pre-bending, rolling bending, shaping slider, and precision cutting processes, high precision requirements are achieved.

[0012] The advantages and beneficial effects of this invention are as follows: by designing the step sequence and combining it with the structural design of the progressive die, the precision requirements of connectors for new energy vehicles can be met; by pre-bending, the stress release of the material can be reduced, which also helps to improve the final required product precision; Two mirrored pre-bends are formed during a single pre-bend, and these mirrored pairs are also set up in subsequent bending processes. Simultaneous bending achieves the final sequential cutting to produce two new energy vehicle connectors of opposite orientations. This improves the stamping efficiency of connectors for new energy vehicles, with a stamping speed of 80 strokes / min in this stage of the die (significantly higher efficiency compared to the current technology's dozen or so strokes per minute). This stage of die-cutting uses a rolling bending method, which eliminates creases and helps improve the final precision required for the product. The shaping slider is used for shaping after bending to improve accuracy and ensure positioning accuracy.

[0013] Pre-bending is used to bend the Z-shaped bend (i.e., the 90° bend) at the square block with a round hole at the end of the unfolded diagram of the new energy vehicle connector by first bending it 45°. When the progressive die is working, the pre-bending punch extrudes the material strip to achieve the pre-bending of 45°, avoiding the large material release stress that would be generated by directly bending 90°, and avoiding the problem that the accuracy cannot be met due to the large material release stress.

[0014] Although the roller is tangent to the curved surface, the section of the strip bent at 45° will first come into contact with the roller, thus achieving rolling bending (that is, bending from 45° to 90°) during the stamping process. The superior arc groove effectively enables the roller to roll relative to the bending punch.

[0015] This setup allows for the creation of two mirrored pre-bends during a single pre-bend. These mirrored pre-bends are then mirrored and paired in subsequent bending processes. Finally, the bending process achieves sequential cutting to produce two new energy vehicle connectors of opposite orientations.

[0016] By combining the original two bends (i.e., two V-shaped bends connected end-to-end) into a single process (this refers to the initial bend used to form the final V-shaped bend and the penultimate V-shaped bend, meaning it doesn't directly form two V-shaped bends, but rather forms one and the other as initial bends), efficiency is improved. Combined with pre-bending and simultaneous bending of two parts during the bend (i.e., mirror bending), this supports the achievement of a final stamping speed of 80 times / min. The high precision requirements are achieved through the setup of pre-bending, rolling bending, shaping slide, and precision cutting processes. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of a progressive die for stamping connectors for new energy vehicles according to the present invention. Figure 2 yes Figure 1 Side view; Figure 3 yes Figure 2 An exploded view of the upper and lower molds; Figure 4 yes Figure 2Enlarged schematic diagram of the elliptical portion A after rotating 90° counterclockwise; Figure 5 yes Figure 3 Enlarged schematic diagram of the elliptical portion B after rotating 90° counterclockwise; Figure 6 yes Figure 2 Enlarged schematic diagram of the elliptical portion C after rotating 90° counterclockwise; Figure 7 yes Figure 6 Exploded view of the bending punch and roller; Figure 8 This is a schematic diagram of the new energy vehicle connector processed according to Embodiment 1 of the present invention; Figure 9 yes Figure 8 A diagram from another perspective; Figure 10 yes Figure 8 A schematic diagram of the material strip unfolding; Figure 11 yes Figure 2 A schematic diagram of the sliding block mold closing process in the shaping section; Figure 12 yes Figure 11 Schematic diagram of the slider mold opening; Figure 13 yes Figure 11 Exploded view of the central top column, shaping slider, wedge block and material strip; Figure 14 yes Figure 12 Exploded view of the central top column, shaping slider, wedge block and material strip; Figure 15 yes Figure 1 A step sequence diagram of the stamping process; Figure 16 yes Figure 15 A diagram of the lower half; Figure 17 yes Figure 15 A schematic diagram of the upper part; Figure 18 This is a schematic diagram of Embodiment 2 of the present invention; Figure 19 yes Figure 18 Another schematic diagram of the working state; Figure 20 yes Figure 18 A schematic diagram illustrating the working principle; Figure 21 yes Figure 19 A schematic diagram illustrating the working principle; Figure 22 yes Figure 21 Enlarged schematic diagram of the upper and middle stripper plate and stop plate section; Figure 23 yes Figure 21 A schematic diagram after removing the flexible metal mesh, connecting ropes, and geared motor; Figure 24 yes Figure 18 Side view; Figure 25 yes Figure 1 A magnified view of the upper part; Figure 26 yes Figure 1 A magnified view of the middle part; Figure 27 yes Figure 1 A magnified view of the lower part.

