Alloy Resistance Stamping Device, Resistance Production Process and Alloy Resistance

Abstract

The present invention provides an alloy resistor stamping device, a resistor production process and an alloy resistor. The alloy resistor stamping device includes an upper die and a lower die. The lower die is provided with a main body forming area, a lead forming area, a blanking area and a plurality of guide pins. A plurality of main body sheaths are arranged in the main body forming area, a plurality of lead sheaths are arranged in the lead forming area, and a plurality of cutting sheaths are arranged in the blanking area. Knife edges are formed on the main body sheaths, the lead sheaths and the cutting sheaths, and a floating top is arranged inside. The floating top includes a contact block and a spring; the upper die is provided with a main body cutting knife, a lead cutting knife and a side material cutting knife; when the upper die and the lower die are closed, the above-mentioned cutting knives extend into the corresponding sheaths and contact the contact blocks inside the sheaths. The lead cutting knife includes a first tool and a second tool. This can avoid lead shedding and position deviation, improve the quality of the alloy resistor, and reduce the defective rate in the production process of the alloy resistor.

Description

Technical Field

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

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

[0003] In the existing processing method, when producing a resistor with long pins, the resistor body and the pins need to be produced separately, and then the two are welded together by a welding device. Since the pin diameter is small, the effective welding area between the pins and the resistor body is small, and the risk of pin detachment is high. At the same time, in the above production method, the pins and the resistor body are processed separately first and then transferred to the welding station to complete the welding. The position where the pins are connected to the resistor body is prone to deviation during welding, resulting in a high defective rate and unstable product quality in the production process of the existing resistor with slender pins. Summary of the Invention

[0004] The purpose of the present invention is to overcome the deficiencies in the prior art, and to provide an alloy resistor, an alloy resistor stamping device, and its production process, to avoid easy detachment and position deviation of the pins, improve the quality of the alloy resistor, and reduce the defective rate in the production process of the alloy resistor.

[0005] The purpose of the present invention is achieved by the following technical solutions:

[0006] An alloy resistor stamping device for producing an alloy resistor with a slender pin structure, the alloy resistor comprising: a resistor body and pins; the pins are integrally formed with the resistor body; the pins include 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;

[0007] A main body forming area, a pin forming area, a blanking area, and a plurality of guide pins are provided in the lower die. A plurality of main body sheaths are provided in the main body forming area, a plurality of pin sheaths are provided in the pin forming area, a plurality of cutting sheaths are provided in the blanking area. Knife edges are provided on the main body sheaths, the pin sheaths, and the cutting sheaths. Floating tops are provided in the main body sheaths, the pin sheaths, and the cutting sheaths. The floating top includes a contact block and a spring, and the contact block abuts against the knife edge;

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

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

[0010] Wherein, the pin cutting knife includes a first cutting tool and a second cutting tool, and the width of the second cutting tool is greater than the width of the first cutting tool.

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

[0012] In one embodiment, a resistance adjusting groove is provided on the resistance body.

[0013] In one embodiment, a bending insert block 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 block.

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

[0015] In one embodiment, the lower die is provided with a blanking hole, the main body knife sheath, the pin knife sheath and the cutting knife sheath are all communicated with the blanking hole, and the floating top is located in the blanking hole.

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

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

[0018] Step 2: Feed the composite metal strip towards the alloy resistor stamping device;

[0019] Step 3: When the upper die and the lower die are closed, the main body cutting knife and the main body knife sheath cooperate to stamp the composite metal strip, forming a resistance 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, continue to drive the composite metal strip forward, so that the semi-finished product is displaced 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 cutting knife and the pin knife sheath cooperate to punch and cut at the end of the transition portion to obtain a body, forming a prototype of the alloy resistor on the composite metal strip;

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

[0023] Step 7: The cutting knife sheath and the side material cutting knife cooperate to cut off the side material on the prototype of the alloy resistor to obtain the alloy resistor.

