Integrated forming stamping process for new energy automobile battery contact spring

Abstract

The invention relates to the technical field of stamping metal processing, in particular to an integral forming stamping process for a new energy automobile battery contact spring, which comprises the following steps: collecting parameters in real time; abnormal judgment is performed to form a result; determining an abnormal event type; judging a processing risk grade; the blanking force and the forming force are adjusted; adjusting a tension threshold value and a synchronization degree threshold value; and the preset feeding speed is adjusted. Through multi-parameter real-time collection and coupling analysis, a closed-loop control system based on abnormal recognition, risk assessment and parameter self-adaptive adjustment is established, the precision and stability of contact spring punch forming are remarkably improved, the blanking force and the forming force are intelligently adjusted in a linkage mode when the risk level is high, so that the punching quality is optimized, and the production efficiency is improved. And the problem of composite disturbance instability caused by incapability of adapting to dynamic change of material elasticity and processing speed due to excessive dependence on a fixed adjustment mode is effectively solved.

Description

Technical Field

[0001] The present invention relates to the technical field of stamping metal processing, and particularly to an integral molding stamping process for a battery contact spring of a new energy vehicle. Background Art

[0002] With the rapid development of the new energy vehicle industry, the demand for high-performance and high-quality manufacturing of key components of battery packs, especially battery contact springs, has been promoted. As an important part connecting the inside of the battery, the forming quality of the battery contact spring directly affects the electrical conductivity and overall safety of the battery pack. During the manufacturing process, the elastic change of materials, the fluctuation of processing speed, and complex production disturbances pose severe challenges to the stability of the forming process. With the acceleration of the production rhythm and the diversification of materials, these dynamic change factors become more prominent. Traditional fixed adjustment means are difficult to achieve precise control and efficient response, thus affecting the overall efficiency and quality level of the manufacturing of battery pack connectors for new energy vehicles.

[0003] The patent document with the publication number CN117943449A discloses a stamping device and a stamping production line for a battery pack connector of a new energy vehicle. The device includes: a support frame, which is in an overall vertical frame structure, and a fixed cylinder body is fixedly arranged on the support frame; a linear drive assembly, which is arranged at the upper end of the support frame, and the linear drive assembly is provided with a movable end; a movable cylinder body, which is slidably connected in the fixed cylinder body, one end of the movable end away from the linear drive assembly is slidably connected in the movable cylinder body, a stamping head fixing seat is arranged at one end of the movable cylinder body away from the linear drive assembly, and the stamping head fixing seat is used to fix the upper die base, and the upper die bases are arranged at intervals below the upper die base; an elastic member, which is sleeved on the movable cylinder body and its two ends respectively push against the movable cylinder body and the bottom wall of the fixed cylinder body; a drainage chamber, which is connected to the lower die base for supporting the lower die base, a pressure flow transfer area is formed between the drainage chamber and the lower die base, the drainage chamber is communicated with an injection pipe, and one end of the injection pipe is communicated with the pressure flow transfer area; a spray pipe, one end of which is communicated with an air hole arranged on the movable cylinder body, and the other end faces between the upper die base and the lower die base; a hose, the first end of which is communicated with the outlet end of the fixed cylinder body, and the second end is inserted into the injection pipe and the pressure flow transfer area is located in the back pressure area of the second end of the hose; when the movable end moves downward, the gas in the movable cylinder body is first pressurized and discharged from the spray pipe, when the movable end moves to the bottom wall of the movable cylinder body, the movable cylinder body moves in the direction of compressing the elastic member and the gas in the fixed cylinder body is pressurized and discharged from the hose, and the gas discharged from the hose injects the gas at the back pressure area.

[0004] It can be seen that the stamping device and stamping production line for the new energy vehicle battery pack connector have the following problems: This device mainly relies on a fixed gas flow path and elastic components to achieve stamping drive and buffering. The adjustment method is relatively static and it is difficult to cope with the tension fluctuations and feeding rhythm changes under complex working conditions; the change in gas pressure in the stamping device is used to drive actions or eject gas, but there is a lack of data feedback and parameter linkage mechanism between it and the actual forming result, resulting in insufficient response ability to state changes; the risk state identification relies on the presentation of structural reaction results, and it is not sensitive enough to factors such as deformation behavior and tension fluctuations, prone to problems such as delayed risk identification and untimely handling. Summary of the Invention

[0005] Therefore, the present invention provides an integrated forming stamping process for the contact spring of a new energy vehicle battery, which overcomes the problem in the prior art that due to excessive reliance on a fixed adjustment method, it is unable to adapt to the dynamic changes of material elasticity and processing speed, resulting in compound disturbance instability, through a multi-parameter linkage closed-loop control and dynamic threshold correction mechanism.

[0006] To achieve the above object, the present invention provides an integrated forming stamping process for the contact spring of a new energy vehicle battery, including: Real-time collect the conveying tension of the conductive strip material on the strip fed at a preset feeding speed, the vibration frequency of the mold, the height of the trimming burr of the conductive strip material at the blanking station blanked based on a preset blanking force, the hook angle of the semi-finished contact spring at the forming station formed based on a preset forming force, and the curvature of the bending section; Judge an abnormal event according to the conveying tension and a preset tension threshold, and form an abnormal judgment result; Based on the abnormal judgment result, determine the event type of the abnormal event as deformation coupling disturbance according to the height of the trimming burr, the vibration frequency, and a preset synchronization threshold, and obtain an abnormal type; Based on the abnormal type, judge the occurrence of processing risks according to the hook angle and the curvature of the bending section, and determine the risk level of the processing risk as a serious level, forming a risk judgment result; Based on the risk judgment result, adjust the preset blanking force and the preset forming force according to the vibration frequency, the height of the trimming burr, and the hook angle; Based on the abnormal type re-determined according to the adjusted preset blanking force and the adjusted preset forming force, adjust the preset tension threshold or the preset synchronization threshold according to the curvature of the bending section; Adjust the preset feeding speed based on the risk judgment result re-determined based on the adjusted threshold or the preset synchronization threshold.

[0007] Further, determining that the event type of the abnormal event is deformation coupling perturbation according to the trimming burr height, the vibration frequency, and a preset synchronization threshold value, the process of obtaining the abnormal type includes: Calculating the standard deviation of all the trimming burr heights at each moment from the current moment to a preset type determination duration to obtain a plurality of burr height fluctuation values; Calculating the standard deviation of all the vibration frequencies at each moment from the current moment to the preset type determination duration to obtain a plurality of vibration frequency fluctuation values; Determining that the event type of the abnormal event is deformation coupling perturbation according to all the burr height fluctuation values, all the vibration frequency fluctuation values, and the preset synchronization threshold value to obtain the abnormal type.

[0008] Further, determining that the event type of the abnormal event is deformation coupling perturbation according to all the burr height fluctuation values, all the vibration frequency fluctuation values, and the preset synchronization threshold value, the process of obtaining the abnormal type includes: Plotting a change curve of the burr height fluctuation values changing with time within the preset type determination duration to obtain a height fluctuation curve; Plotting a change curve of the vibration frequency fluctuation values changing with time within the preset type determination duration to obtain a frequency fluctuation curve; Calculating the absolute value of the cosine similarity of the height fluctuation curve and the frequency fluctuation curve to obtain a change synchronization degree; When the change synchronization degree is greater than the preset synchronization threshold value, determining that the event type of the abnormal event is deformation coupling perturbation.

[0009] Further, the process of judging the occurrence of a processing risk according to the hook angle and the curvature of the bending section includes: When the hook angle is greater than a preset hook angle threshold value, or the curvature of the bending section is greater than a preset curvature threshold value, calculating the standard deviation of the hook angle within a preset risk determination duration to obtain an angle fluctuation value, and calculating the standard deviation of the curvature of the bending section within the preset risk determination duration to obtain a curvature fluctuation value; Judging that a processing risk occurs when the angle fluctuation value is less than a preset angle fluctuation threshold value and the curvature fluctuation value is less than a preset curvature fluctuation threshold value.