[0018] In the diagram: 1. Upper cover plate; 2. Upper mold base; 3. Upper pad plate; 4. Upper clamping plate; 5. Stop plate; 6. Upper stripper plate; 7. Concave mold plate; 8. Lower pad plate; 9. Lower mold base; 10. Lower support foot; 11. Roller; 12. Pre-bending punch; 13. Bending punch; 14. Spring; 15. Top pillar; 16. Shaping slider; 17. Wedge block; 18. Inclined surface; 19. Smooth transition surface; 20. Curved surface; 21. Curved groove; 22. Square block with round hole; 23. V-bend; 24. Placement plate; 25. Flexible metal mesh; 26. Connecting rope; 27. Gear motor; 28. Metal column; 29. ​​Long section; 30. Short section. Detailed Implementation

[0019] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings and examples. The following examples are only used to more clearly illustrate the technical solutions of the present invention and should not be construed as limiting the scope of protection of the present invention.

[0020] Example 1: As Figures 1 to 17 , Figures 25 to 27As shown, the present invention is a progressive die for stamping connectors of new energy vehicles, consisting of an upper die and a lower die. The upper die, from top to bottom, comprises an upper cover plate 1, an upper die base 2, an upper pad plate 3, an upper clamping plate 4, a stop plate 5, and an upper stripper plate 6. The lower die, from top to bottom, comprises a concave template 7, a lower pad plate 8, a lower die base 9, and a lower pad foot 10. The concave template 7 is provided with blind holes for pre-bending, and a pre-bending punch 12 for pre-bending is correspondingly provided on the upper die. The concave template 7 is provided with blind holes for bending, and a bending punch 13 for bending is correspondingly provided on the upper die. Rollers 11 are rotatably mounted on the bending punch 13. Six lower support feet 10 of equal thickness are provided, spaced apart from each other; one lower mold base 9 is provided; three lower pads 8 are provided and arranged side-by-side along the length of the lower mold base 9; three concave templates 7 are provided, each located directly above one of the three lower pads 8 (a connecting block is provided on the lower mold base, and a material guide plate is provided on the connecting block; this is existing technology and will not be described in detail). The bottom surface of the concave template 7 matches the bottom surface of the lower pad 8; one upper mold base is provided, and the size of its bottom surface is the same as the size of the bottom surface of the lower mold base 9; three upper cover plates are provided and arranged side-by-side along the length of the upper mold base, and the sum of the lengths of the three upper cover plates matches the length of the upper mold base; three upper pads are provided and arranged side-by-side along the length of the upper mold base; three upper clamping plates, three stop plates 5, and three upper ejector plates 6 are also provided; the bottom surfaces of the upper pads, upper clamping plates, three stop plates 5, and three upper ejector plates 6 all match the bottom surface of the lower pads 8; the lower mold base 9 has a groove for... A spring 14 is used to accommodate the shaping process. A top plate is fixedly connected to the top of the spring 14, and a top post 15 is fixedly connected to the top plate. The lower pad 8 has a through hole for the top post 15 to pass through and guide it. There are two top posts 15, and a shaping slider 16 is fixedly mounted on each top post 15. The two shaping sliders 16 are symmetrically arranged about the rotation axis of the spring 14. The shaping sliders 16 are slidably mounted on a wedge block 17, which is mounted on a concave template 7. When the shaping slider 16 is not pressed, its upper end face extends beyond the upper end face of the concave template 7. The pre-bending punch 12 has a bevel 18 on its punch head that forms a 45° angle with the vertical side of the pre-bending punch 12. The punch head of the pre-bending punch 12 extends beyond the lower end face of the upper stripper plate 6. The punch head of the bending punch 13 extends beyond the lower end face of the upper stripper plate 6. The punch head of the bending punch 13 has a curved surface 20 that is similar in shape to the Z-shaped bending smooth transition surface 19 of the new energy vehicle connector. The roller 11 is tangent to the curved surface 20. The aforementioned punch head also has a superior arc groove 21 connected to the curved surface 20 for the roller 11 to roll relative to the bending punch 13. The concave template 7 has a pair of mirror-image blind holes for simultaneously performing pre-bending on the strip. The upper clamping plate 4, the stop plate 5, and the upper stripper plate 6 have a pair of mirror-image pre-bending punches 12 for pre-bending.The pre-bending punch 12 is set through the upper clamping plate 4, the stop plate 5 and the upper release plate 6, and the upper end face of the pre-bending punch 12 is flush with the upper end face of the upper clamping plate 4; the bending punch 13 is set through the upper clamping plate 4, the stop plate 5 and the upper release plate 6, and the upper end face of the bending punch 13 is flush with the upper end face of the upper clamping plate 4; the spring 14 is a rectangular helical spring 14SWH20-50.

