Mould structure and control method thereof, and method for smoothing the edges of air conditioner top cover

Abstract

The invention relates to a mold structure and a control method thereof and a method for flattening the curling edges of a top cover of an air conditioner. In the process of performing full-circumferential lateral bending on a top cover blank, a side bending die and a corner bending die are first moved to a position in contact with the inner side of the blank, and then a corner bending convex die is moved from the outside to a position in contact with the corner of the blank and cooperates with the corner bending die to bend the corner of the blank inwardly. Then, the side bending convex die is moved from the outside to a position in contact with the side of the blank and cooperates with the side bending die to bend the side of the blank inwardly. The invention firstly bends the corner of the blank and then delays the straight side bending, thereby overcoming the defect that the bordering part of the straight side and the corner cannot be bent in place, and a flat curling edge is obtained when the blank is subsequently subjected to a circumferential curling process.

Description

Technical Field

[0001] The invention relates to air conditioner manufacturing technology, and in particular to a mold structure and a control method thereof, and a method for flattening the edges of the four sides of an air conditioner top cover. Background Art

[0002] At present, the sheet metal shell of the air conditioner outdoor unit is generally made by powder coating process; usually hot-dip galvanized zinc-iron alloy coated steel plate is selected, which is first stamped (such as deep drawing and trimming steps), and then the parts are processed by powder electrostatic spraying. Figure 1 As shown, the product structure has straight edges all around, and the sides or corners are not intentionally bent inward.

[0003] Another new solution for using pre-coated color steel plate (PCM) for the top cover of the air conditioner outdoor unit is that the product structure is completely different from the powder coating style. The stamping process in the pre-coated color steel plate solution has a total of 6 processes, including profile trimming, forming stretching, trimming around the edges, trimming and shaping at the four corners, full-circle lateral folding, and full-circle dense curling. Figure 2 The product structure shown has a curled edge 93 around the entire circumference.

[0004] When the top cover of the air conditioner outdoor unit was made using the pre-coated color steel plate solution, it was found that the curling of the two adjacent sides of each corner of the top cover had defects, and the height of each side near the corner was inconsistent with the height of the side far from the corner; when such a top cover was assembled with the stepped surface of the air conditioner panel and the rear plate, it was impossible to fit at an equal distance, and after the whole machine was assembled, there was an obvious irregular gap ( Fig.21 The left side of the picture shows that the appearance is seriously affected.

[0005] The main reason for the above defects is that the fifth process (full-circumference lateral folding) of stamping forming in the pre-coated color steel plate solution is not perfect; the fifth process needs to be Figure 3 As shown, the side of the top cover is horizontally bent to form a bent edge 91 around the entire circumference of the top cover (including the left handle, the rear boss, the four sides and the four corners), and the height after bending is required to be consistent. However, the corner bending convex mold and the straight edge bending convex mold in the existing mold do not completely cover the blank during the forming process, resulting in deformation of the border between the corner and the straight edge of the blank during bending ( Fig. 20 (see the left figure), and then after the sixth process of curling, the side height dimension is inconsistent. Therefore, from the perspective of the top cover product and the molding process, an effective means is urgently needed to solve the molding defect of the fifth process. Summary of the invention

[0006] The purpose of the present invention is to provide a mold structure and a control method thereof, and a method for flattening the curling edges of an air conditioner top cover. When the top cover blank is bent laterally around the entire circumference, the corners are bent first, and then the straight edges are bent laterally, thereby overcoming the defect of the original mold that the straight edges and corners are not bent properly.

[0007] In order to achieve the above object, a technical solution of the present invention is to provide a control method for a mold structure, comprising the following process:

[0008] When the mold structure is in a state where punching and molding has not yet begun, the blank is inserted into a concave mold assembly including a corner side bending concave mold (21) and a side side bending concave mold (54), and the blank is supported by a discharge top block (20) connected to a lower mold base (40);

[0009] When the mold structure is in the first state of punching and forming, the upper mold stripper plate (18) moves downward and presses the blank; the side bending die (54) moves from the inside to the direction close to the side of the blank, driving the corner bending die (21) to move from the inside to the direction close to the corner of the blank, until the side bending die (54) and the corner bending die (21) contact the blank;

[0010] When the mold structure is in the second state of punching and forming, the corner side bending convex mold (23) moves from the outside to the direction close to the corner of the blank and contacts the corner of the blank, and the corner side bending convex mold (23) cooperates with the corner side bending concave mold (21) to bend the corner of the blank inward;

[0011] When the mold structure is in the third state of punching and forming, the side bending punch (55) moves from the outside to the direction close to the side of the blank and contacts the side of the blank, and the side bending punch (55) cooperates with the side bending die (54) to bend the side of the blank inward; wherein, the bending of the corner of the blank is earlier than the bending of the side of the blank.

[0012] Optionally, when the mold structure is in the first state of punching and molding, as the first bevel wedge (5) moves downward along with the upper mold base (17), the outer bevel surface of the first bevel wedge (5) contacts the inner bevel surface of the first lower mold stop block (3) and slides along the inner bevel surface of the first lower mold stop block (3), so that the first lower mold stop block (3) drives the lower mold side bending sliding base (61) connected thereto to move outward, and the side bending die (54) connected to the lower mold side bending sliding base (61) moves outward to approach the side of the blank.

[0013] Optionally, when the mold structure is in the first state of stamping and forming, during the process of the side side bending die (54) moving outward, the lateral driving surface of the side side bending die (54) contacts the lateral driven surface of the corner side bending die (21) and slides along the driven surface, driving the corner side bending die (21) to move outward to approach the corner of the blank; the driving surface and the driven surface are both perpendicular to the direction of movement of the corner side bending die (21) toward the corner of the blank.

[0014] Optionally, the ratio of the displacement of the side side bending die (54) toward the side of the blank to the displacement of the corner side bending die (21) toward the corner of the blank is s1:s2, and s1 is greater than s2.

[0015] Optionally, when the mold structure is in the second state of punching and forming, as the second bevel (34) moves downward along with the upper mold base (17), the inner bevel surface of the second bevel (34) contacts the outer bevel surface of the second slider (27) and slides along the outer bevel surface of the second slider (27), so that the second slider (27) drives the corner side bending punch fixing seat (28) connected thereto to move inward, so that the corner side bending punch (23) connected to the corner side bending punch fixing seat (28) moves inward to approach the corner of the blank, and then contacts the corner of the blank and continues to move inward of the corner, cooperating with the corner side bending die (21) to bend the corner of the blank.