[0010] Further, the process of determining that the risk level of the processing risk is a severe level includes: Performing maximum-minimum normalization processing on all the hook angles within the preset risk determination duration to obtain a normalized angle set, and performing maximum-minimum normalization processing on all the curvatures of the bending sections within the preset risk determination duration to obtain a normalized curvature set; Calculate the Pearson correlation coefficient of the set of normalized angles and the set of normalized curvatures to obtain the coupling degree. When the coupling degree is greater than a preset coupling degree threshold, determine that the risk level is a severe level.

[0011] Further, the process of adjusting the preset blanking force and the preset forming force according to the vibration frequency, the trimming burr height, and the hook angle includes: Calculate the standard deviation of the difference between the vibration frequency and the difference of the preset vibration frequency within a preset first adjustment duration to obtain the frequency deviation fluctuation value. When the frequency deviation fluctuation value is greater than a preset frequency deviation fluctuation threshold, adjust the preset blanking force and the preset forming force according to the trimming burr height and the hook angle.

[0012] Further, the process of adjusting the preset blanking force and the preset forming force according to the trimming burr height and the hook angle includes: Perform maximum - minimum normalization processing on all the trimming burr heights within a preset second adjustment duration to obtain a set of normalized heights, and calculate the average value of all the trimming burr heights to obtain the average burr height. Perform maximum - minimum normalization processing on all the hook angles within the preset second adjustment duration to obtain a set of normalized angles, and calculate the average value of all the hook angles to obtain the average angle. Calculate the relative deviation of the average burr height from a preset height adjustment threshold to obtain the height deviation. Calculate the relative deviation of the average angle from a preset angle adjustment threshold to obtain the angle deviation. When the height deviation is greater than a preset height deviation threshold and the angle deviation is greater than a preset angle deviation threshold, calculate the Pearson correlation coefficient of the set of normalized heights and the set of normalized angles to obtain the correlation degree. When the correlation degree is greater than a preset correlation degree threshold, increase the preset blanking force according to the relative deviation of the correlation degree from the preset correlation degree threshold, the preset height deviation weight, and the preset force adjustment coefficient, and increase the preset forming force according to the relative deviation of the correlation degree from the preset correlation degree threshold, the preset angle deviation weight, and the preset force adjustment coefficient.

[0013] Further, the process of adjusting the preset tension threshold or the preset synchronization threshold according to the curvature of the bending section includes: Calculate the average value of all the curvatures of the bending section within a preset threshold adjustment duration to obtain the average curvature. Calculate the absolute value of the relative deviation of the average curvature from a preset average curvature threshold to obtain the curvature deviation. When the curvature deviation is greater than a preset curvature deviation threshold, calculate the absolute value of the first derivative of the curvature of each of the bending sections within the preset threshold adjustment duration to obtain the absolute curvature change rate; When the absolute curvature change rate is less than a preset rate threshold, increase the synchronization threshold according to the relative deviation between the preset rate threshold and the absolute curvature change rate and a preset threshold adjustment coefficient; When the absolute curvature change rate is greater than or equal to the preset rate threshold, calculate the absolute value of the second derivative of the curvature of each of the bending sections within the preset threshold adjustment duration to obtain the absolute curvature change acceleration; When the absolute curvature change acceleration is greater than a preset acceleration threshold, decrease the preset tension threshold according to the relative deviation between the absolute curvature change acceleration and the preset acceleration threshold and the preset threshold adjustment coefficient.

[0014] Further, the process of adjusting the preset feeding speed based on the risk determination result re-determined based on the adjusted threshold or the preset synchronization threshold includes: Calculate the standard deviation of the number of times of forming the risk determination result within the preset speed adjustment duration to obtain the risk number fluctuation value; When the risk number fluctuation value is greater than a preset risk number fluctuation threshold, decrease the preset feeding speed according to the relative deviation between the risk number fluctuation value and the preset risk number fluctuation threshold and a preset feeding adjustment coefficient.

[0015] Further, the process of determining an abnormal event based on the conveying tension and the preset tension threshold to form an abnormal determination result includes: Start recording the current timestamp when the conveying tension is greater than the preset tension threshold, and stop recording when the conveying tension is less than or equal to the preset tension threshold to obtain the duration; When the duration is greater than a preset duration threshold, determine that the abnormal event has occurred and form the abnormal determination result.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows. Through real-time multi-parameter acquisition and coupling analysis, a closed-loop control system based on anomaly recognition, risk assessment, and parameter adaptive adjustment is established, significantly improving the precision and stability of the stamping forming of the contact spring. Among them, the conveying tension reflects the feeding state and is a leading parameter for anomaly recognition; the vibration frequency and the height of the trimming burr are jointly used as references for determining the type of anomaly (such as deformation coupling disturbance), reflecting the coupling relationship between the die vibration and the blanking effect; the hook angle and the curvature of the bending section directly reflect the forming quality, and the processing risk level is further evaluated through their deviations; when the risk level is relatively high, the blanking force and the forming force are intelligently adjusted in a linked manner to optimize the stamping quality; at the same time, based on the new round of parameter feedback, the tension threshold and the synchronization threshold are dynamically corrected, and further affect the feeding speed, realizing the full-process linked control from anomaly recognition to risk suppression and then to the production rhythm, thereby ensuring the consistency and reliability of the new energy vehicle battery contact spring under high-speed continuous stamping conditions, effectively solving the problem of complex disturbance instability caused by the inability to adapt to the dynamic changes of material elasticity and processing speed due to over-reliance on fixed adjustment methods.

[0017] Furthermore, through dynamic coupling analysis of the burr height fluctuation and the vibration frequency fluctuation, a time-series linkage model between the processing precision anomaly and the structural vibration is established. By calculating the statistical difference (standard deviation) of the fluctuation intensities of the two within the same time period, and then using the absolute value of the cosine similarity as a measure, the consistency of their fluctuation trends is judged, so as to capture complex coupling interference phenomena caused by die structure loosening, material rebound, die fatigue, etc. Compared with the traditional single-parameter monitoring method, this method can reveal the coupling relationship and the root cause between multiple physical quantities, improve the accuracy of anomaly detection and the intelligent judgment ability, and facilitate the realization of refined control and early warning management of the stamping process.

[0018] Furthermore, based on the interaction between the mechanics and the vibration system, by introducing the fluctuation synchronization between the burr height (reflecting the microscopic fracture characteristics of the material) and the die vibration frequency (reflecting the dynamic state of the system), the accurate determination of the anomaly type is realized. The cosine similarity, as a quantitative index of the change trend, conforms to the general measurement standard for the correlation of high-dimensional data in mathematics. When the impact and deformation during the processing cause synchronous fluctuations, the system can timely identify the deformation coupling disturbance, providing a basis for subsequent adjustment, closely combining the material mechanics behavior, the processing dynamic response, and the signal analysis, and being able to reflect the processing intelligent judgment ability driven by data, effectively improving the stability and intelligent level of the production process.

[0019] Furthermore, by taking angle and curvature as the main indicators of forming accuracy and integrating the dual judgment logic of their absolute values and volatility, if the finished product has a large angle or curvature but small fluctuations, it indicates that the deviation has been finalized and there is no dynamic correction behavior, suggesting that the mold or material has entered the plastic deformation limit or rigid offset state, which is a typical high-risk signal. By introducing the standard deviation to evaluate the change trend and excluding misjudgments caused by accidental fluctuations, the accuracy and robustness of risk identification are improved, providing a theoretical basis for timely intervention and parameter correction, and achieving stable and controllable stamping quality assurance.

[0020] Furthermore, the hook angle and the curvature of the bending section respectively reflect the macroscopic angle deviation and the degree of local plastic deformation during the forming process, and their coupling reflects the possible common cause disturbances in the mold forming force or material springback response. Using the Pearson correlation coefficient to quantify the statistical linear relationship between the two can accurately identify high-risk abnormal states caused by mold synchronization disorders, material plastic overload, or process fatigue, avoiding misjudgments of single indicators, and thus achieving more scientific and reasonable risk level identification and early warning.