[0021] A stamping forming method, employing the progressive die used for stamping new energy vehicle connectors, includes the following sequential steps: punching, punching, punching, idle step, trimming, idle step, punching, thinning, flattening, idle step, precision cutting, punching, punching, head chamfering, trimming, idle step, precision punching, burr removal, idle step, idle step, pre-bending, idle step, idle step, bending, idle step, shaping, idle step, idle step, idle step, trimming, V-bending, bending, shaping, shaping, shaping, shaping, cutting, and unloading. It also includes a layout design method for new energy vehicle connectors, with the specific steps as follows: S1: Perform a Z-shaped bend on the square block 22 with a round hole at the end of the length direction of the unfolded diagram of the new energy vehicle connector; S2: The two V-shaped bends 23 connected end to end in the length direction are first bent into V-shapes to form the initial bends of the end V-shaped bend 23 and the second to last V-shaped bend 23. S3: Continue bending the initial bend formed in step S2 to form the penultimate V-bend 23 at the end, and then shape it; S4: Cut off the starting end and both sides in the length direction.

[0022] like Figure 12 , 14 As shown, the shaping slider 16 is slidably disposed relative to the wedge block 17. The side of the shaping slider facing the wedge block 17 has an inclined surface that matches the inclined surface of the wedge block 17. When the upper mold presses down, the shaping slider 16 slides downward along the wedge block 17 due to the upper ejector plate 6 abutting against it. The two shaping sliders 16 simultaneously move closer to each other (due to the inclined surface matching, the shaping sliders slide downward while moving closer to each other). The bent portion of the strip is shaped by the two relatively moving shaping sliders. The closed mold state is as follows. Figure 11 , 13 As shown.