[0016] Optionally, when the mold structure is in the third state of stamping, the inner inclined surface of the first bevel (5) contacts the outer inclined surface of the first slider (6) and slides along the outer inclined surface of the first slider (6), so that the first slider (6) drives the side bending punch fixing seat (59) connected to it to move inward, and the side bending punch (55) connected to the side bending punch fixing seat (59) moves inward to approach the side of the blank, and then contacts the side of the blank and continues to move inward of the blank, cooperating with the side bending die (54) to bend the side of the blank.

[0017] Optionally, the time when the inner inclined surface of the first inclined wedge (5) contacts the outer inclined surface of the first sliding block (6) is later than the time when the inner inclined surface of the second inclined wedge (34) contacts the outer inclined surface of the second sliding block (27).

[0018] Optionally, the distance that the side bending punch (55) continues to move toward the inside of the blank after contacting the side surface of the blank is greater than the width of the side bending edge of the blank.

[0019] Optionally, the mold structure is also used to punch holes on the side of at least part of the direction of the blank;

[0020] When the mold structure is in the first state of punching and forming, the first lower mold stopper (3) moves outward, driving the side bending punch fixing seat (59) connected to the first lower mold stopper (3) through the first unloading positioning pin (1) to move outward, thereby driving the first slider (6) and the side punching and flanging hole punch (58) connected to the side bending punch fixing seat (59) to move outward;

[0021] When the mold structure is in the third state of punching and forming, the side bending punch fixing seat (59) moves inward under the drive of the first slider (6), thereby driving the side punching and flanging hole punch (58) to move inward and complete the forming of the side flanging hole.

[0022] Optionally, the side punching and flanging hole punch (58) is fixed to the side side bending punch fixing seat (59) and is also inserted into the lower die stripping plate (12); the lower die stripping plate (12) is fixed to the first slider (6) by a first stripping bolt (7) equipped with a first stripping spring (10), and the first stripping spring (10) is pre-compressed and assembled; the top surface of the lower die stripping plate (12) is provided with an upper die stripping plate stopper (11);

[0023] When the mold structure is in the first state of punching and forming, the first slider (6), the lower mold stripper plate (12), the upper mold stripper plate stopper (11), the side punching and flanging hole punch (58) and the side bending punch (55) move outward synchronously with the side bending punch fixing seat (59);

[0024] When the mold structure is in the third state of punching and forming, the lower mold stripper plate (12), the upper mold stripper plate stopper (11), the side punching and flanging hole punch (58) and the side side bending punch (55) move inward along with the side side bending punch fixing seat (59), the lower mold stripper plate (12) contacts the side surface of the blank and gradually applies pressure, and the upper mold stripper plate stopper (11) contacts the side surface of the upper mold stripper plate (18);

[0025] When the mold structure is in the demoulding state, the contact area between the first inclined wedge (5) and the first slider (6) gradually decreases as the upper mold base (17) moves upward, and under the action of the second unloading spring (2) configured for the first unloading positioning pin (1) being released, the side bending punch fixing seat (59) is pulled by the first unloading positioning pin (1), so that the side bending punch fixing seat (59), the first slider (6), the lower mold stripping plate (12), the upper mold stripping plate stopper (11), the side punching and flanging hole punch (58) and the side bending punch (55) move outward;

[0026] The first unloading spring (10) is gradually decompressed under the outward movement of the first slider (6), so that the lower mold stripping plate (12) gradually reduces the pressure on the side of the blank until the contact with the side of the blank is released, and the upper mold stripping plate stopper (11) also releases the contact with the side of the upper mold stripping plate (18).

[0027] Optionally, the upper mold stripper plate (18) is connected to the upper mold base (17) via a second unloading positioning pin (13); a pressing spring (15) equipped with a spring guide retainer (16) is arranged between the upper mold stripper plate (18) and the upper mold base (17); when the mold structure is in a demolding state, the pressing spring (15) is gradually decompressed when the upper mold stripper plate (18) moves upward along with the upper mold base (17), so that the pressing force of the upper mold stripper plate (18) on the blank is gradually reduced.

[0028] Optionally, a second unloading bolt (32) equipped with a second unloading spring (33) passes through a second lower die block fixing seat (31) fixed to the lower die seat (40) and is connected to the corner side bending punch fixing seat (28), and the second unloading spring (33) is pre-compressed and assembled; when the mold structure is in a demolding state, the contact surface between the second inclined wedge (34) ascending with the upper die seat (17) and the second slider (27) gradually decreases, and under the action of the decompression of the second unloading spring (33), the corner side bending punch fixing seat (28) is pulled by the second unloading bolt (32) and the corner side bending punch (23) is driven to move outward, until the contact surface between the first inclined wedge (5) and the first slider (6) is completely disengaged, and the contact surface between the second inclined wedge (34) and the second slider (27) is completely disengaged.

[0029] Optionally, a third unloading bolt (47) equipped with a third unloading spring (48) passes through a spring baffle (49) fixed on the lower die seat (40) and is connected to the lower die side bending sliding base (61), and the third unloading spring (48) is pre-compressed and assembled; when the mold structure is in a demolding state, the contact surface between the first inclined wedge (5) and the first lower die stopper (3) gradually decreases as the upper die seat (17) continues to move upward, and under the action of the decompression of the third unloading spring (48), the lower die side bending sliding base (61) is pulled by the third unloading bolt (47) and the side side bending die (54) and the corner side bending die (21) are driven to move inward until the side side bending die (54) and the corner side bending die (21) are completely out of contact with the blank.

[0030] Optionally, the side surface of the lower mold corner bending sliding base (39) connected to the corner side bending die (21) is connected to the fifth spring (35) arranged inside the second lower mold stop block fixing seat (31); when the mold structure is in the first state of stamping and forming, the lower mold corner bending sliding base (39) moves outward synchronously with the corner side bending die (21), so that the fifth spring (35) is compressed; when the mold structure is in the demolding state, during the process of the corner side bending die (21) moving inward, the fifth spring (35) is decompressed to provide an auxiliary thrust for moving the lower mold corner bending sliding base (39) inward.

