One-piece stamping process for new energy vehicle battery contact springs

Abstract

The present invention relates to the field of stamping metal processing technology, and in particular to an integrated stamping process for new energy vehicle battery contact springs, comprising: real-time parameter acquisition; abnormality determination and formation results; abnormal event type determination; processing risk level determination; adjustment of blanking force and forming force; adjustment of tension threshold and synchronization threshold; and adjustment of preset feed speed. Through real-time multi-parameter acquisition and coupled analysis, the present invention establishes a closed-loop control system based on abnormality identification, risk assessment, and adaptive parameter adjustment, significantly improving the accuracy and stability of contact spring stamping. When the risk level is high, the blanking force and forming force are intelligently linked to optimize stamping quality, effectively solving the problem of compound disturbance instability caused by over-reliance on fixed adjustment methods that cannot adapt to dynamic changes in material elasticity and processing speed.

Description

Technical Field

[0001] The present invention relates to the technical field of stamping metal processing, and in particular to an integrated stamping process for new energy vehicle battery contact springs. Background Art

[0002] The rapid development of the new energy vehicle industry has driven demand for high-performance and high-quality manufacturing of key battery pack components, particularly battery contact springs. As a crucial component for connecting the battery's internal components, the quality of the battery contact spring's molding directly impacts the battery pack's electrical conductivity and overall safety. During the manufacturing process, material elasticity variations, processing speed fluctuations, and complex production disturbances pose significant challenges to the stability of the molding process. With the accelerated pace of production and the diversification of materials, these dynamic factors have become even more prominent. Traditional fixed adjustment methods struggle to achieve precise control and efficient response, impacting the overall efficiency and quality of new energy vehicle battery pack connector manufacturing.

[0003] The patent document with application publication number CN117943449A discloses a new energy vehicle battery pack connector stamping device and a stamping production line, the device includes: a support frame, which is a vertical frame structure as a whole, and a fixed cylinder body is fixed on the support frame; a linear drive assembly 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 is slidably connected in the fixed cylinder body, and the movable end is slidably connected to the movable cylinder body at one end away from the linear drive assembly, and a punch head fixing seat is provided at the end of the movable cylinder body away from the linear drive assembly, and the punch head fixing seat is used to fix the upper die seat, and the upper die seat is arranged at intervals below the upper die seat; an elastic member is sleeved on the movable cylinder body and its two ends are respectively pushed against the bottom of the movable cylinder body and the fixed cylinder body. On the wall; a drainage chamber, which is connected to the lower die base and is used to support the lower die base, a pressure flow zone is formed between the drainage chamber and the lower die base, the drainage chamber is connected with the ejection tube, and one end of the ejection tube is connected with the pressure flow zone; a nozzle, one end of which is connected with the air hole set on the movable cylinder body, and the other end faces between the upper die base and the lower die base; a hose, a first end of which is connected with the outlet end of the fixed cylinder body, and the second end is inserted into the ejection tube and the pressure flow zone is located in the back pressure zone 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 nozzle, and after the movable end moves to the bottom wall of the movable cylinder body, the movable cylinder body is moved in the direction of the compressed elastic member and the gas in the fixed cylinder body is pressurized and discharged from the hose, and the gas discharged from the hose ejects the gas in the back pressure zone.

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

[0005] To this end, the present invention provides an integrated stamping process for new energy vehicle battery contact springs, which overcomes the problem of compound disturbance instability caused by excessive reliance on fixed adjustment methods in the prior art, resulting in the inability to adapt to dynamic changes in material elasticity and processing speed.

[0006] To achieve the above-mentioned object, the present invention provides an integrated stamping process for a new energy vehicle battery contact spring, comprising:

[0007] Real-time data collection includes the conveying tension of the conductive tape on the material strip fed at a preset feeding speed, the vibration frequency of the mold, the height of the cutting burr of the conductive tape at the punching station punched at a preset punching force, and the hook angle and bending section curvature of the contact spring semi-finished product at the forming station formed at a preset forming force;

[0008] determining the occurrence of an abnormal event based on the transport tension and a preset tension threshold, and forming an abnormality determination result;

[0009] Based on the abnormality determination result, determining that the event type of the abnormal event is deformation coupling disturbance according to the trimming burr height, the vibration frequency, and a preset synchronization threshold, and obtaining the abnormality type;