[0021] Furthermore, the fluctuations in vibration frequency reflect the dynamic state of the mechanical system. By accurately capturing equipment abnormalities or fatigue changes through the frequency deviation fluctuation value, the trimming burr height and the hook angle, as intuitive indicators of processing quality, are closely related to the dynamic changes in vibration frequency. Through the collaborative judgment of the three, the system can scientifically adjust the blanking force and forming force, realize the adaptive optimization of processing parameters, significantly improve the stability and reliability of the finished contact spring, and reduce the defective rate.

[0022] Furthermore, the trimming burr height and the hook angle, as the direct physical manifestations of processing quality, reflect the mutual influence and coupling relationship between the blanking and forming processes. Normalization processing makes the two parameters comparable, and the correlation calculation reveals the collaborative fluctuation law between the two. By dynamically adjusting based on these two key parameters, precise control of the blanking force and forming force can be achieved, effectively suppressing the accumulation of defects caused by processing deviations, improving the consistency and reliability of the finished contact spring, and ensuring the stability of the production process and product quality.

[0023] Furthermore, by multi-level analyzing the average level, change rate, and acceleration of the curvature of the bending section, the dynamic characteristics of material deformation can be accurately reflected, and the scientific adjustment of processing parameters can be achieved. The curvature deviation reflects the static deviation, the change rate reflects the deformation trend, and the acceleration captures the risk of rapid changes. The combination of the three ensures that the adjustment of the tension and synchronization threshold is both sensitive and stable, avoiding over-response or hysteresis, and improving the safety and accuracy of the processing process.

[0024] Furthermore, by comparing the deviation between the fluctuation value and the threshold value and dynamically adjusting in combination with the feeding speed adjustment coefficient, there is a direct dynamic coupling relationship between the feeding speed and the risk formation frequency. When the feeding speed is too fast, it is likely to lead to a decrease in processing stability and frequent errors. Reducing the feeding speed can effectively extend the response time to abnormalities, improve the deformation control accuracy and the finished product quality, reflecting the feedback adjustment mechanism based on the risk fluctuation law.

[0025] Furthermore, by continuously monitoring the relationship between the conveying tension and the set tension threshold value and making a judgment in combination with the duration, real tension abnormality events can be effectively identified. Establishing a judgment mechanism by combining the two dimensions of force value and time conforms to the physical law that the material will be damaged only when the force exceeds the critical value and acts continuously, avoiding false alarms of abnormalities due to instantaneous fluctuations, improving the scientificity and reliability of the judgment, and helping to ensure the stability of subsequent processes and the product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a flowchart of the one-piece stamping process for the battery contact spring of a new energy vehicle in this embodiment; Figure 2 is a determination logic diagram for determining the deformation coupling disturbance in this embodiment; Figure 3 is a determination logic diagram for determining the occurrence of processing risks in this embodiment; Figure 4 is a determination logic diagram for adjusting the preset blanking force and the preset forming force in this embodiment. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0027] In order to make the objectives and advantages of the present invention clearer, the present invention will be further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0028] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are only used to explain the technical principles of the present invention and do not limit the protection scope of the present invention.

[0029] Please refer to Figure 1 as shown, which is a flowchart of the one-piece stamping process for the battery contact spring of a new energy vehicle in this embodiment; This embodiment provides a one-piece stamping process for the battery contact spring of a new energy vehicle, including: Real-time collecting the conveying tension of the conductive strip material on the strip fed based on the preset feeding speed, the vibration frequency of the mold, the height of the trimming burr of the conductive strip material at the blanking station blanked based on the preset blanking force, the hook angle of the semi-finished contact spring at the forming station formed based on the preset forming force, and the curvature of the bending section. Determine that an abnormal event has occurred based on the conveying tension and a preset tension threshold, and form an abnormal determination result; Based on the abnormal determination result, determine that the event type of the abnormal event is deformation coupling perturbation according to the height of the trimming burr, the vibration frequency, and a preset synchronization threshold, and obtain an abnormal type; Based on the abnormal type, determine that there is a processing risk according to the hook angle and the curvature of the bending section, and determine that the risk level of the processing risk is a severe level, and form a risk determination result; Based on the risk determination result, adjust the preset blanking force and the preset forming force according to the vibration frequency, the height of the trimming burr, and the hook angle; Based on the abnormal type re-determined according to the adjusted preset blanking force and the adjusted preset forming force, adjust the preset tension threshold or the preset synchronization threshold according to the curvature of the bending section; Adjust the preset feeding speed based on the risk determination result re-determined based on the adjusted threshold or the preset synchronization threshold.

[0030] This embodiment is applied to the manufacturing process of a contact spring for conductive connection in a new energy vehicle battery module. The semi-finished contact spring has extremely high requirements for elastic deformation ability and conductive reliability. Therefore, during the stamping and forming process, multiple parameters need to be monitored in real time to ensure accurate structure and consistent performance.

[0031] The production process adopts an integrated continuous stamping production line process, that is, a conductive metal strip (such as copper alloy or nickel-plated steel strip) is fed into a multi-station die through an automatic feeding mechanism, and steps such as feeding, blanking, forming, and bending are completed in multiple mutually connected stations, and finally a semi-finished contact spring is obtained.

[0032] The acquisition method of each parameter: Real-time acquisition of the conveying tension: Position: The strip tension control mechanism installed between the feeding unit and the die entrance.

[0033] Sensor type: Precision tension sensor (tensiometer) or tension control roller.

[0034] Real-time detect the tension change of the conductive strip during feeding, identify whether the feeding is uniform, and whether there are abnormalities such as tape jamming, slipping, or over-tightening.

[0035] Acquisition of the die vibration frequency: Position: Installed on the die seat or the die holder structure.

[0036] Sensor type: Triaxial acceleration sensor or vibration frequency sensor.

[0037] Judge the dynamic stability of the die during the stamping process and identify abnormal impacts, die loosening or resonance phenomena.

[0038] Collection of the height of the trimming burr at the blanking station: Location: At the exit of the lower die at the blanking station or immediately before the forming station.

[0039] Sensor type: Laser displacement sensor or 3D line laser measurement head.

[0040] Real-time detection of the burr height of the trimmed edge. Excessive burrs may indicate dulling of the blanking edge, insufficient blanking force or unstable material guiding.

[0041] Collection of the hook angle at the forming station: Location: Detection area after the last bending / stretching forming station.

[0042] Sensor type: Industrial vision system (high-resolution industrial camera + AI image recognition algorithm) or angle measurement laser device.

[0043] Precisely measure the hook angle after forming to judge whether the forming is qualified and whether there are deformations or rebounds.

[0044] Collection of the curvature of the bending section: Location: The same as the hook angle detection area.

[0045] Sensor type: Industrial camera + image processing system, or laser scanning device.

[0046] Judge whether the bending transition of the spring is reasonable through curvature analysis and whether there are problems such as tearing and wrinkling.

[0047] Connection relationship between each station and the production line work process The whole set of equipment usually adopts the following series multi-station progressive die structure, installed on the stamping press platform and coordinated by an automatic control system: The feeding unit contains a feeding wheel, a motor and a tension control system, and accurately pushes the coiled conductive strip into the die at a preset feeding speed.

[0048] The tension sensor is installed on the feeding path to continuously monitor the tension state.

[0049] The blanking station performs preliminary blanking and trimming operations on the conductive strip to form the outer contour and positioning holes.

[0050] The trimming burr detection device follows the blanking station closely to detect the wear of the cutting edge and the stability of the strip.

[0051] The preliminary bending station performs one or more small-angle bendings on the semi-finished product after blanking to pre-form the shapes of the subsequent hook and elastic section.

[0052] The hook part and curvature forming station finely control the die shape and pressure to complete the formation of the hook part of the spring and the overall curvature control.

[0053] An image system / angle detection system is equipped after the station to collect the hook angle and curvature.