[0031] Optionally, the discharge top block (20) is connected to the lower die seat (40) via a fourth discharge bolt (19) equipped with a fourth discharge spring (43); when the die structure is in the first state of stamping, the discharge top block (20) is subjected to the downward pressure transmitted to the blank by the upper die stripping plate (18), so that the fourth discharge spring (43) is compressed, and the upper die stripping plate (18), the discharge top block (20) and the blank move downward synchronously; when the die structure is in the demolding state, when the upper die stripping plate (18) ascending with the upper die seat (17) separates from the blank, the fifth discharge spring (43) is decompressed and lifts the discharge top block (20), and the blank is lifted by the discharge top block (20) for the robot to take away the blank.

[0032] Another technical solution of the present invention is to provide a method for smoothing the circumferential curling, by controlling the working state of the mold structure through any of the above-mentioned mold structure control methods, by first bending the corner of the first blank and then bending the side of the first blank to obtain the second blank, so that the second blank has highly consistent corner bending edges and side bending edges.

[0033] Optionally, a first blank is obtained by performing a preliminary process of stamping the pre-coated color steel plate, and then the mold structure is used to bend the corners and sides of the first blank.

[0034] Optionally, the second blank is subjected to a circumferential curling process.

[0035] Optionally, the curled product is used to make a top cover of an air conditioner outdoor unit; the top cover is used to be assembled with an air conditioner panel and an air conditioner back plate to obtain an outer shell of the air conditioner outdoor unit.

[0036] Another technical solution of the present invention is to provide a mold structure, which is applicable to any one of the control methods of the above mold structures; the mold structure comprises:

[0037] An upper die seat (17) and a lower die seat (40) opposite to each other;

[0038] A discharge top block (20), connected to the lower die base (40), for supporting the blank;

[0039] An upper die stripping plate (18) is connected to the upper die base (17) and can move up and down with the upper die base (17); the upper die stripping plate (18) is used to press the blank when it moves downward;

[0040] The corner side bending die (21) is located in the inner circle of the die structure and can move closer to or away from the corner of the blank;

[0041] The corner side bending convex die (23) is located at the outer ring of the mold structure and can move closer to or away from the corner of the blank; the corner side bending concave die (21) and the corner side bending convex die (23) cooperate to bend the corner of the blank inward when they contact the corner of the blank from the inside and the outside respectively;

[0042] A side bending die (54) is located in the inner circle of the die structure and can move closer to or away from the side of the blank;

[0043] The side bending convex die (55) is located at the outer ring of the mold structure and can move closer to or away from the side of the blank; the side bending concave die (54) and the side bending concave die (54) cooperate to bend the side of the blank inward when they contact the side of the blank from the inside and the outside respectively; wherein the bending of the corner of the blank is earlier than the bending of the side of the blank.

[0044] The mold structure of the present invention can be controlled by a corresponding control method to first perform corner bending on the blank and then delay the straight side bending; the delay mechanism allows the movement trajectory of the corner side bending punch (23) and the side side bending punch (55) to move in steps, thereby avoiding interference between the movement of the corner side bending punch (23) and the side side bending punch (55); thus, the side side bending punch (55) and the corner side bending punch (23) can completely cover all bending surfaces of the blank, effectively improving the product forming quality of the pre-coated color steel plate blank after the fifth stamping forming process; after all subsequent processes such as circumferential curling of the blank are completed, the position height of the corners and sides of the top cover of the air conditioner outdoor unit is consistent, the curling is flat, the top cover and the step surfaces of the air conditioner panel and the rear plate can be equidistantly fitted, and after the whole machine is assembled, the gap is uniform and the appearance is beautiful. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 The present invention is a schematic diagram of the structure of an air conditioner top cover in multiple views, which is made by a sheet metal coating process and has straight edges in the circumference.

[0046] Figure 2 The present invention is a schematic diagram of the structure of an air-conditioning top cover made of pre-coated color steel plate and with a circumferential rolled edge in multiple views.

[0047] Figure 3 yes Figure 2 Schematic diagram of the structure of multiple views of the air-conditioning top cover during the full-circumference lateral folding process.

[0048] Figure 4 It is a side sectional view of the mold structure of the present invention along the BB direction.

[0049] Figure 5 It is a structural schematic diagram of the upper mold in the present invention.

[0050] Figure 6 It is a structural schematic diagram of the lower mold in the present invention.

[0051] Figure 7 It is a schematic diagram of the components used to control the stamping depth of the present invention.

[0052] Figure 8 It is a schematic structural diagram of the mold of the present invention when it is not punched into shape.

[0053] Fig. 9 It is a schematic diagram of the local structure of the lower mold of the present invention when it is not punched into shape.

[0054] Fig.10 yes Fig. 9 An enlarged view of area B in the unpunched state.

[0055] Fig.11 It is a schematic structural diagram of the mold of the present invention in the first state of punching and molding.

[0056] Fig.12 It is a schematic diagram of the local structure of the lower die of the present invention when it is in the first state of punching and forming.

[0057] Fig.13 yes Fig.12 An enlarged view of area B in the first state of punching.

[0058] Fig.14 It is a schematic structural diagram of the mold of the present invention in the second state of punching and molding.

[0059] Fig.15 It is a schematic diagram of the local structure of the lower die of the present invention when it is in the second state of punching and forming.

[0060] Fig.16 yes Fig.15 An enlarged view of area B in the first state of punching.

[0061] Fig.17 It is a schematic structural diagram of the mold of the present invention in the third state of punching and molding.

[0062] Fig.18 It is a schematic diagram of the local structure of the lower die of the present invention when it is in the third state of punching and forming.

[0063] Fig.19 yes Fig.18An enlarged view of area B in the third state of punching.

[0064] Fig. 20 It is a comparison diagram of the bending effects of the top cover of the air conditioner before and after the implementation of the present invention.

[0065] Fig.21 It is a comparison diagram of the assembly effects of the air conditioner top cover before and after the implementation of the present invention. DETAILED DESCRIPTION

[0066] The present invention provides a mold structure suitable for the fifth process in the stamping forming of a pre-coated color steel plate solution, which can perform full-circle lateral folding on a top cover blank, so that the curling of the top cover of an air conditioner outdoor unit subsequently manufactured by the sixth process (full-circumference dense curling) based on the blank is smoother.

[0067] Figure 3 An exemplary structure of a top cover blank is provided. The blank is subjected to full-circumferential lateral hemming by the mold structure of the present application to form a bent edge 91 , and a flange hole 92 can be formed on the side of the short side of the blank through the mold structure.