[0010] Based on the abnormality type, judging the occurrence of processing risk according to the hook angle and the curvature of the bending section, and judging the risk level of the processing risk to be a severe level, thereby forming a risk judgment result;

[0011] Based on the risk determination result, adjusting the preset blanking force and the preset forming force according to the vibration frequency, the trimming burr height, and the hook angle;

[0012] Based on the re-determined abnormality type of the adjusted preset blanking force and the adjusted preset forming force, adjusting the preset tension threshold or the preset synchronization threshold according to the curvature of the bending section;

[0013] The preset feeding speed is adjusted based on the adjusted threshold or the risk determination result re-determined based on the preset synchronization threshold.

[0014] Furthermore, the event type of the abnormal event is determined to be a deformation coupling disturbance according to the trimming burr height, the vibration frequency, and a preset synchronization threshold. The process of obtaining the abnormal type includes:

[0015] Calculating the standard deviation of all the trimming burr heights at each moment from the current moment to a preset type determination time length to obtain a plurality of burr height fluctuation values;

[0016] Calculating the standard deviation of all the vibration frequencies at each moment from the current moment to the preset type determination time length to obtain a plurality of vibration frequency fluctuation values;

[0017] According to all the burr height fluctuation values, all the vibration frequency fluctuation values and the preset synchronization threshold, it is determined that the event type of the abnormal event is deformation coupling disturbance, and the abnormal type is obtained.

[0018] Furthermore, the event type of the abnormal event is determined to be a deformation coupling disturbance according to all the burr height fluctuation values, all the vibration frequency fluctuation values, and the preset synchronization threshold. The process of obtaining the abnormal type includes:

[0019] Drawing a curve of the burr height fluctuation value changing over time within the preset type determination time length to obtain a height fluctuation curve;

[0020] Plotting a curve of the vibration frequency fluctuation value changing over time within the predetermined time period to obtain a frequency fluctuation curve;

[0021] Calculating the absolute value of the cosine similarity between the height fluctuation curve and the frequency fluctuation curve to obtain the change synchronization;

[0022] When the change synchronization degree is greater than the preset synchronization degree threshold, it is determined that the event type of the abnormal event is a deformation coupling disturbance.

[0023] Furthermore, the process of determining whether a processing risk occurs according to the hook angle and the curvature of the bending section includes:

[0024] When the hook angle is greater than a preset hook angle threshold, or the curvature of the bending section is greater than a preset curvature threshold, the standard deviation of the hook angle within the preset risk determination time is calculated to obtain an angle fluctuation value, and the standard deviation of the curvature of the bending section within the preset risk determination time is calculated to obtain a curvature fluctuation value;

[0025] When the angle fluctuation value is smaller than a preset angle fluctuation threshold, and the curvature fluctuation value is smaller than a preset curvature fluctuation threshold, it is determined that a processing risk occurs.

[0026] Furthermore, the process of determining whether the risk level of the processing risk is a serious level includes:

[0027] Performing maximum-minimum normalization processing on all the hook angles within the preset risk determination time to obtain a normalized angle set, and performing maximum-minimum normalization processing on all the bending section curvatures within the preset risk determination time to obtain a normalized curvature set;

[0028] Calculating the Pearson correlation coefficient between the normalized angle set and the normalized curvature set to obtain a coupling degree;

[0029] When the coupling degree is greater than a preset coupling degree threshold, the risk level is determined to be a severe level.

[0030] Furthermore, 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:

[0031] Calculating the standard deviation of the difference between the vibration frequency and the preset vibration frequency within the preset first adjustment time period to obtain a frequency deviation fluctuation value;

[0032] When the frequency deviation fluctuation value is greater than a preset frequency deviation fluctuation threshold, the preset punching force and the preset forming force are adjusted according to the trimming burr height and the hook angle.