[0023] Example 2: The difference from Example 1 is that, as shown in Example 2... Figures 18 to 24 As shown (for ease of illustration), Figure 18 , 19 Flexible metal mesh and hanging rod components are not shown. Figure 20 The flexible metal mesh is shown, but the overall length of the progressive die has been reduced for easier display. Figure 20 The upper mold base and upper cover plate are not shown. Figure 21 and Figure 22In the middle, the plate above the upper ejector plate is the stop plate. A placement plate 24 is fixedly installed extending outwards from the side end faces of the upper ejector plate 6 and the lower die base 9 (actually two of the four side end faces of the upper ejector plate 6 and the lower die base 9, as the other two side end faces are the material feed and discharge points). A flexible metal mesh 25 (or a flexible mesh fabric can be used instead of a flexible metal mesh) is placed on the placement plate 24 of the upper ejector plate 6. There are four flexible metal meshes 25, each located on a ring of side end faces of the placement plate 24 of the upper ejector plate 6. The length of the flexible metal mesh 25 is consistent with the length of the placement plate 24 on which the upper ejector plate 6 is placed, and the width is consistent with the maximum distance between the upper ejector plate 6 and the lower die base 9 during progressive die operation. The upper end of the flexible metal mesh 25 is fixedly connected to the side end face of the placement plate 24, and the lower end of the flexible metal mesh is connected to the output shaft of the reduction motor 27 through the connecting rope 26 (in order to ensure the smoothness and balance of the winding and unwinding process of the flexible metal mesh 25, a pair of reduction motors 27 can be set at the two ends above the flexible metal mesh respectively). The reduction motors 27 are fixedly installed on the upper ejector plate 6. On the placement plate 24; the lowest end of the flexible metal mesh can be set as a thicker metal column 28, making the lower end of the entire flexible metal mesh relatively heavy, so that the flexible metal mesh 25 can be smoothly lowered and rolled up when the reduction motor 27 is running (or an alternative solution: the lower end of the flexible metal mesh is no longer connected to the connecting rope, but is fixedly connected to the ferromagnetic block, the ferromagnetic block is fixedly connected to the lower end of the compression spring, the top end of the compression spring is fixedly connected to the lower surface of the placement plate of the upper release plate 6, and the upper end of the ferromagnetic block faces one end of the electromagnet). The end face of the electromagnet facing the ferromagnetic block is positioned to avoid the compression spring. With this configuration, before the equipment starts running, the electromagnet is energized to connect with the ferromagnetic block, overcoming the spring force and causing the flexible metal mesh to retract. After the equipment starts running, the electromagnet is de-energized, releasing the spring force, allowing the flexible metal mesh to unwind and cover the entire progressive die. When the equipment stops running, the electromagnet is re-energized, connecting with the ferromagnetic block, overcoming the spring force, and the flexible metal mesh is retracted again, thus automating the entire process.

[0024] A hanging rod is provided on the placement plate 24 of the lower mold base 9. The hanging rod is folded, with the longer segment 29 inclined upwards to the horizontal line, and the shorter segment 30 forming an acute angle with the longer segment 29. The shorter segment 30 is made of an elastic material (such as hard rubber or other materials with a certain degree of elasticity). One end of the longer segment 29 of the hanging rod is fixedly connected to the side end face of the placement plate 24 of the lower mold base 9. The distance between the furthest part of the hanging rod from the side end face of the placement plate 24 of the lower mold base 9 and the side end face of the placement plate 24 is slightly larger than the distance between the flexible metal mesh 25 after unwinding and the side end face of the placement plate 24 of the lower mold base 9. Thus, when the equipment is running (the equipment is connected to the controller signal, and the controller is connected to the geared motor signal), the geared motor 27 rotates in the forward direction, realizing the unwinding of the connecting rope wound on the output shaft of the geared motor. Correspondingly, the flexible metal mesh 25 is unwound, and because the shorter segment 30 is downward and inward (here, inward refers to towards the middle of the progressive die width direction, that is...), the flexible metal mesh 25 is unwound. Figure 24 The middle part) is tilted, such as Figure 24 As shown, the flexible metal mesh 25 (firstly, the lower end of the flexible metal mesh 25, i.e., its metal column 28, shifts inward along the short segment 30, so it is finally hooked by the hanging rod) is hooked by the hanging rod (since the width of the flexible metal mesh is consistent with the maximum distance between the upper ejector plate 6 and the lower die base 9 during the operation of the progressive die, the hanging rod always keeps hooked on the flexible metal mesh during the process of the upper and lower dies approaching and moving away), so that the gap (or interval space) between the upper and lower dies of the progressive die is covered by the flexible metal mesh 25 when the equipment is running, the human hand is blocked and cannot enter the aforementioned gap to pick up or put down parts or remove residual materials, which can completely eliminate such accidents, and is fully automated, responding dynamically with the operation and stopping of the equipment. When the equipment stops running, the controller controls the geared motor 27 to rotate in reverse, so that the previously unwound connecting rope is wound back onto the output shaft of the geared motor. Due to the elastic material of the short section 30 of the folded hanging rod, the flexible metal mesh that is wound up overcomes the elasticity of the hanging rod when the geared motor 27 rotates in reverse. That is, the short section 30 of the hanging rod deforms due to the force, resulting in a larger angle between the short section and the long section, or the short section bends upward from the middle part to make the flexible metal mesh detach from the hanging rod and rewound onto the placement plate of the upper release plate 6 so that when the equipment stops running, a person can enter the space between the upper and lower molds to pick up and put down parts and remove residual materials.