[0068] like Figures 4 to 7 In the mold structure shown, the parts structure shown mainly includes:

[0069] Unloading positioning pin CSR16-150 (1), spring SWM35-10 (2), first lower die stopper (3), fixing screw M16-160 (4), first bevel (5), first slide block (6), unloading bolt MSB10-55 (7), flanging hole punch stopper (8), flanging hole punch fixing block (9), spring SWL22-50 (10), upper die stripper plate stopper (11), lower die stripper plate (12), unloading positioning pin CSR16-85 (13), unloading positioning pin fixing block (14), spring SWL40-125 (15), spring guide retainer SGC16-60 (16), upper die base (17), upper die stripper plate (18), unloading Bolt MSB8-120 (19), unloading top block (20), corner side bending die (21), fixing screw M12-L50 (22), corner side bending punch (23), fixing screw M10-L30 (24), fixing screw M12-L50 (25), positioning pin MTT10-L50 (26), second slide block (27), corner side bending punch fixing seat (28), second lower die stopper (29), fixing screw M10-L55 (30), second lower die stopper fixing seat (31), unloading bolt MSB13-170 (32), spring SWM30-150 (33), second bevel wedge (34), spring SWM25-125 (35) , fixing screw M12-L45 (36), lower die pad (37), second wear-resistant plate (38), lower die corner bending sliding base (39), lower die base (40), fixing screw M10-L80 (41), fixing screw M10-L25 (42), spring SWF25-100 (43), V-shaped guide slider PCVP150 (44), V-shaped guide slider PCVPS150 (45), lower die positioning plate (46), unloading bolt MSB13-90 (47), spring SWM30-70 (48), spring baffle (49), fixing screw M10-L80 (50), spring SWF10-15 (51), unloading ejector rod (52), fixing key (53), side bending die (54), side bending punch (55), fixing screw M10-L25 (56), fixing screw M8-25 (57), side punch flanging hole punch (58), side bending punch fixing seat (59), fixing screw M8-30 (60), lower die side bending sliding base (61), first wear plate (62), depth control rod (63), guide column guide sleeve set MMYKP38-180 (64), independent guide column gasket MMABPS38-80 (65), corner bending guide rail pressure plate (66), first side bending guide rail pressure plate (67), second side bending guide rail pressure plate (68), third side bending guide rail pressure plate (69)

[0070] like Figures 4 to 7As shown, an embodiment of the present invention provides a mold structure, which adopts a non-standard steel plate structure, including an upper mold base (17) and a lower mold base (40), both of which adopt a whole piece of 45 steel; the upper mold base size: 1380mm×700mm×47mm, the lower mold base size: 1380mm×750mm×52mm. A plurality of lower mold pads (37) are connected between the lower mold base (40) and the lower mold positioning plate (46) below it. The dimensions, specifications and materials of the various components herein are only examples and are not intended to limit the mold structure of the present invention.

[0071] Four sets of ball guide devices are used between the upper die base (17) and the lower die base (40) to ensure accurate positioning of the upper die and the lower die during stamping. Figure 7 As shown, after the mold is closed, the distance between the bottom surface of the upper mold base (17) and the top surface of the lower mold base (40) is 210 mm; in order to control the punching depth, a steel ball type independent guide column assembly (64) containing a fixed stopper and an independent guide column liner (65) can be selected. The guide column is installed on the upper mold base (17). The independent guide column liner (65) is installed on the lower mold base (40), and the guide sleeve is installed on the independent guide column liner (65).

[0072] The bottom shape of the upper die stripper plate (18) matches the upper surface of the top cover blank, and 8 stripper positioning pins (13) are connected to the upper die seat (17) through 8 stripper positioning pin fixing blocks (14); 24 pressure springs (15) are distributed on the upper die stripper plate (18), 22 of which are evenly and symmetrically distributed on the outer ring, and the remaining 2 pressure springs (15) are distributed in the center. A spring guide retainer (16) is configured in the center of each pressure spring (15), and the spring guide retainer (16) is fixed on the upper die stripper plate (18). The material specification of the upper die stripper plate (18) is 45# carbon structural steel.

[0073] In the mold structure of the present invention, the convex mold system for corner side bending forming, side side bending forming and flanging hole punching forming is installed on the outer ring of the lower mold, and the concave mold system for corner side bending forming, side side bending forming and flanging hole punching forming is installed on the inner ring of the lower mold.

[0074] The corner side bending forming, side side bending forming and flange hole punching forming adopt a slider structure. The first oblique wedge (5) related to the side side bending forming and flange hole punching forming is fixed to the upper die seat (17) by a fixing screw (4). The second oblique wedge (34) related to the corner side bending forming is positioned by a positioning pin (26) and fixed to the upper die seat (17) by a fixing screw (22). The material specification of the first oblique wedge (5) and the second oblique wedge (34) is selected from high wear-resistant and tough general cold working die steel SKD11, and the quenching hardness is HRC58.

[0075] The punch system structure for the side bending forming and flanging hole punching forming of the lower die outer ring includes:

[0076] The lower die side bending sliding base (61) is connected to the lower die seat (40) by a discharge bolt (47) and a spring baffle (49), and a discharge spring (48) is arranged in the middle, and the discharge spring (48) is pre-compressed by 2.9 mm and fixed. A first wear-resistant plate (62) is arranged between the lower die side bending sliding base (61) and the lower die seat (40). The first wear-resistant plate (62) is connected to the lower die seat (40) by a fixing screw (56). The side bending punch (55) is fixed to the side bending punch fixing seat (59) by a fixing screw (57). The side bending punch fixing seat (59) is connected by a first lower die stopper (3) fixed on the lower die side bending sliding base (61) and a discharge positioning pin (1), and a discharge spring (2) is selected.

[0077] The first slide block (6) is fixedly connected to the side bending punch fixing seat (59) by fixing screws M10-30. The lower die stripping plate (12) is fixed to the first slide block (6) by means of stripping bolts (7), and a stripping spring (10) is selected in the middle for connection, and the stripping spring (10) is pre-compressed by 4 mm and fixed.