[0033] Furthermore, the process of adjusting the preset blanking force and the preset forming force according to the trimming burr height and the hook angle includes:

[0034] Performing maximum-minimum normalization processing on all the trimming burr heights within the preset second adjustment time to obtain a normalized height set, and calculating an average value of all the trimming burr heights to obtain an average burr height;

[0035] Performing maximum-minimum normalization processing on all the hook angles within the preset second adjustment time to obtain a normalized angle set, and calculating an average value of all the hook angles to obtain an average angle;

[0036] Calculating a relative deviation between the average burr height and a preset height adjustment threshold to obtain a height deviation;

[0037] Calculating a relative deviation between the average angle and a preset angle adjustment threshold to obtain an angle deviation;

[0038] When the height deviation is greater than a preset height deviation threshold, and the angle deviation is greater than a preset angle deviation threshold, calculating the Pearson correlation coefficient of the normalized height set and the normalized angle set to obtain a correlation;

[0039] When the correlation is greater than the preset correlation threshold, the preset blanking force is increased according to the relative deviation between the correlation and the preset correlation threshold, the preset height deviation weight and the preset force adjustment coefficient, and the preset forming force is increased according to the relative deviation between the correlation and the preset correlation threshold, the preset angle deviation weight and the preset force adjustment coefficient.

[0040] Furthermore, the process of adjusting the preset tension threshold or the preset synchronization threshold according to the curvature of the bending section includes:

[0041] Calculating the average curvature of all the bending sections within the preset threshold adjustment time to obtain an average curvature;

[0042] Calculating the absolute value of the relative deviation between the average curvature and a preset average curvature threshold to obtain a curvature deviation;

[0043] When the curvature deviation is greater than a preset curvature deviation threshold, calculating the absolute value of the first-order derivative of the curvature of each bending section within the preset threshold adjustment time to obtain the absolute curvature change rate;

[0044] When the absolute curvature change rate is less than a preset rate threshold, increasing the synchronization threshold according to a relative deviation between the preset rate threshold and the absolute curvature change rate and a preset threshold adjustment coefficient;

[0045] When the absolute curvature change rate is greater than or equal to a preset rate threshold, calculating the absolute value of the second-order derivative of the curvature of each bending section within the preset threshold adjustment time to obtain the absolute curvature change acceleration;

[0046] When the absolute curvature change acceleration is greater than a preset acceleration threshold, the preset tension threshold is reduced according to a relative deviation between the absolute curvature change acceleration and the preset acceleration threshold and the preset threshold adjustment coefficient.

[0047] Furthermore, 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:

[0048] Calculate the standard deviation of the number of times risk determination results are formed within the preset speed adjustment time to obtain the risk frequency fluctuation value;

[0049] When the risk number fluctuation value is greater than a preset risk number fluctuation threshold, the preset feeding speed is reduced according to a relative deviation between the risk number fluctuation value and the preset risk number fluctuation threshold and a preset feeding adjustment coefficient.

[0050] Furthermore, the process of determining whether an abnormal event occurs based on the transport tension and the preset tension threshold and forming an abnormality determination result includes:

[0051] When the transport tension is greater than the preset tension threshold, start recording the current timestamp, and when the transport tension is less than or equal to the preset tension threshold, stop recording to obtain a duration;

[0052] When the duration is greater than a preset duration threshold, it is determined that the abnormal event occurs, and the abnormality determination result is formed.

[0053] Compared with existing technologies, the present invention achieves significant improvements in the precision and stability of contact spring stamping by establishing a closed-loop control system based on anomaly identification, risk assessment, and adaptive parameter adjustment through real-time multi-parameter acquisition and coupled analysis. The system utilizes feed tension, a leading parameter for anomaly identification, to reflect the feed state. Vibration frequency and trimming burr height are combined to determine anomaly types (such as deformation coupling disturbances), demonstrating the coupling relationship between die vibration and the punching effect. The hook angle and bending section curvature directly reflect forming quality, and their deviations further assess the processing risk level. When the risk level is high, the system intelligently adjusts the punching and forming forces to optimize stamping quality. Furthermore, based on a new round of parameter feedback, the tension and synchronization thresholds are dynamically adjusted, further influencing the feed speed. This achieves integrated control of the entire process, from anomaly identification to risk mitigation to production pacing. This ensures the consistency and reliability of contact springs for new energy vehicle batteries under high-speed continuous stamping conditions. This effectively addresses the problem of compound perturbation instability caused by overreliance on fixed adjustment methods, which cannot adapt to dynamic changes in material elasticity and processing speed.

