Alloy resistor stamping device, resistor production process and alloy resistor

Abstract

The invention provides an alloy resistor stamping device, a resistor production process and an alloy resistor. The alloy resistor stamping device comprises an upper die and a lower die. A main body forming area, a pin forming area, a blanking area and a plurality of guide pins are arranged in the lower die, a plurality of main body sheaths are arranged in the main body forming area, a plurality of pin sheaths are arranged in the pin forming area, a plurality of cutting sheaths are arranged in the blanking area, and the main body sheaths, the pin sheaths and the cutting sheaths are all provided with knife edges and internally provided with floating roofs; the floating roof comprises a contact block and a spring; the upper die is provided with a main body cutter, a pin cutter and an offcut cutter; and when the upper die and the lower die are closed, the cutters extend into the corresponding sheaths and are in contact with the contact blocks in the sheaths. The pin cutter comprises a first cutter and a second cutter. Therefore, pin falling and position deviation can be avoided, the quality of the alloy resistor is improved, and the reject ratio in the production process of the alloy resistor is reduced.

Description

Technical Field

[0001] The invention relates to the field of resistor production, and in particular to an alloy resistor stamping device, a resistor production process and an alloy resistor. Background Art

[0002] Increasing the pin length of the resistor can ensure the stability of the resistor connection in the circuit. The pin diameter of the existing long-pin resistor is 0.8mm, and the pin length is more than 12mm. The pins in this resistor product are slender and easy to be bent during production.

[0003] In the existing processing method, when producing resistors with long pins, the resistor body and the pins need to be produced separately, and then the two need to be welded together using welding equipment. Due to the small diameter of the pins, the effective welding area between the pins and the resistor body is small, and the risk of the pins falling off is high; at the same time, in the above production method, the pins and the resistor body are first processed separately and then transferred to the welding station for welding. During welding, the position where the pins and the resistor body are connected is prone to deviation, which results in a high defect rate in the existing production process of resistors with slender pins and unstable product quality. Summary of the invention

[0004] The purpose of the present invention is to overcome the shortcomings of the prior art and provide an alloy resistor, an alloy resistor stamping device and a production process thereof to prevent the pins from easily falling off and shifting in position, improve the quality of the alloy resistors, and reduce the defective rate in the alloy resistor production process.

[0005] The objective of the present invention is achieved through the following technical solutions:

[0006] An alloy resistor stamping device is used to produce an alloy resistor with a slender pin structure, the alloy resistor comprises: a resistor body and a pin; the pin and the resistor body are integrally formed; the pin comprises a transition portion and a body, the transition portion is connected to the resistor body, and the thickness of the transition portion is greater than the thickness of the body, the alloy resistor stamping device comprises: an upper die and a lower die;

[0007] The lower mold is provided with a main body molding area, a pin molding area, a blanking area and a plurality of guide pins, the main body molding area is provided with a plurality of main body scabbards, the pin molding area is provided with a plurality of pin scabbards, the blanking area is provided with a plurality of cutting scabbards, the main body scabbards, the pin scabbards and the cutting scabbards are all provided with blade edges, the main body scabbards, the pin scabbards and the cutting scabbards are all provided with floating tops, the floating tops include a contact block and a spring, the contact block abuts against the blade edge;

[0008] The upper die is provided with a main body cutter matching the main body scabbard, a pin cutter matching the pin scabbard, and a side material cutter matching the cutting scabbard;

[0009] When the upper mold and the lower mold are closed, the cutting knife extends into the corresponding sheath and contacts the contact block in the sheath.

[0010] The lead cutter includes a first cutter and a second cutter, and the width of the second cutter is greater than the width of the first cutter.

[0011] In one embodiment, a step is provided between the transition portion and the main body.

[0012] In one of the embodiments, a resistance adjustment groove is provided on the resistor body.

[0013] In one of the embodiments, a bending insert is provided between the main body forming area and the pin forming area, and the upper mold is provided with a pressing block matching the bending insert.

[0014] In one of the embodiments, a plurality of lifting push blocks are provided in the lower mold, and the plurality of lifting push blocks are used to push up the upper mold.

[0015] In one of the embodiments, the lower mold is provided with a feed hole, the main body scabbard, the pin scabbard and the cutting scabbard are all connected to the feed hole, and the floating top is located in the feed hole.