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

[0025] In one embodiment, in step 5, the upper die and the lower die are closed twice. When closing for the first time, the semi-finished product is located below the first cutting tool, and the first cutting tool cuts off part of the side material on the composite metal strip to obtain a body prototype with the same width as the transition part; when closing for the second time, the semi-finished product moves below the second cutting tool, and the second cutting tool trims the body prototype to obtain the body.

[0026] The alloy resistor, the alloy resistor stamping device and its production process provided by this application can avoid the easy falling off and position deviation of the pins, improve the quality of the alloy resistor, and reduce the defective rate in the production process of the alloy resistor. Description of the Drawings

[0027] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following will briefly introduce the drawings required to be used in the embodiments. It should be understood that the following drawings only show some embodiments of the present invention, and therefore should not be regarded as a limitation of the scope. For those of ordinary skill in the art, without creative efforts, other related drawings can also be obtained based on these drawings.

[0028] Figure 1 It is a schematic structural diagram of an alloy resistor;

[0029] Figure 2 It is a schematic diagram of a defective product;

[0030] Figure 3 It is a schematic structural diagram of a composite metal strip;

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

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

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

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

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

[0036] Reference Numerals: 1, raw material of resistor body; 2, raw material of lead; 20, bending structure; 100, alloy resistor; 110, resistor body; 111, trimming groove; 120, lead; 121, transition part; 122, body; 123, step; 200, alloy resistor stamping device; 210, upper die; 211, main body cutter; 212, lead cutter; 2121, first cutter; 2122, second cutter; 213, side material cutter; 214, pressing block; 220, lower die; 21, main body forming area; 22, lead forming area; 23, blanking area; 24, guiding pin; 25, cutting edge; 221, main body sheath; 222, lead sheath; 223, cutting sheath; 224, bending insert block; 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 Embodiment

[0037] For the convenience of understanding the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings. The preferred embodiments of the present invention are shown 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, these embodiments are provided so that the disclosure of the present invention can be understood more thoroughly and comprehensively.

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

[0039] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the technical field to which the present invention belongs. The terms used in the description of the present invention herein 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 of the related listed items.

[0040] Please refer to Figure 1 , the present invention provides an alloy resistor 100, which includes: a resistor body 110 and a lead 120.

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

[0042] The lead 120 includes a transition part 121 and a body 122. The transition part 121 is connected to the resistor body 110, and the thickness of the transition part 121 is greater than the thickness of the body 122.

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

[0044] In the above alloy resistor 100, the pin 120 and the resistor body 110 are integrally formed, and the pin 120 is not connected to the resistor body 110 by welding in a subsequent process. Therefore, the pin 120 will not fall off due to insufficient welding area. Moreover, a transition part 121 is provided at the contact part of the pin 120 with the main body 122, and the thickness of the transition part 121 is greater than the thickness of the main 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 integral formation of the pin 120 and the resistor body 110 also avoids the problem of the pin 120 shifting in position during the welding of the pin 120 in the original process, ensuring the dimensional accuracy of the alloy resistor 100.

[0045] In the above alloy resistor 100, the pin 120 and the resistor body 110 are integrally formed, and the raw material needs to be processed by punching. Specifically, the alloy raw material is punched by a punching device. 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 is likely to cause the pin 120 to bend, forming a bending structure 20 as shown in Figure 2 That is, defective products are likely to be produced when the alloy resistor 100 is made by the original equipment.

[0046] Please refer to Figure 4 To solve the above problems, the present application also provides the following alloy resistor punching device 200 for producing the above alloy resistor 100. The alloy resistor punching device 200 includes: an upper die 210 and a lower die 220;

[0047] Please refer to Figure 4 、 Figure 5 and Figure 6 As shown in, the lower die 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. A plurality of main body sheaths 221 are provided in the main body forming area 21, a plurality of pin sheaths 222 are provided in the pin forming area, and a plurality of cutting sheaths 223 are provided in the blanking area 23;