[0054] Furthermore, by dynamically coupling burr height fluctuations with vibration frequency fluctuations, a time-series linkage model between machining accuracy anomalies and structural vibration was established. By calculating the statistical difference (standard deviation) in the fluctuation intensity of the two over the same time period and measuring the absolute value of cosine similarity, the consistency of their fluctuation trends was determined, thereby capturing complex coupling interference phenomena caused by loose mold structure, material rebound, mold fatigue, etc. Compared with traditional single-parameter monitoring methods, this method can reveal the coupling relationships and root causes between multiple physical quantities, improve the accuracy of anomaly detection and intelligent judgment capabilities, and facilitate refined control and early warning management of the stamping process.

[0055] Furthermore, based on the interaction between mechanics and vibration systems, the system accurately determines the type of anomaly by introducing the synchronization of fluctuations between burr height (reflecting the material's microscopic fracture characteristics) and mold vibration frequency (reflecting the system's dynamic state). Cosine similarity, a quantitative indicator of change trends, conforms to a common mathematical metric for correlations in high-dimensional data. When impact and deformation during machining trigger synchronous fluctuations, the system can promptly identify deformation coupling disturbances, providing a basis for subsequent adjustments. This close integration of material mechanical behavior, machining dynamic response, and signal analysis demonstrates data-driven intelligent machining judgment capabilities, effectively improving the stability and intelligence of the production process.

[0056] Furthermore, by taking angle and curvature as the main indicators of forming accuracy and integrating the dual judgment logic of absolute value and volatility, if the angle or curvature of the finished product is large but the fluctuation is small, it means that the deviation has been finalized and no dynamic correction behavior has occurred, indicating 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, occasional fluctuation misjudgment can be eliminated, the accuracy and robustness of risk identification can be improved, and a theoretical basis can be provided for timely intervention and parameter correction to achieve stable and controllable stamping quality assurance.

[0057] Furthermore, the hook angle and bend curvature, respectively, reflect macro-angular deviation and local plastic deformation during the forming process. Their coupling reflects the potential for 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 allows accurate identification of high-risk abnormalities caused by mold synchronization misalignment, material plastic overload, or process fatigue, avoiding misjudgment based on a single indicator and enabling more scientific and rational risk level identification and early warning.

[0058] Furthermore, vibration frequency fluctuations reflect the dynamic state of the mechanical system, and frequency deviation fluctuations accurately capture equipment anomalies or fatigue changes. The trimming burr height and hook angle serve as intuitive indicators of processing quality, closely related to the dynamic changes in vibration frequency. By synergizing these three factors, the system can scientifically adjust the blanking and forming forces, achieving adaptive optimization of processing parameters, significantly improving the stability and reliability of the finished contact spring and reducing the defective rate.

[0059] Furthermore, the trimming burr height and hook angle, as direct physical indicators of processing quality, reflect the mutual influence and coupling relationship between the blanking and forming processes. Normalization makes the two parameters comparable, and correlation calculations reveal their synergistic fluctuation patterns. Dynamic adjustment based on these two key parameters enables precise control of the blanking and forming forces, 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.

[0060] Furthermore, through multi-level analysis of the average level, rate of change, and acceleration of the bending section's curvature, the dynamic characteristics of material deformation are accurately reflected, enabling scientific adjustment of processing parameters. Curvature deviation reflects static deviation, rate of change reflects deformation trend, and acceleration captures the risk of rapid changes. The combination of these three ensures that the adjustment of tension and synchronization thresholds is both sensitive and stable, avoiding over-response or hysteresis, and improving the safety and accuracy of the processing process.

[0061] Furthermore, by comparing the deviation between the fluctuation value and the threshold value and combining the feeding speed adjustment coefficient for dynamic adjustment, it is found that there is a direct dynamic coupling relationship between the feeding speed and the risk formation frequency. When the feeding is too fast, it is easy to lead to reduced processing stability and frequent errors. Reducing the feeding speed can effectively extend the response time to anomalies, improve deformation control accuracy and finished product quality, and reflect a feedback adjustment mechanism based on the law of risk fluctuations.