[0016] A resistor production process, based on the above alloy resistor stamping device, comprises the following steps:

[0017] Step 1: Combine the resistor body raw material and the pin raw material together through a rolling process to obtain a composite metal strip;

[0018] Step 2: conveying the composite metal strip toward the alloy resistance stamping device;

[0019] Step 3: When the upper die and the lower die are closed, the main cutting knife and the main scabbard cooperate to stamp the composite metal strip, forming a resistor body and a transition portion on the composite metal strip to obtain a semi-finished product;

[0020] Step 4: When the upper die and the lower die are opened, the composite metal strip is continuously driven forward to move the semi-finished product from the main body forming area to the pin forming area;

[0021] Step 5: The upper die and the lower die are closed, and the pin cutter and the pin sheath cooperate to punch out the main body at the terminal end of the transition part, forming the prototype of the alloy resistor in the composite metal strip;

[0022] Step 6: After the upper die and the lower die are closed and opened again, the part of the composite metal strip containing the prototype of the alloy resistor is moved to the unloading area;

[0023] Step 7: Cut off the scabbard and the edge material cutter to cooperate to cut off the edge material on the prototype of the alloy resistor to obtain the alloy resistor.

[0024] In one embodiment, in step 3, step 5 and step 7, when the upper mold and the lower mold are closed, each cutting knife extends into the corresponding sheath and contacts the floating top therein.

[0025] In one of the embodiments, in step 5, the upper mold and the lower mold are molded together twice. During the first mold closing, the semi-finished product is located below the first tool, and the first tool cuts off part of the edge material on the composite metal strip to obtain a main body prototype with the same width as the transition part; during the second mold closing, the semi-finished product is moved to the bottom of the second tool, and the second tool trims the main body prototype to obtain the main body.

[0026] The alloy resistor, alloy resistor stamping device and production process provided in the present application can prevent the pins from falling off and shifting in position, improve the quality of the alloy resistors, and reduce the defective rate in the alloy resistor production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0028] Figure 1 It is the structural diagram of the alloy resistor;

[0029] Figure 2 This is a schematic diagram of defective products;

[0030] Figure 3 is a schematic diagram of the structure of the composite metal strip;

[0031] Figure 4 It is a structural schematic diagram of the alloy resistor stamping device;

[0032] Figure 5 It is a structural schematic diagram of the lower mold;

[0033] Figure 6 It is a structural schematic diagram of the upper die;

[0034] Figure 7 It is a schematic diagram of the cooperation between the pin cutter and the pin sheath;

[0035] Figure 8 It is a structural schematic diagram of the pin scabbard and the floating top.

[0036] Figure numerals: 1, resistor body raw material; 2, pin raw material; 20, bending structure; 100, alloy resistor; 110, resistor body; 111, resistance adjustment groove; 120, pin; 121, transition part; 122, body; 123, step; 200, alloy resistor stamping device; 210, upper die; 211, main body cutter; 212, pin cutter; 2121, first tool; 2122, second tool; 213, edge material Cutter; 214, pressing block; 220, lower die; 21, main body forming area; 22, pin forming area; 23, unloading area; 24, guide pin; 25, blade; 221, main body scabbard; 222, pin scabbard; 223, cutting scabbard; 224, bending insert; 225, lifting push block; 230, floating top; 231, contact block; 232, spring; 30, composite metal strip; 31, semi-finished product; 32, main body prototype. DETAILED DESCRIPTION

[0037] In order to facilitate the understanding of the present invention, the present invention will be described more fully below with reference to the relevant drawings. The preferred embodiments of the present invention are given in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thoroughly understood.

[0038] It should be noted that when an element is referred to as being "fixed to" another element, it may be directly on the other element or there may be a central element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a central element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only and do not represent the only implementation method.

[0039] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used herein in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0040] See also Figure 1 The present invention provides an alloy resistor 100 , which includes: a resistor body 110 and a pin 120 .

[0041] The pin 120 is integrally formed with the resistor body 110;

[0042] The pin 120 includes a transition portion 121 and a body 122 . The transition portion 121 is connected to the resistor 110 . The thickness of the transition portion 121 is greater than that of the body 122 .

[0043] Preferably, a step 123 is provided between the transition portion 121 and the main body 122 ; and a resistance adjustment groove 111 is provided on the resistor body 110 .

[0044] In the above-mentioned alloy resistor 100, the pin 120 is integrally formed with the resistor body 110, and the pin 120 is not connected to the resistor body 110 by welding in the subsequent process. Therefore, the pin 120 will not fall off due to the problem of insufficient welding area, and a transition portion 121 is provided at the contact point between the pin 120 and the body 122, and the thickness of the transition portion 121 is greater than the thickness of the body 122. On the basis of the integral formation of the pin 120 and the resistor body 110, the connected area is increased, making the pin 120 more secure; at the same time, the pin 120 is integrally formed with the resistor body 110, which also avoids the problem of the position of the pin 120 being offset when welding the pin 120 in the original process, so that the dimensional accuracy of the alloy resistor 100 is guaranteed.