[0054] Finished product inspection and blanking station: Integrate a defect identification + rejection system to reject springs that do not meet the angle, curvature, or burr standards.

[0055] The semi-finished product of the contact spring is sent to the collection device or automatically enters the next electroplating / assembly process.

[0056] The preset feeding speed is the feeding length per unit time when the strip enters the stamping die, which depends on the die rhythm and production rhythm. It is usually set between 100 mm / s and 500 mm / s. In this embodiment, it is set to 300 mm / s, which can ensure the coordinated operation of each station and maintain the stability of the strip tension.

[0057] Based on the preset blanking force, which is the initial pressure value applied by the blanking station when cutting the conductive material, depends on the material thickness and the shape of the die edge. It is usually set between 2 kN and 10 kN. In this embodiment, it is set to 5 kN, which can effectively ensure the trimming quality and suppress the excessive burr height.

[0058] The preset forming force is the pressing force when the forming station bends the contact spring, which depends on the elastic modulus of the material and the forming angle requirements. It is usually set between 3 kN and 12 kN. In this embodiment, it is set to 7 kN, which can ensure the stable shape of the hook part and the bending section.

[0059] The preset tension threshold is an important reference tension range for judging whether there is an abnormality in the feeding process, which depends on the strip width and the die friction resistance. It is usually set between 20 N and 60 N. In this embodiment, it is set to 40 N, which can timely identify the risk of feeding blockage or slippage.

[0060] The preset synchronization threshold is a judgment threshold set based on whether the change trends between the burr height fluctuation and the die vibration frequency fluctuation are highly consistent. Its essence reflects the strength of the coupling correlation between two physical change phenomena in the time series, which depends on whether there is a cooperative disturbance mechanism caused by material hardening, die wear, or synchronization abnormality between blanking and die dynamics in the process system. It is usually set between 0.65 and 0.85. In this embodiment, it is set to 0.78, which is used to measure whether the absolute value of the cosine similarity between the height fluctuation curve and the frequency fluctuation curve is high enough, so as to judge whether there is a deformation coupling disturbance based on structural and load changes, and realize the early identification and intervention of abnormal events.

[0061] First, key process parameters such as the conveying tension of the conductive strip material, the die vibration frequency, the trimming burr height, the hook angle, and the curvature of the bending section are collected in real time through sensors during the feeding process. Subsequently, abnormal events are identified by comparing the conveying tension with a preset tension threshold, and the types of abnormal events are further analyzed in combination with the trimming burr height and the vibration frequency. Then, the processing risks and their levels are judged based on the hook angle and the curvature of the bending section. Finally, process parameters such as the blanking force and the forming force are dynamically adjusted according to the risk level, and the tension threshold, the synchronization threshold, and the feeding speed are feedback-adjusted to form a closed-loop adaptive optimization mechanism.

[0062] In continuous and high-speed stamping production, the forming process of the contact spring is essentially a multi-physical-field coupling system. All kinds of parameters (tension, vibration, trimming quality, structural geometric features) interact and superimpose on each other, just like "resonance" in mechanical structures or "nonlinear deformation" in material microstructures. This deformation coupling perturbation essentially conforms to the general law of "multi-factor coupling causing system instability" in nature - when the feeding tension, blanking impact, and forming load synchronously deviate, the system will quickly enter a new and often uncontrollable dynamic equilibrium state. If this coupling perturbation persists and its forming characteristics (such as the hook angle and bending curvature) stably deviate under low fluctuations and high coupling degrees, it constitutes a risk of a serious level: that is, although the system does not show severe vibration, it has steadily deviated from the design value and is difficult to self-recover through single-parameter adjustment.

[0063] Through multi-parameter real-time acquisition and coupling analysis, a closed-loop control system based on abnormal identification, risk assessment, and parameter adaptive adjustment has been established, significantly improving the accuracy and stability of the stamping forming of the contact spring. Among them, the conveying tension reflects the feeding state and is a leading parameter for abnormal identification; the vibration frequency and the trimming burr height are jointly used as references for judging the type of abnormal event (such as deformation coupling perturbation), reflecting the coupling relationship between die vibration and blanking effect; the hook angle and the curvature of the bending section directly reflect the forming quality, and the processing risk level is further evaluated through their deviations; when the risk level is relatively high, the blanking force and the forming force are intelligently linked and adjusted to optimize the stamping quality; at the same time, based on the new round of parameter feedback, the tension threshold and the synchronization threshold are dynamically corrected, and further affect the feeding speed, realizing the full-process linkage control from abnormal identification to risk suppression and then to production rhythm, thereby ensuring the consistency and reliability of the contact spring of the new energy vehicle battery under high-speed continuous stamping conditions, and effectively solving the problem of composite perturbation instability caused by over-reliance on fixed adjustment methods and inability to adapt to the dynamic changes of material elasticity and processing speed.

[0064] Specifically, determining that the event type of the abnormal event is deformation coupling perturbation according to the trimming burr height, the vibration frequency, and a preset synchronization threshold, the process of obtaining the abnormal type includes: Calculate the standard deviation of all the trimming burr heights at each moment from the current moment to the preset type determination duration, and obtain a number of burr height fluctuation values; Calculate the standard deviation of all the vibration frequencies at each moment from the current moment to the preset type determination duration, and obtain a number of vibration frequency fluctuation values; Determine that the event type of the abnormal event is deformation coupling disturbance according to all the burr height fluctuation values, all the vibration frequency fluctuation values, and the preset synchronization threshold, and obtain the abnormal type.

[0065] The preset type determination duration refers to the time window for statistically analyzing the vibration frequency and burr height fluctuation characteristics, which depends on the stamping rhythm, process stability, and signal sampling frequency. It is usually set between 0.5 seconds and 5 seconds. In this embodiment, it is set to 2 seconds, which can ensure that representative fluctuation data is extracted within a time range sufficient to cover multiple processing cycles, thereby improving the stability and accuracy of deformation coupling disturbance identification.

[0066] Through the set type determination duration, continuously collect the time series data of the trimming burr height and the die vibration frequency, and calculate the standard deviation for each of them within this time window to obtain the burr height fluctuation value and the vibration frequency fluctuation value representing the degree of processing state fluctuation; further plot the two sets of fluctuation values as curves, and calculate the absolute value of their cosine similarity. If this value exceeds the preset synchronization threshold, it is determined that there is an obvious time series coordination relationship between the burr fluctuation and the vibration change, that is, it is identified as the abnormal type of "deformation coupling disturbance".

[0067] By performing dynamic coupling analysis on the burr height fluctuation and the vibration frequency fluctuation, a time series linkage model between machining accuracy anomalies and structural vibrations is established. By calculating the statistical difference (standard deviation) in the fluctuation intensity of the two within the same time period, and using the absolute value of the cosine similarity as a measure, the consistency of their fluctuation trends is judged, so as to capture complex coupling interference phenomena caused by die structure loosening, material rebound, die fatigue, etc. Compared with traditional single-parameter monitoring methods, this method can reveal the coupling relationship and root causes between multiple physical quantities, improve the accuracy of abnormal detection and intelligent judgment ability, and facilitate the realization of refined control and early warning management of the stamping process.

[0068] Please continue to refer to Figure 2 shown, which is the determination logic diagram for determining deformation coupling disturbance in this embodiment; The process of determining that the event type of the abnormal event is deformation coupling disturbance according to all the burr height fluctuation values, all the vibration frequency fluctuation values, and the preset synchronization threshold, and obtaining the abnormal type includes: Plot the change curve of the burr height fluctuation value over time within the preset type determination duration to obtain the height fluctuation curve; Plot a variation curve of the vibration frequency fluctuation value over time within the preset type determination duration to obtain a frequency fluctuation curve; Calculate the absolute value of the cosine similarity between the height fluctuation curve and the frequency fluctuation curve to obtain a change synchronization degree; When the change synchronization degree is greater than the preset synchronization degree threshold, determine that the event type of the abnormal event is deformation coupling perturbation.