[0062] Furthermore, by continuously monitoring the relationship between transport tension and a set tension threshold and incorporating duration into the judgment, true tension anomalies can be effectively identified. This combined force and time dimension of the judgment mechanism adheres to the physical law that material damage occurs only when forces exceeding a critical value and persist. This avoids false alarms due to transient fluctuations, improves the scientific nature and reliability of the judgment, and helps ensure the stability of subsequent processes and product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0063] Figure 1 This is a flow chart of the one-piece stamping process for the new energy vehicle battery contact spring in this embodiment;

[0064] Figure 2 A decision logic diagram for determining deformation coupling disturbance for this embodiment;

[0065] Figure 3 This is a logic diagram for determining the occurrence of processing risks in this embodiment;

[0066] Figure 4 The determination logic diagram for adjusting the preset blanking force and the preset forming force is provided for this embodiment. DETAILED DESCRIPTION

[0067] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention.

[0068] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0069] See also Figure 1 As shown, it is a flow chart of the one-piece stamping process for the new energy vehicle battery contact spring in this embodiment;

[0070] This embodiment provides an integrated stamping process for a new energy vehicle battery contact spring, comprising:

[0071] Real-time data collection includes the conveying tension of the conductive tape on the material strip fed at a preset feeding speed, the vibration frequency of the mold, the height of the cutting burr of the conductive tape at the punching station punched at a preset punching force, and the hook angle and bending section curvature of the contact spring semi-finished product at the forming station formed at a preset forming force;

[0072] determining the occurrence of an abnormal event based on the transport tension and a preset tension threshold, and forming an abnormality determination result;

[0073] Based on the abnormality determination result, determining that the event type of the abnormal event is deformation coupling disturbance according to the trimming burr height, the vibration frequency, and a preset synchronization threshold, and obtaining the abnormality type;

[0074] Based on the abnormality type, judging the occurrence of processing risk according to the hook angle and the curvature of the bending section, and judging the risk level of the processing risk to be a severe level, thereby forming a risk judgment result;

[0075] Based on the risk determination result, adjusting the preset blanking force and the preset forming force according to the vibration frequency, the trimming burr height, and the hook angle;

[0076] Based on the re-determined abnormality type of the adjusted preset blanking force and the adjusted preset forming force, adjusting the preset tension threshold or the preset synchronization threshold according to the curvature of the bending section;

[0077] The preset feeding speed is adjusted based on the adjusted threshold or the risk determination result re-determined based on the preset synchronization threshold.

[0078] This embodiment is applied to the manufacturing process of contact springs used for conductive connections in new energy vehicle battery modules. The semi-finished contact springs have extremely high requirements for elastic deformation capacity and conductive reliability. Therefore, multiple parameters need to be monitored in real time during the stamping process to ensure structural accuracy and consistent performance.

[0079] The production process adopts an integrated continuous stamping production line process, that is, the conductive metal strip (such as copper alloy or nickel-plated steel strip) is fed into a multi-station mold through an automatic feeding mechanism. The feeding, punching, forming, bending and other steps are completed in multiple stations connected in series to finally obtain the semi-finished contact spring.

[0080] Collection method of each parameter:

[0081] Real-time collection of transport tension:

[0082] Position: The material belt tensioning control mechanism is installed between the feeding unit and the mold entrance.

[0083] Sensor type: precision tension sensor (tensiometer) or tension control roller.

[0084] Real-time detection of tension changes in the conductive tape during feeding, identification of whether the feeding is uniform, and whether there are abnormalities such as tape jamming, slipping, or over-tightening.

[0085] Collection of mold vibration frequency:

[0086] Location: Installed on the mold base or mold frame structure.

[0087] Sensor type: triaxial accelerometer or vibration frequency sensor.

[0088] Determine the dynamic stability of the die during the stamping process and identify abnormal impacts, die loosening or resonance.

[0089] Collection of trimming burr height on the punching station:

[0090] Position: Located at the lower die exit of the punching station or just before the forming station.

[0091] Sensor type: Laser displacement sensor or 3D line laser measuring head.

[0092] Real-time detection of burr height on the cutting edge. Excessive burrs may indicate blunt cutting edge, insufficient cutting force or unstable material guiding.

[0093] Hook angle collection at the forming station:

[0094] Location: Inspection area after the last bending / stretch forming station.

[0095] Sensor type: Industrial vision system (high-resolution industrial camera + AI image recognition algorithm) or angle measurement laser device.

[0096] Accurately measure the hook angle after forming to determine whether the forming is qualified and whether there is deformation or rebound.

[0097] Bending section curvature collection:

[0098] Position: Same as the hook angle detection area.