[0078] The flanging hole punch block (8) is fixedly connected to the side side bending punch fixing seat (59) by fixing screws (60). The bottom surface of the flanging hole punch fixing block (9) is embedded in the side side bending punch fixing seat (59) by 10 mm and fixed by screws. The side punch flanging hole punch (58) is fixed by the flanging hole punch block (8) and the flanging hole punch fixing block (9), and penetrates into the lower die stripping plate (12). An upper die stripping plate block (11) is arranged on the top surface of the lower die stripping plate (12), so that the upper die stripping plate block (11) and the upper die stripping plate (18) can guide each other stably.

[0079] The side bending forming and flanging hole punching forming die system structure of the lower die inner ring includes:

[0080] The fixing key (53) has a total height of 20 mm and is embedded in the lower die side bending sliding base (61) by 10 mm for fixing. The side bending concave die (54) is positioned by the fixing key (53) and is fixedly connected to the lower die side bending sliding base (61) by a fixing screw (50). A discharge push rod (52) is arranged in the side bending concave die (54), and a discharge spring (51) is arranged at the tail side of the discharge push rod (52), which can provide auxiliary demoulding thrust to the side punching and flanging hole punch (58) after the molding is completed to avoid the occurrence of material wrapping.

[0081] The material specification of the side punching and flanging hole punch (58) is a high wear-resistant and tough general cold-working die steel SKD11, and the quenching hardness is HRC58-61. The material specification of the side bending punch (55) and the side bending die (54) is a high wear-resistant and tough general cold-working die steel Cr12MoV, and the quenching hardness is HRC56-58. The material specification of the lower die side bending sliding base (61) is a high wear-resistant and tough general cold-working die steel Cr12MoV, and the quenching hardness is HRC54. The material specification of the first lower die stopper (3) and the first slide block (6) is a high wear-resistant and tough general cold-working die steel Cr12MoV, and the quenching hardness is HRC58.

[0082] The corner side bending forming punch system structure of the lower die outer ring includes:

[0083] The side surface of the lower die corner bending sliding base (39) is connected to a spring (35) arranged inside the second lower die stopper fixing base (31), and a second wear-resistant plate (38) is arranged between the bottom of the lower die corner bending sliding base (39) and the lower die base (40). The second wear-resistant plate (38) is connected to the lower die base (40) through a fixing screw (42).

[0084] The corner side bending punch (23) and the corner side bending punch fixing seat (28) are fixed by fixing screws (24). The corner side bending punch fixing seat (28) is connected to the second lower die stopper fixing seat (31) by a discharge bolt (32), and a discharge spring (33) is arranged in the middle, and the discharge spring (33) is pre-compressed by 3mm for assembly. The second lower die stopper fixing seat (31) is embedded in the lower die seat (40) by 15mm, and is fixedly connected to the lower die seat (40) by fixing screws (36).

[0085] The second lower die block (29) is embedded in the second lower die block fixing seat (31) and fixed to the second lower die block fixing seat (31) by fixing screws (30). The second slider (27) is embedded in the corner side bending punch fixing seat (28) and fixedly connected to the corner side bending punch fixing seat (28) by fixing screws (25). In order to ensure that the slider does not vibrate up and down during the lateral movement of the slider during the corner side bending molding and the side side bending molding, such as Figure 6 As shown, a corner bending guide rail pressure plate (66), a first side bending guide rail pressure plate (67), a second side bending guide rail pressure plate (68) and a third side bending guide rail pressure plate (69) are respectively arranged on the top surfaces of both sides of the slider.

[0086] The structure of the corner side bending forming die system of the lower die inner ring includes:

[0087] The corner side bending die (21) is fixedly connected to the lower die corner bending sliding base (39) by fixing screws (41). The material specification of the corner side bending punch (23) is selected from high wear-resistant and tough general cold working die steel Cr12MoV, and the quenching hardness is HRC58-62. The material specification of the corner side bending die (21) and the corner side bending punch fixing seat (28) is selected from high wear-resistant and tough general cold working die steel Cr12MoV, and the quenching hardness is HRC56-58. The material specification of the lower die corner bending sliding base (39) is selected from high wear-resistant and tough general cold working die steel Cr12MoV, and the quenching hardness is HRC54.

[0088] Two discharging top blocks (20) are arranged at the center of the lower die blank in the transverse direction. The discharging top block (20) is fixed to the lower die seat (40) through discharging bolts (19) arranged on the inner side. A discharging spring (43) is arranged on the bottom surface of the discharging top block (20) and connected to the lower die seat (40).

[0089] The side bending forming structure in the long side direction is the same as the side bending forming structure in the short side direction. In order to stabilize the side bending forming in the long side direction, a guiding mechanism for the movement direction is set at the middle line position of the lower mold, including a V-shaped guide slider (44) recessed at the bottom and a V-shaped guide slider (45) protruding at the top. The linear guidance of the upper and lower parts connected is ensured by the overlap of the convex and concave guide sliders. In addition to the lubrication effect and excellent wear resistance, the convex and concave surfaces are used to limit the movement in the left and right directions, thereby further improving the performance of the linear guidance and ensuring the stability of the side bending forming in the long side direction.

[0090] The following describes the mold structure of the present invention and the working principle of the mold when performing full-circumference lateral folding and punching flanging holes on the top cover blank:

[0091] 1) The mold is not punched into shape

[0092] like Figures 8 to 10 As shown, the blank D is inserted into the concave mold assembly consisting of the corner side bending concave mold (21) and the side side bending concave mold (54) by a robot, and the unloading top block (20) contacts the blank D to support the blank D. At this time, the upper and lower molds have not yet contacted, and are ready to start molding.

[0093] like Fig.10 As shown, at this time, the corner side bending die (21) and the side side bending die (54) do not contact the inner side of the corner and side of the blank D, and the corner side bending punch (23) and the side side bending punch (55) do not contact the outer side of the corner and side of the blank D.

[0094] 2) The first state of die stamping

[0095] like Figure 11 to Figure 13As shown, the upper mold moves downward, and the upper mold stripper plate (18) fixed by the stripper positioning pin (13) contacts the blank D and continues to move downward. The stripper top block (20) is subjected to the downward pressure transmitted to the blank D by the upper mold stripper plate (18), so that the stripper spring (43) is compressed, and the upper mold stripper plate (18), the stripper top block (20) and the blank D move downward synchronously.