[0025] Because progressive dies require strict adherence to operating rules, it is forbidden to insert hands into the die to pick up or remove parts or residual material while the equipment is running. However, operational errors and accidents still occur from time to time, and relying solely on the operator's vigilance cannot completely prevent such incidents. Therefore, this design completely avoids this situation. Once the equipment is running, the flexible metal mesh unwinds and covers the gap between the upper and lower dies of the progressive die, preventing the operator from inserting their hands into the die to pick up or remove parts or residual material. After the equipment stops running, the flexible metal mesh automatically rewinds, completely automatically, without requiring additional manpower. Thus, it achieves automated protection of the operator and completely eliminates such accidents.

[0026] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A stamping forming method, characterized in that, The layout design method for connectors in new energy vehicles includes the following specific steps: S1: Perform a Z-shaped bend on the square block with a round hole at the end of the length direction of the unfolded diagram of the new energy vehicle connector; S2: For two V-shaped bends that are connected end to end in the length direction, a V-bend is first made to form the initial bend of the end V-shaped bend and the second to last V-shaped bend at the end. S3: Continue bending the initial bend formed in step S2 to form the penultimate V-shaped bend at the end, and then shape it; S4: Cut off the starting end and both sides in the length direction; Before the equipment runs, the electromagnet is energized to connect with the ferromagnetic block, the spring force is overcome, and the flexible metal mesh is rolled up. After the equipment runs, the electromagnet is de-energized, the spring force is released, and the flexible metal mesh is unrolled to cover the entire progressive die. When the equipment stops running, the electromagnet is energized again, connecting with the ferromagnetic block, the spring force is overcome, and the flexible metal mesh is rolled up again. Alternatively, when the equipment is running, the geared motor rotates in the forward direction, unwinding the connecting rope wound on the output shaft of the geared motor. Correspondingly, the flexible metal mesh unwinds, and because the short section is inclined downwards towards the middle of the progressive die width, the lower end of the flexible metal mesh, i.e., its metal column, first shifts inwards along the short section, so it is finally hooked by the hanging rod. This ensures that when the equipment is running, the space between the upper and lower dies of the progressive die is covered by the flexible metal mesh, blocking human hands from entering the gap to pick up or put down parts or remove residual materials, completely eliminating such accidents. Furthermore, it is fully automated, responding to the operation and stopping of the equipment; when the equipment stops... When the machine is running, the controller controls the geared motor to run in reverse, so that the previously unwound connecting rope is wound back onto the output shaft of the geared motor. Due to the elastic material of the short section of the folded hanging rod, the flexible metal mesh that is wound up overcomes the elasticity of the hanging rod when the geared motor runs in reverse. That is, the short section of the hanging rod deforms due to the force, resulting in a larger angle between the short section and the long section, or the short section bends upward from the middle part to allow the flexible metal mesh to detach from the hanging rod and be wound back up onto the placement plate of the upper release plate. This makes it easier for a person to enter the space between the upper and lower molds to pick up and put down parts and remove residual materials when the equipment stops running. The progressive die used for stamping connectors for new energy vehicles consists of an upper die and a lower die. The upper die, from top to bottom, comprises an upper cover plate, an upper die base, an upper pad plate, an upper clamping plate, a stop plate, and an upper stripper plate. The lower die, from top to bottom, comprises a concave die plate, a lower pad plate, a lower die base, and a lower pad foot. The concave die is provided with blind holes for the pre-bending process, and the upper die is provided with corresponding pre-bending punches for pre-bending. The concave die has blind holes for bending, and the upper die has corresponding bending punches for bending; rollers are rotatably mounted on the bending punch. A placement plate is fixedly installed on the outer side surface of the upper ejector plate and the lower mold base. A flexible metal mesh is placed on the placement plate of the upper ejector plate. The lower end of the flexible metal mesh is fixedly connected to a ferromagnetic block. The ferromagnetic block is fixedly connected to the lower end of a compression spring. The top end of the compression spring is fixedly connected to the lower plate surface of the placement plate of the upper ejector plate. The upper end face of the ferromagnetic block faces one end of the electromagnet so that the gap between the upper and lower molds of the progressive die is blocked during equipment operation, preventing the entry of parts for picking up and placing and removing residual materials. Alternatively, the ferromagnetic block can be replaced by a connecting rope. The length of the flexible metal mesh is the same as the length of the placement plate on which the upper ejector plate is placed, and the width is the same as the maximum distance between the upper ejector plate and the lower die base during progressive die operation. The upper end of the flexible metal mesh is fixedly connected to the side end face of the placement plate, and the lower end of the flexible metal mesh is connected to the output shaft of the geared motor via a connecting rope. A pair of geared motors are provided, located at opposite ends above the flexible metal mesh, and the geared motors are fixedly mounted on the placement plate of the upper ejector plate. The bottom of the flexible metal mesh is a metal column to make the bottom of the entire flexible metal mesh relatively heavy. When the geared motor is running, the flexible metal mesh can be smoothly laid down and rolled up; the placement plate of the lower mold base is equipped with a hanging rod, which is folded and the long section is inclined upward with the horizontal line, while the short section is set at an acute angle with the long section. The short section is made of elastic material. One end of the long section of the hanging rod is fixedly connected to the side end face of the placement plate of the lower mold base. The distance between the farthest part of the hanging rod and the side end face of the placement plate of the lower mold base is slightly greater than the distance between the flexible metal mesh and the side end face of the placement plate of the lower mold base after unwinding.