[0069] By collecting continuous fluctuation data of the trimming burr height and the die vibration frequency within the preset type determination duration, calculate their standard deviations respectively to form a burr height fluctuation value and a vibration frequency fluctuation value, and plot them as curves changing over time. Subsequently, by calculating the absolute value of the cosine similarity between the two fluctuation curves (first vectorize them respectively and then calculate the cosine similarity, which is a prior art and will not be elaborated here), the synchronization of their change trends is quantified. If the change synchronization degree exceeds the preset synchronization degree threshold, it is considered that there is a significant coupling relationship between the burr fluctuation and the vibration fluctuation, and thus the current abnormal event is determined as "deformation coupling perturbation".

[0070] Based on the interaction between the mechanics and the vibration system, by introducing the fluctuation synchronization between the burr height (reflecting the microscopic fracture characteristics of the material) and the die vibration frequency (reflecting the dynamic state of the system), the accurate determination of the abnormal type is realized. The cosine similarity, as a quantification index of the change trend, conforms to the general measurement standard for the correlation of high-dimensional data in mathematics. When the impact and deformation during the processing cause synchronous fluctuations, the system can timely identify the deformation coupling perturbation, provide a basis for subsequent adjustment, closely combine the material mechanics behavior, the processing dynamic response and the signal analysis, and can reflect the processing intelligent judgment ability driven by data, effectively improving the stability and intelligent level of the production process.

[0071] Please continue to refer to Figure 3 as shown, which is the determination logic diagram for judging the occurrence of processing risks in this embodiment; The process of judging the occurrence of processing risks according to the hook angle and the curvature of the bending section includes: When the hook angle is greater than the preset hook angle threshold, or the curvature of the bending section is greater than the preset curvature threshold, calculate the standard deviation of the hook angle within the preset risk determination duration to obtain an angle fluctuation value, and calculate the standard deviation of the curvature of the bending section within the preset risk determination duration to obtain a curvature fluctuation value; Judge that a processing risk occurs when the angle fluctuation value is less than the preset angle fluctuation threshold and the curvature fluctuation value is less than the preset curvature fluctuation threshold.

[0072] The preset hook angle threshold refers to the upper limit of the angle used to determine whether the forming of the contact spring hook is out of tolerance. It depends on the hook function requirements and assembly tolerances in the product design drawing, and is usually set between 5° and 15°. In this embodiment, it is set to 10°, which can timely identify functional deviations or die fatigue problems caused by excessive hook forming.

[0073] The preset curvature threshold refers to the maximum curvature value used to determine whether the deformation degree of the bending section of the contact spring is abnormal. It depends on the designed radius of the bending structure and the elastic modulus of the material, and is usually set between 0.1mm -1 and 0.5mm -1 In this embodiment, it is set to 0.3mm -1 which can effectively detect local stress concentration or uneven deformation during the forming process.

[0074] The preset angle fluctuation threshold is the allowable fluctuation range for judging whether there is dynamic abnormality in the hook angle. It depends on the stamping stability of the equipment and the material consistency, and is usually set between 0.2° and 1.0°. In this embodiment, it is set to 0.5°, which can be used to identify whether the processing process is stable or there is a small fatigue accumulation effect.

[0075] The preset curvature fluctuation threshold is the upper limit of the standard deviation used to evaluate whether the change range of the bending curvature is within the normal range. It depends on the force control accuracy of the bending station and the material stiffness fluctuation, and is usually set between 0.01mm -1 and 0.05mm -1 In this embodiment, it is set to 0.03mm -1 which can determine whether there is a forming deviation caused by uneven die clearance or insufficient lubrication.

[0076] By continuously monitoring the hook angle and the bending section curvature of the contact spring finished product, first judge whether they exceed the preset angle or curvature threshold; if there is an overlimit, then calculate the standard deviation of the hook angle and the bending section curvature respectively within the preset risk judgment time length to obtain the angle fluctuation value and the curvature fluctuation value. When both fluctuations are small, that is, lower than their respective fluctuation thresholds, it is determined that there is a processing risk in the current forming process.

[0077] By taking the angle and curvature as the main indicators of the forming accuracy and integrating the dual judgment logics of their absolute values and volatility, if the finished product angle or curvature is large and the fluctuation is small, it indicates that the deviation has been finalized and there is no dynamic correction behavior, suggesting that the die or material has entered the plastic deformation limit or the rigid offset state, which is a typical high-risk signal. By introducing the standard deviation to evaluate the change trend and excluding the misjudgment of accidental fluctuations, the accuracy and robustness of risk identification are improved, providing a theoretical basis for timely intervention and parameter correction, and realizing stable and controllable stamping quality assurance.

[0078] Specifically, the process of determining that the risk level of the processing risk is a severe level includes: Perform maximum-minimum normalization processing on all the hook angles within the preset risk determination duration to obtain a set of normalized angles, and perform maximum-minimum normalization processing on all the bending section curvatures within the preset risk determination duration to obtain a set of normalized curvatures; Calculate the Pearson correlation coefficient of the set of normalized angles and the set of normalized curvatures to obtain the coupling degree; When the coupling degree is greater than the preset coupling degree threshold, determine that the risk level is a severe level.

[0079] The preset risk determination duration is a time window for collecting hook angle and bending section curvature data, which depends on the processing process stability and the equipment response time, and is usually set between 1 second and 10 seconds. In this embodiment, it is set to 5 seconds, which can effectively capture key processing fluctuations and ensure the timeliness and accuracy of the determination.

[0080] The preset coupling degree threshold is a critical value for determining the linear correlation degree between the hook angle and the bending section curvature, which depends on the process tolerance and the abnormal sensitivity requirements, and is usually set between 0.7 and 0.95. In this embodiment, it is set to 0.85, which can accurately identify high-risk processing abnormalities and avoid false alarms and missed judgments.

[0081] By performing maximum-minimum normalization processing (prior art, not elaborated) on the hook angle and the bending section curvature respectively within the preset risk determination duration, a set of normalized angles and a set of normalized curvatures are formed, thereby eliminating the influence of dimension and the difference in numerical scale. Subsequently, calculate the Pearson correlation coefficient between the two (prior art, not elaborated) to obtain the degree of their linear coupling relationship. If the coupling degree is higher than the preset coupling degree threshold, it indicates that there is a high degree of correlation in the change trend between the angle and the curvature, and further determine that the processing risk has reached a severe level.

[0082] The hook angle and the bending section curvature respectively reflect the macroscopic angle deviation and the degree of local plastic deformation during the forming process, and their coupling reflects the possible common cause disturbance in the die forming force or the material springback response. Using the Pearson correlation coefficient to quantify the statistical linear relationship between the two can accurately identify the high-risk abnormal states caused by die synchronization disorder, material plastic overload or process fatigue, avoid misjudgment of a single index, and thus achieve more scientific and reasonable risk level identification and early warning.

[0083] Please continue to refer to Figure 4 as shown, which is the determination logic diagram for adjusting the preset blanking force and the preset forming force in this embodiment; The process of adjusting the preset blanking force and the preset forming force according to the vibration frequency, the trimming burr height, and the hook angle includes: Calculate the standard deviation of the difference between the vibration frequency and the preset vibration frequency within a preset first adjustment duration to obtain a frequency deviation fluctuation value; When the frequency deviation fluctuation value is greater than a preset frequency deviation fluctuation threshold, adjust the preset blanking force and the preset forming force according to the trimming burr height and the hook angle.

[0084] The preset frequency deviation fluctuation threshold is a threshold for determining abnormal vibration frequency fluctuations, which depends on the mechanical rigidity and process stability of the equipment. It is usually set between 0.1 Hz and 1 Hz. In this embodiment, it is set to 0.3 Hz, which can effectively identify abnormal vibrations and trigger process parameter adjustments to ensure the stability of the stamping process.

[0085] The preset first adjustment duration is a time window for calculating vibration frequency fluctuations, which depends on the equipment response speed and signal sampling rate. It is usually set between 0.5 seconds and 3 seconds. In this embodiment, it is set to 1 second, which can accurately capture vibration mutations.