[0096] The upper die continues to move downward, and the outer inclined surface of the first inclined wedge (5) contacts the inner inclined surface of the first lower die stopper (3) fixed on the lower die side bending sliding base (61). As the upper die continues to move downward, the outer inclined surface of the first inclined wedge (5) contacts the inner inclined surface of the first lower die stopper (3) and slides at a 45° angle, so that the first lower die stopper (3) moves horizontally outward, driving the lower die side bending sliding base (61) connected to the first lower die stopper (3) to move outward; the unloading bolt (47) connected to the lower die side bending sliding base (61) passes through the spring baffle (49) and moves synchronously outward, and the unloading spring (48) is compressed during the movement.

[0097] As the first lower die block (3) moves, the side bending punch fixing seat (59) connected by the unloading positioning pin (1) drives the first slide block (6), the flanging hole punch block (8), the lower die stripping plate (12), the upper die stripping plate block (11), the side punch flanging hole punch (58) and the side bending punch (55) to move synchronously outward; the side bending die (54) positioned by the fixing key (53) and connected by the fixing screw (50) moves synchronously outward as the lower die side bending sliding base (61) moves outward, until the side bending die (54) moves into position and abuts against the inner side surface of the blank D.

[0098] When the side bending die (54) moves, the lateral driving surface (81) of the side bending die (54) contacts and slides along the lateral driven surface (82) of the corner side bending die (21), driving the corner side bending die (21) to move outward at a displacement ratio of s1:s2 (s1>s2, for example, 1.4:1), until the corner side bending die (21) moves into position and abuts against the inner corner ( Fig.13 ).

[0099] The lower die corner bending sliding base (39) connected to the corner side bending concave die (21) by means of a fixing screw (41) moves outward synchronously with the movement of the corner side bending concave die (21). During the movement of the lower die corner bending sliding base (39), the spring (35) is compressed.

[0100] Thus, the blank D is pressed together by the side bending die (54), the corner bending die (21) and the upper die stripping plate (18), so that the blank D is stably fixed on the lower die.

[0101] 3) The second state of die stamping

[0102] like Figure 14 to Figure 16 As shown, the upper die continues to move downward, the pressing spring (15) is compressed, and the blank is pressed by the upper die stripper plate (18). The second inclined wedge (34) contacts the second slider (27) and continues to move downward, and the inner inclined surface of the second inclined wedge (34) contacts the outer inclined surface of the second slider (27) to slide at a 45° inclined surface, driving the corner side bending punch fixing seat (28) connected by the fixing screw (25) to move inward in the horizontal direction, thereby driving the corner side bending punch (23) connected by the fixing screw (24) to move inward at a 45° horizontal direction, contacting the corner of the blank and cooperating with the corner side bending die (21) to complete the 90° bending of the corner side. At this time, the side side bending punch (55) in the length and width directions has not yet been subjected to thrust to perform side bending.

[0103] 4) The third state of die stamping

[0104] During the corner bending process, the moment when the inner inclined surface of the first bevel (5) contacts the outer inclined surface of the first slider (6) is delayed from the moment when the inner inclined surface of the second bevel (34) of the corner contacts the outer inclined surface of the second slider (27). When the corner bending reaches the end, the right inclined surface of the first bevel (5) contacts the left inclined surface of the first slider (6) and continues to move downward, the first slider (6) drives the side bending punch fixing seat (59) to move inward, and the lower die stripping plate (12) contacts the side of the blank and gradually pressurizes it.

[0105] like Figure 17 to Figure 19 As shown, the side bending punch fixing seat (59) continues to move inward, the discharge spring (10) is compressed, the flanging hole punch block (8) and the flanging hole punch fixing block (9) fixed on the side bending punch fixing seat (59) move inward synchronously, and the side punch flanging hole punch (58) completes the forming of the side flanging hole; the side bending punch (55) fixed on the side bending punch fixing seat (59) moves inward and cooperates with the side bending die (54) to complete the side bending.

[0106] Until the punching depth control rods (63) of the upper die and the lower die hit each other, the upper die stops moving downward, and the forming of the full-circle lateral folding and the punching and flanging holes is completed.

[0107] The corner bending and side bending of the blank are covered from the second state to the third state, the movement trajectory of the corner side bending punch (23) and the movement trajectory of the side side bending punch (55) are staggered, and the step-by-step movement is performed through a delay mechanism, thereby avoiding the problem of movement interference between the corner side bending punch (23) and the side side bending punch (55).

[0108] In this example, if Fig.19 As shown, the distance that the side bending punch (55) continues to move toward the inside of the blank after contacting the blank is 9.5 mm, and the width of the side bending edge of the blank is 8.5 mm, 9.5 mm>8.5 mm. The side bending punch (55) and the corner bending punch (23) can completely cover the entire bending surface of the blank. Fig.19 The 4.7mm length position is covered and bent to ensure the beauty of the bent edge.

[0109] 5) Demolding status

[0110] like Figures 4 to 8 As shown, the upper die moves upward, the pressing spring (15) is gradually decompressed, and the pressing force of the upper die stripping plate (18) on the blank is gradually reduced.

[0111] As the upper die moves upward, the first inclined wedge (5) gradually reduces the contact surface with the first slider (6). Under the decompression effect of the discharge spring (2), the side bending punch fixing seat (59), the flanging hole punch stopper (8), the flanging hole punch fixing block (9), the side punch flanging hole punch (58) and the side bending punch (55) are pulled outward together through the discharge positioning pin (1). Under the outward movement effect of the first slider (6), the discharge spring (10) gradually decompresses, and the lower die stripping plate (12) also gradually reduces the pressure on the blank until the contact is released.

[0112] As the upper die continues to move upward, the second oblique wedge (34) gradually reduces the contact surface with the second slider (27), is decompressed by the unloading spring (33), and pulls the corner side bending punch fixing seat (28) outward through the unloading bolt (32), driving the corner side bending punch (23) to move outward together, until the contact surface of the first oblique wedge (5) and the first slider (6) is completely separated, and the contact surface of the second oblique wedge (34) and the second slider (27) is completely separated.

[0113] The upper die continues to move upward, the first inclined wedge (5) gradually reduces the contact surface with the first lower die stopper (3), the unloading spring (48) gradually decompresses, and the lower die side bending sliding base (61) fixedly connected to the first lower die stopper (3) is pulled inward by the unloading bolt (47). The side bending die (54) connected to the lower die side bending sliding base (61) by the fixing screw (50) moves inward synchronously, and at the same time drives the corner side bending die (21) to move inward, and the lower die corner bending sliding base (39) connected to the corner side bending die (21) is pushed inward by the decompression of the spring (35). The side bending die (54) and the corner side bending die (21) are completely separated from the blank.