[0048] Please refer to Figure 7 and Figure 8 As shown in, cutting edges 25 are provided on the main body sheaths 221, the pin sheaths 222 and the cutting sheaths 223. Floating tops 230 are provided in the main body sheaths 221, the pin sheaths 222 and the cutting sheaths 223. The floating top 230 includes a contact block 231 and a spring 232, and the contact block 231 abuts against the cutting edge 25;

[0049] Please refer to Figure 6 , the upper die 210 is provided with a main body cutting knife 211 matching the main body knife sheath 221, a pin cutting knife 212 matching the pin knife sheath 222, and a scrap cutting knife 213 matching the cutting knife sheath 223; when producing the alloy resistor 100, the upper die 210 is driven by a stamping device to press or separate from the lower die 220, so that the mold closing and mold opening are repeated. During this process, the raw material is punched and cut into a shape as shown in Figure 3 .

[0050] When the upper die 210 and the lower die 220 are closed, each cutting knife extends into its corresponding knife sheath and contacts the contact block 231 in the knife sheath. The cutting knives refer to the main body cutting knife 211, the pin cutting knife 212 and the scrap cutting knife 213, and the knife sheaths refer to the main body knife sheath, the pin knife sheath 222 and the cutting knife sheath 223.

[0051] Please refer to Figure 6 , the pin cutting knife 212 includes a first cutting tool 2121 and a second cutting tool 2122, and the width of the second cutting tool 2122 is greater than the width of the first cutting tool 2121.

[0052] Please refer to Figure 5 and Figure 6 , preferably, a bending insert block 224 is provided between the main body forming area 21 and the pin forming area 22, and the upper die 210 is provided with a pressing block 214 matching the bending insert block 224. A plurality of lifting push blocks 225 are provided in the lower die 220, and the plurality of lifting push blocks 225 are used to push up the upper die 210. The lower die 220 is provided with a blanking hole (not shown in the figure), and the main body knife sheath 221, the pin knife sheath 222 and the cutting knife sheath 223 are all communicated with the blanking hole, and the floating top 230 is located in the blanking hole.

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

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

[0055] Step 2: Feed the composite metal strip 30 towards the alloy resistor stamping device 200; the composite metal strip 30 is fed intermittently, stops when the upper die 210 and the lower die 220 are closed, and feeds after the upper die 210 and the lower die 220 are opened. When the composite metal strip 30 is fed, it passes through the main body forming area 21, the pin forming area 22 and the blanking area 23 in sequence.

[0056] Step 3: When the upper die 210 and the lower die 220 are closed, the main body cutter 211 and the main body scabbard 221 cooperate to punch and compound the composite metal strip 30, forming the resistor body 110 and the transition part 121 on the composite metal strip 30, and obtaining the semi-finished product 31;

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

[0058] Step 5: The upper die 210 and the lower die 220 are closed, and the pin cutter 212 and the pin scabbard 222 cooperate to punch and cut at the termination end of the transition part 121 to obtain the main body 122 of the alloy resistor 100, forming the prototype of the alloy resistor 100 on the composite metal strip 30;

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

[0060] Step 7: The cutting scabbard 223 and the side material cutter 213 cooperate to cut off the side materials on the prototype of the alloy resistor 100, obtaining the alloy resistor 100.

[0061] From the above processing process of the alloy resistor 100, it can be seen that the composite metal strip 30 first enters the main body forming area 21, and under the cooperation of the main body cutter 211 and the main body scabbard 221, the resistor body 110 and the transition part 121 are first punched out, and then the part containing the semi-finished product 31 is transferred to the pin forming area 22 during the next feeding action to punch and cut the main body 122 part of the pin 120.

[0062] It should be noted that the transition part 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 a segmented manner. As a result, the length of the pin cutter 212 is shortened. During the punching process, the pin cutter 212 is only responsible for punching the main body 122 part of the pin 120, and the main body cutter 211 shares the punching work of the transition part 121, so that the length of the material that needs to be cut by the cutter during the processing of the pin 120 is halved. The material that the cutter needs to cut off is less, which is beneficial to reducing the cutting force, reducing the acting force on the pin 120 itself during the cutting process, and is beneficial to maintaining the dimensional accuracy of the pin 120, making it not easy to bend and deform during the punching process; at the same time, the material that the cutter needs to cut off becomes less, which also reduces the reaction force on the cutter during the punching process, is beneficial to reducing the wear of the cutter itself, extending the service life of the cutter, and avoiding problems such as reduced punching accuracy and increased defective rate caused by cutter wear.