[0086] By calculating the standard deviation of the difference between the vibration frequency and the preset vibration frequency in real time within a preset adjustment duration, a frequency deviation fluctuation value is obtained. When this value exceeds the preset threshold, combined with the changes in the trimming burr height and the hook angle, the preset blanking force or forming force is dynamically adjusted to optimize the stamping process parameters and ensure the quality of the finished product.

[0087] Based on the fluctuations in the vibration frequency reflecting the dynamic state of the mechanical system, the frequency deviation fluctuation value is used to accurately capture equipment abnormalities or fatigue changes. The trimming burr height and the hook angle, as intuitive indicators of processing quality, are closely related to the dynamic changes in the vibration frequency. Through the collaborative judgment of the three, the system can scientifically adjust the blanking force and the forming force to achieve adaptive optimization of the processing parameters, significantly improve the stability and reliability of the finished contact spring, and reduce the defective rate.

[0088] Specifically, the process of adjusting the preset blanking force and the preset forming force according to the trimming burr height and the hook angle includes: Perform maximum-minimum normalization processing on all the trimming burr heights within a preset second adjustment duration to obtain a normalized height set, and calculate the average value of all the trimming burr heights to obtain an average burr height; Perform maximum-minimum normalization processing on all the hook angles within the preset second adjustment duration to obtain a normalized angle set, and calculate the average value of all the hook angles to obtain an average angle; Calculate the relative deviation between the average burr height and a preset height adjustment threshold to obtain a height deviation; Calculate the relative deviation between the average angle and a preset angle adjustment threshold to obtain an angle deviation; When the height deviation is greater than the preset height deviation threshold and the angle deviation is greater than the preset angle deviation threshold, calculate the Pearson correlation coefficient of the normalized height set and the normalized angle set to obtain the correlation degree; When the correlation degree is greater than the preset correlation degree threshold, increase the preset blanking force according to the relative deviation between the correlation degree and the preset correlation degree threshold, the preset height deviation weight, and the preset force adjustment coefficient, and increase the preset forming force according to the relative deviation between the correlation degree and the preset correlation degree threshold, the preset angle deviation weight, and the preset force adjustment coefficient, Fc’=Fc×[1+kf×a×(W-W0) / W0], where Fc’ is the increased preset blanking force, Fc is the preset blanking force before increase, kf is the preset force adjustment coefficient, W is the correlation degree, W0 is the preset correlation degree threshold, and a is the preset height deviation weight; Fx’=Fx×[1+kf×b×(W-W0) / W0], where Fx’ is the increased preset forming force, Fc is the preset forming force before increase, and b is the preset angle deviation weight.

[0089] The preset second adjustment duration is the time window for calculating the trimming burr height and the hook angle fluctuation, which depends on the blanking and forming cycle, and is usually set between 2 seconds and 8 seconds. In this embodiment, it is set to 4 seconds, which can balance the data representativeness and response timeliness.

[0090] The preset height adjustment threshold is the burr height reference value that triggers the blanking force adjustment, which depends on the material thickness and the die clearance, and is usually set between 20µm and 80µm. In this embodiment, it is set to 50µm, which can effectively suppress the burr exceeding the standard.

[0091] The preset angle adjustment threshold is the hook angle deviation reference value that triggers the forming force adjustment, which depends on the spring design requirements and the tolerance range, and is usually set between 1° and 3°. In this embodiment, it is set to 2°, which can ensure the geometric accuracy of the hook.

[0092] The preset height deviation threshold is the boundary value for judging the average burr height deviation, which depends on the trimming quality requirements, and is usually set between 0.1 and 0.5 times the height adjustment threshold. In this embodiment, it is set to 0.3 times, which can distinguish between minor and serious deviations.

[0093] The preset angle deviation threshold is the boundary value for judging the average angle deviation, which depends on the forming accuracy standard, and is usually set between 0.1 and 0.5 times the angle adjustment threshold. In this embodiment, it is set to 0.4 times, which can accurately identify the deviation degree.

[0094] The preset correlation threshold is the Pearson correlation coefficient boundary value for evaluating the relationship between burrs and angles, which depends on the coupling sensitivity and misjudgment tolerance. It is usually set between 0.7 and 0.9. In this embodiment, it is set to 0.8, which can identify high-coupling perturbations.

[0095] The preset height deviation weight is the weight coefficient for the contribution degree of burr height deviation when adjusting the blanking force, which depends on the influence ratio of burrs on the forming quality. It is usually set between 0.5 and 0.8. In this embodiment, it is set to 0.6, which can balance the influence of each parameter.

[0096] The preset angle deviation weight is the weight coefficient for the contribution degree of the hook angle deviation when adjusting the forming force, which depends on the sensitivity of the angle to the spring performance. It is usually set between 0.3 and 0.7. In this embodiment, it is set to 0.4, which can ensure accurate angle adjustment.

[0097] The preset force adjustment coefficient is the proportional coefficient for converting the deviation and weight into the actual force increment, which depends on the rigidity of the stamping machine frame and the response characteristics of the actuator. It is usually set between 50N / unit deviation and 200N / unit deviation. In this embodiment, it is set to 100N / unit deviation, which can achieve stable and effective parameter correction.

[0098] First, normalize the trimming burr height and the hook angle within the preset second adjustment duration respectively to obtain a height set and an angle set with a unified dimension. At the same time, calculate their average values to reflect the overall processing state. Subsequently, calculate the relative deviations of the average burr height and the preset height adjustment threshold and the average hook angle and the preset angle adjustment threshold, and judge whether they exceed the corresponding thresholds. If both exceed the thresholds, further calculate the Pearson correlation coefficient of the normalized height set and the normalized angle set to evaluate their correlation. When the correlation is higher than the preset correlation threshold, dynamically increase the preset blanking force and the preset forming force based on the correlation relative deviation and the preset weight to optimize the processing parameters and improve the process stability.

[0099] The trimming burr height and the hook angle, as the direct physical manifestations of the processing quality, reflect the mutual influence and coupling relationship between the blanking and forming processes. The normalization process makes the two parameters comparable, and the correlation calculation reveals the co-fluctuation law between them. Through the dynamic adjustment based on these two key parameters, the precise control of the blanking force and the forming force can be realized, which can effectively suppress the defect accumulation caused by processing deviation, improve the consistency and reliability of the finished contact spring, and ensure the stability of the production process and the product quality.

[0100] Specifically, the process of adjusting the preset tension threshold or the preset synchronization threshold according to the curvature of the bending section includes: Calculate the average value of the curvatures of all the bending sections within the preset threshold adjustment duration to obtain the average curvature; Calculate the absolute value of the relative deviation between the calculated mean curvature and a preset mean curvature threshold to obtain a curvature deviation; When the curvature deviation is greater than a preset curvature deviation threshold, calculate the absolute value of the first derivative of the curvature of each of the bending sections within the preset threshold adjustment duration to obtain an absolute curvature change rate; When the absolute curvature change rate is less than a preset rate threshold, increase the synchronization threshold according to the relative deviation between the preset rate threshold and the absolute curvature change rate and a preset threshold adjustment coefficient, R’ = R × [1 + r × (V0 - V) / V], where R’ is the increased synchronization threshold, R is the synchronization threshold before increase, r is the preset threshold adjustment coefficient, V0 is the preset rate threshold, and V is the absolute curvature change rate; When the absolute curvature change rate is greater than or equal to the preset rate threshold, calculate the absolute value of the second derivative of the curvature of each of the bending sections within the preset threshold adjustment duration to obtain an absolute curvature change acceleration; When the absolute curvature change acceleration is greater than a preset acceleration threshold, decrease the preset tension threshold according to the relative deviation between the absolute curvature change acceleration and the preset acceleration threshold and the preset threshold adjustment coefficient, Y’ = Y × [1 - r × (Va - Va0) / Va0], where Y’ is the decreased preset tension threshold, Y is the preset tension threshold before decrease, Va is the absolute curvature change acceleration, and Va0 is the preset acceleration threshold.