[0114] The upper die continues to move upward, the upper die stripper plate (18) is separated from the blank, the discharge spring (43) is decompressed to lift the discharge top block (20), and the blank is lifted by the discharge top block (20). The upper die moves upward and returns to the starting point. The robot enters the mold, sucks and removes the blank, and moves to the next process.

[0115] like Fig. 20 As shown, the mold structure of the present invention first performs corner bending and then delays straight edge bending, which significantly improves the product forming quality of the pre-coated color steel plate blank after the fifth stamping forming process; Fig.21 As shown, after completing all the processes, the four corners of the top cover of the air conditioner outdoor unit and their respective adjacent side surfaces are highly consistent, the curling edges are flat, the top cover and the step surfaces of the air conditioner panel and rear plate can be fitted at equal distances, and after the whole machine is assembled, the gap is uniform and the appearance is beautiful.

[0116] Although the content of the present invention has been described in detail through the above preferred embodiments, it should be appreciated that the above description should not be considered as a limitation of the present invention. After reading the above content, it will be apparent to those skilled in the art that various modifications and substitutions of the present invention will occur. Therefore, the protection scope of the present invention should be limited by the appended claims.

Claims

1. A method for controlling a mold structure, characterized in that: The following procedures are included: When the mold structure is in a state where punching and molding has not yet begun, the blank is inserted into a concave mold assembly including a corner side bending concave mold (21) and a side side bending concave mold (54), and the blank is supported by a discharge top block (20) connected to a lower mold base (40); When the mold structure is in the first state of punching and forming, the upper mold stripper plate (18) moves downward and presses the blank; the side bending die (54) moves from the inside to the direction close to the side of the blank, driving the corner bending die (21) to move from the inside to the direction close to the corner of the blank, until the side bending die (54) and the corner bending die (21) contact the blank; When the mold structure is in the second state of punching and forming, the corner side bending convex mold (23) moves from the outside to the direction close to the corner of the blank and contacts the corner of the blank, and the corner side bending convex mold (23) cooperates with the corner side bending concave mold (21) to bend the corner of the blank inward; When the mold structure is in the third state of punching and forming, the side bending punch (55) moves from the outside to the direction close to the side of the blank and contacts the side of the blank, and the side bending punch (55) cooperates with the side bending die (54) to bend the side of the blank inward; wherein, the bending of the corner of the blank is earlier than the bending of the side of the blank.

2. The control method according to claim 1, characterized in that: When the mold structure is in the first state of punching and forming, the first bevel (5) moves downward along with the upper mold base (17), and the outer bevel surface of the first bevel (5) contacts the inner bevel surface of the first lower mold stopper (3) and slides along the inner bevel surface of the first lower mold stopper (3), so that the first lower mold stopper (3) drives the lower mold side bending sliding base (61) connected thereto to move outward, and the side bending die (54) connected to the lower mold side bending sliding base (61) moves outward to approach the side of the blank.

3. The control method according to claim 2, characterized in that: When the mold structure is in the first state of punching and forming, during the process of the side bending die (54) moving outward, the lateral driving surface of the side bending die (54) contacts the lateral driven surface of the corner side bending die (21) and slides along the driven surface, driving the corner side bending die (21) to move outward to approach the corner of the blank; the driving surface and the driven surface are both perpendicular to the direction in which the corner side bending die (21) moves toward the corner of the blank; The ratio of the displacement of the side bending die (54) toward the side of the blank to the displacement of the corner bending die (21) toward the corner of the blank is s1:s2, and s1 is greater than s2.

4. The control method according to claim 2 or 3, characterized in that: When the mold structure is in the second state of punching and forming, the second bevel (34) moves downward with the upper mold base (17), and the inner bevel surface of the second bevel (34) contacts the outer bevel surface of the second slider (27) and slides along the outer bevel surface of the second slider (27), so that the second slider (27) drives the corner side bending punch fixing seat (28) connected thereto to move inward, so that the corner side bending punch (23) connected to the corner side bending punch fixing seat (28) moves inward to approach the corner of the blank, and then contacts the corner of the blank and continues to move inward of the corner, cooperating with the corner side bending die (21) to bend the corner of the blank.

5. The control method according to claim 4, characterized in that: When the mold structure is in the third state of punching and forming, the inner inclined surface of the first inclined wedge (5) contacts the outer inclined surface of the first slider (6) and slides along the outer inclined surface of the first slider (6), so that the first slider (6) drives the side bending punch fixing seat (59) connected thereto to move inward, so that the side bending punch (55) connected to the side bending punch fixing seat (59) moves inward to approach the side of the blank, and then contacts the side of the blank and continues to move inward to cooperate with the side bending die (54) to bend the side of the blank; The time when the inner inclined surface of the first inclined wedge (5) contacts the outer inclined surface of the first slider (6) is later than the time when the inner inclined surface of the second inclined wedge (34) contacts the outer inclined surface of the second slider (27); The distance that the side bending punch (55) continues to move toward the inside of the blank after contacting the side of the blank is greater than the width of the side bending edge of the blank.

6. The control method according to claim 5, characterized in that: The die structure is also used to punch holes on the side of at least part of the direction of the blank; When the mold structure is in the first state of punching and forming, the first lower mold stopper (3) moves outward, driving the side bending punch fixing seat (59) connected to the first lower mold stopper (3) through the first unloading positioning pin (1) to move outward, thereby driving the first slider (6) and the side punching and flanging hole punch (58) connected to the side bending punch fixing seat (59) to move outward; when the mold structure is in the third state of punching and forming, the side bending punch fixing seat (59) moves inward under the drive of the first slider (6), driving the side punching and flanging hole punch (58) to move inward and complete the forming of the side flanging hole.