[0045] The pin 120 and the resistor body 110 in the alloy resistor 100 are integrally formed, and the raw material needs to be processed by punching. Specifically, the alloy raw material is punched by a stamping machine, wherein the length of the pin 120 is 12 mm and the diameter is 0.8 mm, and the ratio of the two is 15:1. Due to the large aspect ratio of the pin, the pressure generated during the punching process can easily cause the pin 120 to bend, forming a shape such as Figure 2 The bending structure 20 shown is prone to produce defective products when the alloy resistor 100 is manufactured using the original equipment.

[0046] See also Figure 4 , in order to solve the above problems, the present application also provides the following alloy resistor stamping device 200, which is used to produce the above alloy resistor 100, and the alloy resistor stamping device 200 includes: an upper die 210 and a lower die 220;

[0047] See also Figure 4 , Figure 5 and Figure 6 The lower mold 220 is provided with a main body forming area 21, a pin forming area 22, a blanking area 23 and a plurality of guide pins 24, the main body forming area 21 is provided with a plurality of main body scabbards 221, the pin forming area is provided with a plurality of pin scabbards 222, and the blanking area 23 is provided with a plurality of cutting scabbards 223;

[0048] See also Figure 7 and Figure 8 The main scabbard 221, the pin scabbard 222 and the cutting scabbard 223 are all provided with a knife edge 25, and the main scabbard 221, the pin scabbard 222 and the cutting scabbard 223 are all provided with a floating top 230, and the floating top 230 includes a contact block 231 and a spring 232, and the contact block 231 abuts against the knife edge 25;

[0049] See also Figure 6 The upper die 210 is provided with a main body cutter 211 matching the main body scabbard 221, a pin cutter 212 matching the pin scabbard 222, and a side material cutter 213 matching the cutting scabbard 223; when producing the alloy resistor 100, the upper die 210 and the lower die 220 are pressed or separated by the stamping equipment to repeat the mold closing and opening, and the raw material is punched and cut into the following shapes: Figure 3 Shape shown.

[0050] When the upper mold 210 and the lower mold 220 are closed, each cutter extends into the corresponding scabbard and contacts the contact block 231 in the scabbard. The cutters refer to the main cutter 211, the lead cutter 212 and the edge cutter 213, and the scabbards refer to the main scabbard, the lead scabbard 222 and the cutting scabbard 223.

[0051] See also Figure 6 The lead cutter 212 includes a first cutter 2121 and a second cutter 2122 , and the width of the second cutter 2122 is greater than the width of the first cutter 2121 .

[0052] See also Figure 5 and Figure 6 Preferably, a bending insert 224 is provided between the main body molding area 21 and the pin molding area 22, and the upper mold 210 is provided with a pressing block 214 matching the bending insert 224. A plurality of lifting push blocks 225 are provided in the lower mold 220, and the plurality of lifting push blocks 225 are used to push the upper mold 210. The lower mold 220 is provided with a material discharge hole (not shown), and the main body scabbard 221, the pin scabbard 222 and the cutting scabbard 223 are all connected to the material discharge hole, and the floating top 230 is located in the material discharge hole.

[0053] Based on the above alloy resistor stamping device 200, the present application also provides a production process of an alloy resistor 100, comprising the following steps:

[0054] Step 1: Combining the resistor body raw material 1 and the lead pin raw material 2 together through a rolling process to obtain a composite metal strip 30; Figure 3 The dotted line is used as the boundary. The upper part is the resistor body material 1, and the lower part is the pin material 2. The two metal materials are integrated together by rolling to ensure that they will not separate from each other during subsequent punching.

[0055] Step 2: Convey the composite metal strip 30 toward the alloy resistor stamping device 200; feed the composite metal strip 30 intermittently, pause when the upper mold 210 and the lower mold 220 are closed, and feed after the upper mold 210 and the lower mold 220 are opened. When feeding, the composite metal strip 30 passes through the main body forming area 21, the pin forming area 22 and the unloading area 23 in sequence.