[0101] The preset threshold adjustment duration refers to the time window for calculating curvature-related parameters, which depends on the dynamic characteristics of the processing process and is usually set between 5 seconds and 40 seconds. In this embodiment, it is set to 30 seconds, which can effectively capture the curvature change trend and ensure the timeliness and stability of the adjustment.

[0102] The preset mean curvature threshold is the reference value for judging whether the curvature of the bending section is abnormal, which depends on the material and process requirements and is usually set between 0.1 mm -1 and 0.5 mm -1 In this embodiment, it is set to 0.3 mm -1 , which can accurately reflect the reasonable deformation range.

[0103] The preset curvature deviation threshold is the boundary for judging whether the mean curvature deviation is significant, which depends on the process tolerance and is usually set between 0.05 and 0.15. In this embodiment, it is set to 0.1, which can effectively distinguish normal fluctuations from abnormal deviations.

[0104] The preset rate threshold is the threshold for determining whether the curvature change rate is in a rapid change state, which depends on the processing speed and material response and is usually set between 0.01 mm -1 / s and 0.05 mm -1Between / s, it is set to 0.02 mm in this embodiment -1 / s, which can sensitively capture the curvature change trend.

[0105] The preset threshold adjustment coefficient is the proportional coefficient that controls the adjustment range of the synchronization threshold and the tension threshold. It depends on the system response speed and stability requirements and is usually set between 0.1 and 0.5. It is set to 0.3 in this embodiment, which can ensure a moderate adjustment range and avoid excessive fluctuations.

[0106] The preset acceleration threshold is the threshold for judging whether the curvature change acceleration reaches the risk of rapid deformation. It depends on the material mechanical properties and is usually set between 0.001 mm -1 / s 2 and 0.01 mm -1 / s 2 Between them, it is set to 0.005 mm in this embodiment -1 / s 2 , which can accurately identify sharp deformations and give early warnings of risks.

[0107] First, calculate the average value of the curvature in the bending section within the preset threshold adjustment duration, and obtain the curvature deviation accordingly; when the curvature deviation exceeds the preset threshold, further calculate the absolute value of the first derivative of the curvature to obtain the curvature change rate, and adjust the synchronization threshold according to the comparison between the rate and the preset rate threshold; if the curvature change rate is higher than the threshold, calculate the absolute value of the second derivative of the curvature to reflect the curvature change acceleration, and appropriately lower the preset tension threshold according to the relationship between the acceleration and the acceleration threshold to achieve dynamic optimization adjustment of the tension and synchronization thresholds.

[0108] By multi-level analysis of the average level, change rate and acceleration of the curvature in the bending section, it accurately reflects the dynamic characteristics of material deformation and realizes scientific adjustment of processing parameters. The curvature deviation reflects the static deviation, the change rate reflects the deformation trend, and the acceleration captures the risk of rapid change. The combination of the three ensures that the adjustment of the tension and synchronization thresholds is both sensitive and stable, avoiding over-response or hysteresis, and improving the safety and accuracy of the processing process.

[0109] Specifically, the process of adjusting the preset feeding speed based on the risk determination result re-determined based on the adjusted threshold or the preset synchronization threshold includes: Calculate the standard deviation of the number of times the risk determination result is formed within the preset speed adjustment duration to obtain the risk number fluctuation value; When the risk occurrence fluctuation value is greater than the preset risk occurrence fluctuation threshold, reduce the preset feeding speed according to the relative deviation between the risk occurrence fluctuation value and the preset risk occurrence fluctuation threshold and the preset feeding adjustment coefficient, Vs’ = Vs × [1 - g × (P - P0) / P0], where Vs’ is the reduced preset feeding speed, Vs is the preset feeding speed before reduction, g is the preset feeding adjustment coefficient, P is the risk occurrence fluctuation value, and P0 is the preset risk occurrence fluctuation threshold.

[0110] The preset speed adjustment duration is the time interval for counting the number of times of forming the risk determination result, which depends on the feeding cycle and the processing beat. It is usually set between 5 seconds and 30 seconds. In this embodiment, it is set to 20 seconds, which can ensure obtaining representative fluctuation characteristic data.

[0111] The preset risk occurrence fluctuation threshold is the reference value for judging whether the risk formation fluctuation is abnormal, which depends on the product fault tolerance rate and the control precision requirement. It is usually set between 0.5 times and 2 times. In this embodiment, it is set to 1 time, which can effectively identify the unstable state of the risk determination result in the processing process.

[0112] The preset feeding adjustment coefficient is the proportional parameter for adjusting the feeding speed according to the risk fluctuation degree, which depends on the equipment response ability and the speed regulation sensitivity requirement. It is usually set between 0.05 and 0.2. In this embodiment, it is set to 0.1, which can realize stable and effective dynamic regulation of the feeding speed.

[0113] By monitoring the number of times of forming the risk determination result within the preset speed adjustment duration, calculate its standard deviation to obtain the risk occurrence fluctuation value. If this fluctuation value is greater than the preset risk occurrence fluctuation threshold, it is considered that the current system has an unstable risk state. At this time, according to the relative deviation between the risk occurrence fluctuation value and the threshold, and combined with the preset feeding adjustment coefficient, adjust the current preset feeding speed, specifically, reduce the preset feeding speed to reduce the system operation rate, so as to relieve the risk fluctuation caused by the too high abnormal formation rate.

[0114] By comparing the deviation amount between the fluctuation value and the threshold, and combining with the feeding speed adjustment coefficient for dynamic adjustment, there is a direct dynamic coupling relationship between the feeding speed and the risk formation frequency. When the feeding speed is too fast, it is easy to cause the reduction of processing stability and frequent errors, while reducing the feeding speed can effectively extend the response time to abnormalities, improve the deformation control precision and the finished product quality, reflecting the feedback adjustment mechanism based on the risk fluctuation law.

[0115] Specifically, the process of determining an abnormal event according to the conveying tension and the preset tension threshold and forming an abnormal determination result includes: Start recording the current timestamp when the conveying tension is greater than the preset tension threshold, and stop recording when the conveying tension is less than or equal to the preset tension threshold to obtain the duration. When the duration is greater than the preset duration threshold, it is determined that the abnormal event has occurred, and the abnormal determination result is formed.

[0116] The preset duration threshold is the time benchmark for judging whether the tension abnormality persists, which depends on the stress tolerance of the material and the process rhythm, and is usually set between 0.5 seconds and 3 seconds. In this embodiment, it is set to 1.5 seconds, which can effectively distinguish short-term fluctuations from actual abnormal events and improve the accuracy of abnormal determination.

[0117] By continuously monitoring the relationship between the conveying tension and the preset tension threshold, start recording the timestamp when the conveying tension exceeds the threshold, and stop recording when the tension returns below the threshold to obtain the duration of the abnormal tension. When the duration exceeds the preset duration threshold, the system determines that an abnormal event has occurred and generates the corresponding abnormal determination result.

[0118] By continuously monitoring the relationship between the conveying tension and the set tension threshold and making a judgment in combination with the duration, the true tension abnormal event can be effectively identified. Establishing a determination mechanism by combining the two dimensions of force value and time conforms to the physical law that the material will be damaged only when the force exceeds the critical value and acts continuously, avoids false alarms of abnormalities due to instantaneous fluctuations, improves the scientificity and reliability of the determination, and helps to ensure the stability of subsequent processes and product quality.