2. The stamping forming method according to claim 1, characterized in that, The lower mold base is provided with a groove to accommodate the spring used in the shaping process. A top plate is fixedly connected to the top of the spring, and a top post is fixedly connected to the top plate. The lower pad is provided with a through hole for the top post to pass through and guide the top post. There are two top posts, and a shaping slider is fixedly installed on each top post. The two shaping sliders are symmetrically arranged about the rotation axis of the spring. The shaping slider is slidably mounted on the wedge block, which is mounted on the concave template. When the shaping slider is not pressed, its upper end face extends beyond the upper end face of the concave template.

3. The stamping forming method according to claim 2, characterized in that, The pre-bending punch has a beveled surface on its punch head that forms a 45° angle with the vertical side of the pre-bending punch; the punch head of the pre-bending punch extends beyond the lower end face of the upper stripper plate.

4. The stamping forming method according to claim 3, characterized in that, The punch head of the bending punch extends beyond the lower end face of the upper stripper plate; the punch head of the bending punch is provided with a curved surface that is similar to and adapted to the smooth transition surface of the Z-shaped bending of the new energy vehicle connector; the roller is tangent to the curved surface; the aforementioned punch head is also provided with an arc groove connected to the curved surface for the roller to roll relative to the bending punch.

5. The stamping forming method according to claim 4, characterized in that, The concave template is provided with a pair of mirror-shaped blind holes for simultaneously performing a pre-bending process on the strip, and the upper clamping plate, the stop plate and the upper stripping plate are provided with a pair of mirror-shaped pre-bending punches for pre-bending.

6. The stamping forming method according to claim 4, characterized in that, The pre-bending punch is configured to pass through the upper clamping plate, the stop plate, and the upper release plate, and the upper end face of the pre-bending punch is flush with the upper end face of the upper clamping plate; the bending punch is configured to pass through the upper clamping plate, the stop plate, and the upper release plate, and the upper end face of the bending punch is flush with the upper end face of the upper clamping plate; the spring is a rectangular helical spring SWH20-50.

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