[0099] Sensor type: industrial camera + image processing system, or laser scanning device.

[0100] Curvature analysis is used to determine whether the bending transition of the spring is reasonable and whether there are problems such as cracks and wrinkles.

[0101] The connection relationship between each workstation and the assembly line workflow

[0102] The entire equipment usually adopts the following tandem multi-station progressive die structure, installed on the stamping press platform, and coordinated by the automatic control system:

[0103] The feeding unit contains a feeding wheel, a motor and a tension control system, which accurately pushes the rolled conductive tape into the mold at a preset feeding speed.

[0104] The tension sensor is installed on the feeding path to continuously monitor the tension status.

[0105] The punching station performs preliminary punching and trimming operations on the conductive tape to form the outer contour and positioning holes.

[0106] The edge burr detection equipment is located close to the punching station to detect edge wear and material stability.

[0107] The preliminary bending station bends the blanked semi-finished product once or multiple times at small angles to preform the shape of the subsequent hook and elastic section.

[0108] The hook and curvature forming station precisely controls the mold shape and pressure to complete the hook formation and overall curvature control of the spring.

[0109] The workstation is equipped with an image system / angle detection system to collect hook angles and curvatures.

[0110] Finished product inspection and unloading station: integrated defect recognition + rejection system to remove springs that do not meet the angle, curvature or burr standards.

[0111] The semi-finished contact springs are sent to a collection device or automatically enter the next electroplating / assembly process.

[0112] The preset feeding speed is the feeding length per unit time of the material strip entering the stamping die, which depends on the die beat and production rhythm. It is usually set between 100mm / s and 500mm / s. In this embodiment, it is set to 300mm / s, which can ensure the coordinated operation of each workstation and maintain stable tension of the material strip.

[0113] The preset blanking force is the initial pressure value applied by the blanking station when cutting conductive materials. It depends on the material thickness and the shape of the mold blade. It is usually set between 2kN and 10kN. In this embodiment, it is set to 5kN, which can effectively ensure the cutting quality and suppress the burr height from exceeding the standard.

[0114] The preset forming force is the pressing force of the forming station when bending the contact spring. It depends on the material elastic modulus and the forming angle requirements. It is usually set between 3kN and 12kN. In this embodiment, it is set to 7kN, which can ensure the stability of the shape of the hook and the bending section.

[0115] The preset tension threshold is an important reference tension range for determining whether an abnormality occurs in the feeding process. It depends on the width of the material strip and the friction resistance of the mold. It is usually set between 20N and 60N. In this embodiment, it is set to 40N, which can promptly identify the risk of feeding blockage or slippage.

[0116] The preset synchronization threshold is a judgment threshold set based on whether the changing trends between the burr height fluctuation and the mold vibration frequency fluctuation are highly consistent. Its essence reflects the strength of the coupling correlation between the two physical change phenomena in the time series. It depends on whether there is a collaborative disturbance mechanism between the punching and mold dynamics in the process system due to material hardening, mold loss or synchronization anomaly. It is usually set between 0.65 and 0.85. In this embodiment, it is set to 0.78 to measure whether the absolute value of the cosine similarity of 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 structure and load changes, and realize early identification and intervention of abnormal events.

[0117] First, sensors are used to collect key process parameters such as the conveying tension of the conductive tape, mold vibration frequency, cutting burr height, hook angle, and bending section curvature during the feeding process in real time. Subsequently, abnormal events are identified by comparing the conveying tension with the preset tension threshold, and the type of abnormal event is further analyzed based on the cutting burr height and vibration frequency. The processing risk and its level are then determined based on the hook angle and bending section curvature. Finally, process parameters such as blanking force and forming force are dynamically adjusted according to the risk level, and the tension threshold, synchronization threshold, and feeding speed are adjusted through feedback to form a closed-loop adaptive optimization mechanism.

[0118] In continuous, high-speed stamping production, the contact spring forming process is essentially a multi-physics coupled system, where various parameters (tension, vibration, trimming quality, and structural geometry) interact and superimpose their influences, much like "resonance" in mechanical structures or "nonlinear deformation" in material microstructures. This deformation coupling perturbation inherently conforms to the universal law in nature where multi-factor coupling triggers system instability. When feed tension, punching impact, and forming load deviate synchronously, the system rapidly enters a new, often uncontrollable, dynamic equilibrium state. If this coupled perturbation persists and forming characteristics (such as hook angle and curvature) steadily deviate under low fluctuations and high coupling, it poses a severe risk: while the system may not experience severe chattering, it has steadily deviated from the design value, making it difficult to self-recover through single parameter adjustment.