[0119] The above are only the preferred embodiments of the present invention and are not used to limit the present invention; for those skilled in the art, various changes and modifications can be made to the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An integrated stamping process for the battery contact spring of a new energy vehicle, characterized in that, Including: Real-time collection of the conveying tension of the conductive strip material on the strip fed at a preset feeding speed, the vibration frequency of the die, the height of the trimming burr of the conductive strip material at the blanking station blanked based on a preset blanking force, the hook angle of the semi-finished contact spring at the forming station formed based on a preset forming force, and the curvature of the bending section; Judging an abnormal event according to the conveying tension and a preset tension threshold value to form an abnormal judgment result; Based on the abnormal judgment result, determining that the event type of the abnormal event is deformation coupling disturbance according to the height of the trimming burr, the vibration frequency, and a preset synchronization threshold value to obtain an abnormal type; Based on the abnormal type, judging the occurrence of a processing risk according to the hook angle and the curvature of the bending section, and determining that the risk level of the processing risk is a severe level to form a risk judgment result; Based on the risk judgment result, adjusting the preset blanking force and the preset forming force according to the vibration frequency, the height of the trimming burr, and the hook angle; Based on the abnormal type re-determined according to the adjusted preset blanking force and the adjusted preset forming force, adjusting the preset tension threshold value or the preset synchronization threshold value according to the curvature of the bending section; Adjusting the preset feeding speed based on the risk judgment result re-determined based on the adjusted threshold value or the preset synchronization threshold value; 2. The one-piece stamping process for the battery contact spring of a new energy vehicle according to claim 1, characterized in that, The process of determining that the event type of the abnormal event is deformation coupling disturbance according to the height of the trimming burr, the vibration frequency, and a preset synchronization threshold value to obtain an abnormal type includes: Calculating the standard deviation of all the heights of the trimming burrs at each moment from the current moment to a preset type determination duration to obtain a number of burr height fluctuation values; Calculating the standard deviation of all the vibration frequencies at each moment from the current moment to the preset type determination duration to obtain a number of vibration frequency fluctuation values; Determining that the event type of the abnormal event is deformation coupling disturbance according to all the burr height fluctuation values, all the vibration frequency fluctuation values, and the preset synchronization threshold value to obtain the abnormal type; 3. The one-piece stamping process for the battery contact spring of a new energy vehicle according to claim 2, wherein, The process of determining that the event type of the abnormal event is deformation coupling disturbance according to all the burr height fluctuation values, all the vibration frequency fluctuation values, and the preset synchronization threshold value to obtain the abnormal type includes: Drawing a change curve of the burr height fluctuation value changing with time within the preset type determination duration to obtain a height fluctuation curve; Drawing a change curve of the vibration frequency fluctuation value changing with time within the preset type determination duration to obtain a frequency fluctuation curve; Calculating the absolute value of the cosine similarity of the height fluctuation curve and the frequency fluctuation curve to obtain a change synchronization degree; When the change synchronization degree is greater than the preset synchronization threshold value, determining that the event type of the abnormal event is deformation coupling disturbance; 4. The one-piece stamping process for the battery contact spring of a new energy vehicle according to claim 3, characterized in that, The process of judging the occurrence of a processing risk according to the hook angle and the curvature of the bending section includes: When the hook angle is greater than a preset hook angle threshold or the curvature of the bent section is greater than a preset curvature threshold, calculate the standard deviation of the hook angle within a preset risk determination duration to obtain an angle fluctuation value, and calculate the standard deviation of the curvature of the bent section within the preset risk determination duration to obtain a curvature fluctuation value; When the angle fluctuation value is less than a preset angle fluctuation threshold and the curvature fluctuation value is less than a preset curvature fluctuation threshold, it is determined that a processing risk occurs.

5. The one-piece stamping process for the battery contact spring of a new energy vehicle according to claim 4, characterized in that The process of determining that the risk level of the processing risk is a severe level includes: Perform maximum-minimum normalization processing on all the hook angles within the preset risk determination duration to obtain a normalized angle set, and perform maximum-minimum normalization processing on all the curvatures of the bent sections within the preset risk determination duration to obtain a normalized curvature set; Calculate the Pearson correlation coefficient of the normalized angle set and the normalized curvature set to obtain a coupling degree; When the coupling degree is greater than a preset coupling degree threshold, determine that the risk level is a severe level.

6. The one-piece stamping process for the battery contact spring of a new energy vehicle according to claim 5, characterized in that, The process of adjusting the preset blanking force and the preset forming force according to the vibration frequency, the trimming burr height, and the hook angle includes: Calculate the standard deviation of the difference between the vibration frequency and the preset vibration frequency difference within a preset first adjustment duration to obtain a frequency deviation fluctuation value; When the frequency deviation fluctuation value is greater than a preset frequency deviation fluctuation threshold, adjust the preset blanking force and the preset forming force according to the trimming burr height and the hook angle.

7. The one-piece stamping process for the battery contact spring of a new energy vehicle according to claim 6, wherein, The process of adjusting the preset blanking force and the preset forming force according to the trimming burr height and the hook angle includes: Perform maximum-minimum normalization processing on all the trimming burr heights within a preset second adjustment duration to obtain a normalized height set, and calculate the average value of all the trimming burr heights to obtain an average burr height; Perform maximum-minimum normalization processing on all the hook angles within the preset second adjustment duration to obtain a normalized angle set, and calculate the average value of all the hook angles to obtain an average angle; Calculate the relative deviation between the average burr height and a preset height adjustment threshold to obtain a height deviation; Calculate the relative deviation between the average angle and a preset angle adjustment threshold to obtain an angle deviation; When the height deviation is greater than a preset height deviation threshold and the angle deviation is greater than a preset angle deviation threshold, calculate the Pearson correlation coefficient of the normalized height set and the normalized angle set to obtain a correlation degree; When the correlation degree is greater than a preset correlation degree threshold, increase the preset blanking force according to the relative deviation between the correlation degree and the preset correlation degree threshold, the preset height deviation weight, and the preset force adjustment coefficient, and increase the preset forming force according to the relative deviation between the correlation degree and the preset correlation degree threshold, the preset angle deviation weight, and the preset force adjustment coefficient.

8. The one-piece stamping process for the battery contact spring of a new energy vehicle according to claim 7, characterized in that, The process of adjusting the preset tension threshold or the preset synchronization threshold according to the curvature of the bent section includes: Calculate the average value of all the curvatures of the bent sections within a preset threshold adjustment duration to obtain an average curvature; Calculate the absolute value of the relative deviation between the average curvature and a preset average curvature threshold to obtain a curvature deviation; When the curvature deviation is greater than a preset curvature deviation threshold, calculate the absolute value of the first derivative of the curvature of each of the bending sections within the preset threshold adjustment duration to obtain the absolute curvature change rate; When the absolute curvature change rate is less than a preset rate threshold, increase the synchronization threshold according to the relative deviation between the preset rate threshold and the absolute curvature change rate and a preset threshold adjustment coefficient; When the absolute curvature change rate is greater than or equal to the preset rate threshold, calculate the absolute value of the second derivative of the curvature of each of the bending sections within the preset threshold adjustment duration to obtain the absolute curvature change acceleration; When the absolute curvature change acceleration is greater than a preset acceleration threshold, reduce the preset tension threshold according to the relative deviation between the absolute curvature change acceleration and the preset acceleration threshold and the preset threshold adjustment coefficient.

9. The one-piece stamping process for the battery contact spring of a new energy vehicle according to claim 8, characterized in that, The process of adjusting the preset feeding speed based on the risk determination result re-determined by the adjusted threshold or the preset synchronization threshold includes: Calculate the standard deviation of the number of times the risk determination result is formed within the preset speed adjustment duration to obtain the risk number fluctuation value; When the risk number fluctuation value is greater than a preset risk number fluctuation threshold, reduce the preset feeding speed according to the relative deviation between the risk number fluctuation value and the preset risk number fluctuation threshold and a preset feeding adjustment coefficient.

10. The one-piece stamping process for the battery contact spring of a new energy vehicle according to claim 9, characterized in that, The process of determining an abnormal event based on the conveying tension and the preset tension threshold to form an abnormal determination result includes: Start recording the current timestamp when the conveying tension is greater than the preset tension threshold, and stop recording when the conveying tension is less than or equal to the preset tension threshold to obtain the duration; When the duration is greater than a preset duration threshold, determine that the abnormal event has occurred and form the abnormal determination result.

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