[0056] Step 3: When the upper mold 210 and the lower mold 220 are closed, the main cutting knife 211 and the main scabbard 221 cooperate to stamp the composite metal strip 30, forming the resistor 110 and the transition portion 121 on the composite metal strip 30, and obtaining a semi-finished product 31;

[0057] Step 4: When the upper mold 210 and the lower mold 220 are opened, the composite metal strip 30 is continuously driven forward, so that the semi-finished product 31 moves from the main body molding area 21 to the pin molding area 22;

[0058] Step 5: The upper mold 210 and the lower mold 220 are closed, and the pin cutter 212 and the pin scabbard 222 cooperate with each other to punch out the body 122 at the terminal end of the transition part 121, and form the prototype of the alloy resistor 100 on the composite metal strip 30;

[0059] Step 6: After the upper mold 210 and the lower mold 220 are closed and opened again, the portion of the composite metal strip 30 containing the prototype of the alloy resistor 100 moves to the unloading area 23;

[0060] Step 7: The cutting scabbard 223 cooperates with the edge material cutter 213 to cut off the edge material on the prototype of the alloy resistor 100 to obtain the alloy resistor 100.

[0061] From the above-mentioned processing process of the alloy resistor 100, it can be known that the composite metal strip 30 first enters the main body forming area 21, and the resistor body 110 and the transition part 121 are first punched out with the cooperation of the main body cutter 211 and the main body scabbard 221. Then, in the middle of the next feeding action, the part containing the semi-finished product 31 is sent to the pin forming area 22 for punching to obtain the main body 122 part of the pin 120.

[0062] It should be noted that the transition portion 121 and the main body 122 of the pin 120 are not processed in the same punching area, but are separated in two independent punching partitions, that is, the pin 120 is processed in sections, thereby shortening the length of the pin cutter 212. During the punching process, the pin cutter 212 is only responsible for the punching work of the main body 122 of the pin 120, and the punching work of the transition portion 121 is shared by the main body cutter 211, so that the length of the material that the cutter needs to cut when processing the pin 120 is halved, and the cutter needs to cut less material, which is conducive to reducing the cutting force and the force of the cutting process on the pin 120 itself, which is conducive to maintaining the dimensional accuracy of the pin 120, so that it is not easy to bend and deform during the punching process; at the same time, the cutter needs to cut less material, which also reduces the reaction force of the punching process on the cutter, which is conducive to reducing the wear on the cutter itself, extending the adaptability life of the cutter, and avoiding the problems of reduced punching accuracy and increased defective rate caused by cutter wear.

[0063] Furthermore, in step 3, step 5 and step 7, when the upper mold 210 and the lower mold 220 are closed, each cutter extends into the corresponding scabbard and contacts the floating top 230 therein. The principle of the cutter and the scabbard cooperating to punch the material is as follows: the scabbard is provided with a blade 25 consistent with the cross-sectional profile of the cutter, the cutter passes through the blade 25 and enters the scabbard, and the portion of the composite metal strip 30 that contacts the end of the cutter is squeezed into the scabbard. This process will generate pressure acting on the blade 25. Furthermore, in the present application, the pin 120 of the alloy resistor 100 is a slender structure, so the blade 25 on the scabbard is also slender, the pressure bearing capacity of the blade 25 is poor, and the structural strength of the blade 25 decreases from the edge to the center, that is, the punching process easily causes the blade 25 to bend and deform, and thus causes the shape of the alloy resistor 100 obtained by punching to change, burrs and other problems.

[0064] In order to solve the above problems, the main scabbard 221, the pin scabbard 222 and the cutting scabbard 223 are all provided with a blade 25, and the main scabbard 221, the pin scabbard 222 and the cutting scabbard 223 are all provided with a floating top 230, and the floating top 230 includes a contact block 231 and a spring 232, and the contact block 231 abuts against the blade 25, such as Figure 8 The support force of the contact block 231 on the blade 25 can buffer the pressure generated by the cutting process of the cutter, offset the impact force on the blade 25 when punching the material, make the blade 25 not easy to deform, and avoid the rapid wear of the scabbard, ensure that the size of the processed alloy resistor 100 meets the standard, and reduce the probability of defective products.

[0065] It should be noted that the pin 120 in the present application is a slender structure, and the aspect ratio of the pin 120 is as high as 15:1, and the bending resistance is weak. When the main body 122 is punched by the pin cutter 212, the dimensional accuracy of the main body 122 is unstable.

[0066] To solve the above problem, in step 5, the upper mold 210 and the lower mold 220 are molded twice. During the first mold closing, the semi-finished product 31 is located below the first cutter 2121. The first cutter 2121 cuts off part of the edge material on the composite metal strip 30 to obtain a main body prototype 32 with the same width as the transition portion 121. The main body prototype 32 is connected to the transition portion 121. Figure 3 As shown; during the second mold closing, the semi-finished product 31 moves to the bottom of the second tool 2122, and the second tool 2122 trims the body prototype 32 to obtain the body 122.