[0063] Further, in Steps 3, 5, and 7, when the upper die 210 and the lower die 220 are closed, each cutting knife extends into the corresponding knife sheath and contacts the floating top 230 therein. The principle of the cutting knife and the knife sheath for punching the material is as follows: The knife sheath is provided with a cutting edge 25 that is consistent with the cross-sectional contour of the cutting knife. The cutting knife passes through the cutting edge 25 and enters the knife sheath, and the part of the composite metal strip 30 that contacts the end of the cutting knife is squeezed into the knife sheath. During this process, pressure is generated and acts on the cutting edge 25. Further, in this application, the lead 120 of the alloy resistor 100 is of an elongated structure. Therefore, the cutting edge 25 on the knife sheath is also elongated. The bearing capacity of the cutting edge 25 is poor, and the structural strength of the cutting edge 25 decreases from the edge to the center position. That is, during the punching process, the cutting edge 25 is prone to bending deformation, which may cause problems such as a change in the shape of the alloy resistor 100 obtained by punching and the generation of burrs.

[0064] To solve the above problems, the main body knife sheath 221, the lead knife sheath 222, and the cutting-off knife sheath 223 are all provided with a cutting edge 25. The main body knife sheath 221, the lead knife sheath 222, and the cutting-off knife sheath 223 are all provided with a floating top 230. The floating top 230 includes a contact block 231 and a spring 232. The contact block 231 abuts against the cutting edge 25, as Figure 8 shown. The supporting force of the contact block 231 on the cutting edge 25 can buffer the pressure generated during the cutting process of the cutting knife, offset the punching force on the cutting edge 25 when punching the material, make the cutting edge 25 not easily deformed, and thereby avoid rapid wear of the knife sheath, ensure that the size of the alloy resistor 100 obtained by processing meets the standard, and reduce the generation probability of defective products.

[0065] It should be noted that in this application, the lead 120 is of an elongated structure, and the aspect ratio of the length to the width of the lead 120 is as high as 15:1, and the anti-bending ability is weak. When punching the body 122 with the lead cutting knife 212, the dimensional accuracy of the body 122 is unstable.

[0066] To solve the above problems, in Step 5, the upper die 210 and the lower die 220 are closed twice. When closing the die for the first time, the semi-finished product 31 is located below the first cutting tool 2121. The first cutting tool 2121 cuts off part of the side material on the composite metal strip 30 to obtain a body prototype 32 that is the same width as the transition part 121. The body prototype 32 is connected to the transition part 121, as Figure 3 shown; when closing the die for the second time, the semi-finished product 31 moves below the second cutting tool 2122, and the second cutting tool 2122 trims the body prototype 32 and obtains the body 122.

[0067] Among them, the first tool 2121 first performs preliminary punching to obtain the body prototype 32, and then the second tool 2122 performs finish machining. The second punching is carried out to trim the body prototype 32 into the target size, which reduces the processing difficulty of the body 122. Moreover, when the second tool 2122 trims, the amount of scrap to be cut is small, and the vibration of the second tool 2122 during punching is small. The machining error caused by the tool vibration can be reduced, and the deformation of the pin 120 caused by the tool vibration can be avoided, thereby ensuring the machining accuracy of the pin 120.

[0068] The above embodiments only represent several implementation manners of the present invention. The description is relatively specific and detailed, but it should not be construed as a limitation on the scope of the invention patent. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several deformations and improvements can still be made, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the present invention patent shall be subject to the appended 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; the main body cutter cooperates with the main body scabbard to punch the composite metal strip, forming the resistor body and the transition part on the composite metal strip, and the pin cutter cooperates with the pin scabbard to punch out the body at the terminal end of the transition part; 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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