7. The control method according to claim 6, characterized in that: The side punching and flanging hole punch (58) is fixed to the side side bending punch fixing seat (59) and is also inserted into the lower die stripping plate (12); the lower die stripping plate (12) is fixed to the first slider (6) by a first stripping bolt (7) equipped with a first stripping spring (10), and the first stripping spring (10) is pre-compressed and assembled; the top surface of the lower die stripping plate (12) is provided with an upper die stripping plate stopper (11); When the mold structure is in the first state of punching and forming, the first slider (6), the lower mold stripper plate (12), the upper mold stripper plate stopper (11), the side punching and flanging hole punch (58) and the side bending punch (55) move outward synchronously with the side bending punch fixing seat (59); When the mold structure is in the third state of punching and forming, the lower mold stripper plate (12), the upper mold stripper plate stopper (11), the side punching flanging hole punch (58) and the side side bending punch (55) move inward along with the side side bending punch fixing seat (59), the lower mold stripper plate (12) contacts the side surface of the blank and gradually applies pressure, and the upper mold stripper plate stopper (11) contacts the side surface of the upper mold stripper plate (18); when the mold structure is in the demoulding state, it moves upward along with the upper mold seat (17). The contact surface between the first inclined wedge (5) and the first slider (6) gradually decreases, and under the action of the decompression of the second unloading spring (2) configured for the first unloading positioning pin (1), the side bending punch fixing seat (59) is pulled by the first unloading positioning pin (1), so that the side bending punch fixing seat (59), the first slider (6), the lower die stripping plate (12), the upper die stripping plate stopper (11), the side punching and flanging hole punch (58) and the side bending punch (55) move outward; The first unloading spring (10) is gradually decompressed under the outward movement of the first slider (6), so that the lower mold stripping plate (12) gradually reduces the pressure on the side of the blank until the contact with the side of the blank is released, and the upper mold stripping plate stopper (11) also releases the contact with the side of the upper mold stripping plate (18).

8. The control method according to claim 7, characterized in that: The upper mold stripper plate (18) is connected to the upper mold base (17) via a second stripper positioning pin (13); a pressing spring (15) equipped with a spring guide retainer (16) is arranged between the upper mold stripper plate (18) and the upper mold base (17); when the mold structure is in a demoulding state, the pressing spring (15) is gradually decompressed when the upper mold stripper plate (18) moves upward along with the upper mold base (17), so that the pressing force of the upper mold stripper plate (18) on the blank is gradually reduced; A second unloading bolt (32) equipped with a second unloading spring (33) passes through a second lower die block fixing seat (31) fixed to a lower die seat (40) and is connected to the corner side bending punch fixing seat (28), and the second unloading spring (33) is pre-compressed and assembled; when the mold structure is in a demoulding state, the contact surface between the second oblique wedge (34) and the second slider (27) as the upper die seat (17) moves upward gradually decreases, and under the action of the decompression of the second unloading spring (33), the corner side bending punch fixing seat (28) is pulled by the second unloading bolt (32) and the corner side bending punch (23) is driven to move outward, until the contact surface between the first oblique wedge (5) and the first slider (6) is completely separated, and the contact surface between the second oblique wedge (34) and the second slider (27) is completely separated; A third unloading bolt (47) equipped with a third unloading spring (48) passes through a spring baffle (49) fixed on the lower die seat (40) and is connected to the lower die side bending sliding base (61), and the third unloading spring (48) is pre-compressed and assembled; when the mold structure is in a demoulding state, the contact surface between the first inclined wedge (5) that continues to move upward with the upper die seat (17) and the first lower die stopper (3) is gradually reduced, and under the action of the decompression of the third unloading spring (48), the lower die side bending sliding base (61) is pulled by the third unloading bolt (47) and the side side bending die (54) and the corner side bending die (21) are driven to move inwards until the side side bending die (54) and the corner side bending die (21) are completely out of contact with the blank; The side surface of the lower die corner bending sliding base (39) connected to the corner side bending die (21) is connected to the fifth spring (35) arranged inside the second lower die stopper fixing seat (31); when the mold structure is in the first state of punching and molding, the lower die corner bending sliding base (39) moves outward synchronously with the corner side bending die (21), so that the fifth spring (35) is compressed; when the mold structure is in the demoulding state, during the process of the corner side bending die (21) moving inward, the fifth spring (35) is decompressed to provide an auxiliary thrust for moving the lower die corner bending sliding base (39) inward; The discharge top block (20) is connected to the lower die seat (40) via a fourth discharge bolt (19) equipped with a fourth discharge spring (43); when the die structure is in the first state of punching and molding, the discharge top block (20) is subjected to the downward pressure transmitted to the blank by the upper die stripping plate (18), so that the fourth discharge spring (43) is compressed, and the upper die stripping plate (18), the discharge top block (20) and the blank move downward synchronously; when the die structure is in the demoulding state, when the upper die stripping plate (18) that moves upward with the upper die seat (17) is separated from the blank, the fifth discharge spring (43) is decompressed and lifts the discharge top block (20), and the blank is lifted by the discharge top block (20) for the robot to take away the blank.

9. A method for circumferential curling and leveling, characterized in that: The working state of the mold structure is controlled by the control method of the mold structure according to any one of claims 1 to 8, and the second blank is obtained by first bending the corner of the first blank and then bending the side of the first blank, so that the second blank has highly consistent corner bending edges and side bending edges; The second blank is subjected to a circumferential curling process; the curled product is used to make a top cover of an air conditioner outdoor unit; the top cover is used to be assembled with an air conditioner panel and an air conditioner rear plate to obtain an outer shell of the air conditioner outdoor unit.

10. A mold structure, applicable to the control method of the mold structure according to any one of claims 1 to 8, characterized in that: The mold structure comprises: An upper die seat (17) and a lower die seat (40) opposite to each other; A discharge top block (20), connected to the lower die base (40), for supporting the blank; An upper die stripper plate (18) connected to the upper die base (17) and movable up and down with the upper die base (17); The upper mold stripping plate (18) is used to press the blank when it moves downward; The corner side bending die (21) is located in the inner circle of the die structure and can move closer to or away from the corner of the blank; The corner side bending convex die (23) is located at the outer ring of the mold structure and can move closer to or away from the corner of the blank; the corner side bending concave die (21) and the corner side bending convex die (23) cooperate to bend the corner of the blank inward when they contact the corner of the blank from the inside and the outside respectively; A side bending die (54) is located in the inner circle of the die structure and can move closer to or away from the side of the blank; The side bending convex die (55) is located at the outer ring of the mold structure and can move closer to or away from the side of the blank; the side bending concave die (54) and the side bending concave die (54) cooperate to bend the side of the blank inward when they contact the side of the blank from the inside and the outside respectively; wherein the bending of the corner of the blank is earlier than the bending of the side of the blank.

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