[0067] Among them, the first tool 2121 first performs preliminary punching to obtain the main body prototype 32, and then the second tool 2122 performs fine processing, and the secondary punching is performed to trim the main body prototype 32 to the target size, which reduces the processing difficulty of the main body 122, and the second tool 2122 needs to cut less edge material during trimming, and the second tool 2122 vibrates less during punching, which can reduce the processing error caused by the tool vibration, avoid the deformation of the pin 120 due to the tool vibration, thereby ensuring the processing accuracy of the pin 120.

[0068] The above-mentioned embodiments only express several implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. An alloy resistor stamping device for producing an alloy resistor with a slender pin structure, the alloy resistor comprising: Resistor body and pins; The pin is integrally formed with the resistor body; the pin includes a transition portion and a body, the transition portion is connected to the resistor body, and the thickness of the transition portion is greater than the thickness of the body. The alloy resistor stamping device includes: an upper die and a lower die; The lower mold is provided with a main body molding area, a pin molding area, a blanking area and a plurality of guide pins, the main body molding area is provided with a plurality of main body scabbards, the pin molding area is provided with a plurality of pin scabbards, the blanking area is provided with a plurality of cutting scabbards, the main body scabbards, the pin scabbards and the cutting scabbards are all provided with blade edges, the main body scabbards, the pin scabbards and the cutting scabbards are all provided with floating tops, the floating tops include a contact block and a spring, the contact block abuts against the blade edge; The upper die is provided with a main body cutter matching the main body scabbard, a pin cutter matching the pin scabbard, and a side material cutter matching the cutting scabbard; When the upper mold and the lower mold are closed, the cutting knife extends into the corresponding sheath and contacts the contact block in the sheath. The lead cutter includes a first cutter and a second cutter, and the width of the second cutter is greater than the width of the first cutter.

2. The alloy resistor stamping device according to claim 1, characterized in that: A step is arranged between the transition portion and the main body.

3. The alloy resistor stamping device according to claim 1, characterized in that: The resistor body is provided with a resistance adjustment groove.

4. The alloy resistor stamping device according to claim 1, characterized in that: A bending insert is provided between the main body forming area and the pin forming area, and the upper die is provided with a pressing block matching the bending insert.

5. The alloy resistor stamping device according to claim 1, characterized in that: A plurality of lifting push blocks are arranged in the lower die, and the plurality of lifting push blocks are used for pushing up the upper die.

6. The alloy resistor stamping device according to claim 1, characterized in that: The lower die is provided with a feed hole, the main body scabbard, the pin scabbard and the cutting scabbard are all connected with the feed hole, and the floating top is located in the feed hole.

7. A resistor production process, based on the alloy resistor stamping device according to any one of claims 1 to 6, characterized in that: The steps include: Step 1: Combine the resistor body raw material and the pin raw material together through a rolling process to obtain a composite metal strip; Step 2: conveying the composite metal strip toward the alloy resistance stamping device; Step 3: When the upper die and the lower die are closed, the main cutting knife and the main scabbard cooperate to stamp the composite metal strip, forming a resistor body and a transition portion on the composite metal strip to obtain a semi-finished product; Step 4: When the upper die and the lower die are opened, the composite metal strip is continuously driven forward to move the semi-finished product from the main body forming area to the pin forming area; Step 5: The upper die and the lower die are closed, and the pin cutter and the pin sheath cooperate to punch out the main body at the terminal end of the transition part, forming the prototype of the alloy resistor in the composite metal strip; Step 6: After the upper die and the lower die are closed and opened again, the part of the composite metal strip containing the prototype of the alloy resistor is moved to the unloading area; Step 7: Cut off the scabbard and the edge material cutter to cooperate to cut off the edge material on the prototype of the alloy resistor to obtain the alloy resistor.

8. The resistor production process according to claim 7, characterized in that: In step 3, step 5 and step 7, when the upper mold and the lower mold are closed, each cutting knife extends into the corresponding sheath and contacts the floating top therein.

9. The resistor production process according to claim 7, characterized in that: In step 5, the upper mold and the lower mold are closed twice. During the first closing of the mold, the semi-finished product is located below the first tool, and the first tool cuts off part of the edge material on the composite metal strip to obtain a main body prototype with the same width as the transition part; during the second closing of the mold, the semi-finished product moves to the bottom of the second tool, and the second tool trims the main body prototype to obtain the main body.

10. An alloy resistor, produced by the resistor production process according to claim 7.

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