[0119] Through real-time multi-parameter acquisition and coupled analysis, a closed-loop control system based on anomaly identification, risk assessment, and adaptive parameter adjustment was established, significantly improving the accuracy and stability of contact spring stamping. The conveying tension reflects the feeding state and serves as a leading parameter for anomaly identification. The vibration frequency and trimming burr height are combined as a reference for determining anomaly types (such as deformation coupling disturbances), reflecting the coupling relationship between die vibration and the punching effect. The hook angle and bending section curvature directly reflect the forming quality, and their deviations further assess the processing risk level. When the risk level is high, the punching and forming forces are intelligently adjusted to optimize stamping quality. Furthermore, based on a new round of parameter feedback, the tension and synchronization thresholds are dynamically adjusted, further influencing the feed speed. This achieves integrated control of the entire process, from anomaly identification to risk mitigation to production rhythm. This ensures the consistency and reliability of contact springs for new energy vehicle batteries under high-speed continuous stamping conditions. This effectively addresses the problem of compound perturbation instability caused by over-reliance on fixed adjustment methods, which cannot adapt to dynamic changes in material elasticity and processing speed.

[0120] Specifically, the event type of the abnormal event is determined to be a deformation coupling disturbance according to the trimming burr height, the vibration frequency, and a preset synchronization threshold, and the process of obtaining the abnormal type includes:

[0121] Calculating the standard deviation of all the trimming burr heights at each moment from the current moment to a preset type determination time length to obtain a plurality of burr height fluctuation values;

[0122] Calculating the standard deviation of all the vibration frequencies at each moment from the current moment to the preset type determination time length to obtain a plurality of vibration frequency fluctuation values;

[0123] According to all the burr height fluctuation values, all the vibration frequency fluctuation values and the preset synchronization threshold, it is determined that the event type of the abnormal event is deformation coupling disturbance, and the abnormal type is obtained.

[0124] The preset type determination time refers to the time window used to count the vibration frequency and burr height fluctuation characteristics, which depends on the stamping cycle, 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.

[0125] The time length is determined by the set type, and the time series data of the trimming burr height and the mold vibration frequency are continuously collected. The standard deviation is calculated for each within the time window to obtain the burr height fluctuation value and the vibration frequency fluctuation value that represent the degree of fluctuation of the processing state; the two sets of fluctuation values are further plotted, and the absolute value of their cosine similarity is calculated. If the value exceeds the preset synchronization threshold, it is determined that there is an obvious time series synergistic relationship between the burr fluctuation and the vibration change, that is, it is identified as an abnormal type of "deformation coupling disturbance".

[0126] By dynamically coupling burr height fluctuations with vibration frequency fluctuations, a time-series linkage model between machining accuracy anomalies and structural vibration was established. By calculating the statistical difference (standard deviation) in the fluctuation intensity of the two over the same time period and measuring the absolute value of cosine similarity, the consistency of their fluctuation trends was determined. This approach captures complex coupling interference phenomena caused by loose mold structure, material rebound, mold fatigue, and other factors. Compared to traditional single-parameter monitoring methods, this method can reveal the coupling relationships and root causes between multiple physical quantities, improve the accuracy of anomaly detection and intelligent judgment capabilities, and facilitate refined control and early warning management of the stamping process.

[0127] Please continue reading Figure 2 As shown, it is a decision logic diagram for determining deformation coupling disturbance in this embodiment;

[0128] The process of determining the event type of the abnormal event as deformation coupling disturbance according to all the burr height fluctuation values, all the vibration frequency fluctuation values, and the preset synchronization threshold includes:

[0129] Drawing a curve of the burr height fluctuation value changing over time within the preset type-determined time length to obtain a height fluctuation curve;

[0130] Plotting a curve of the vibration frequency fluctuation value changing over time within the predetermined time period to obtain a frequency fluctuation curve;

[0131] Calculating the absolute value of the cosine similarity between the height fluctuation curve and the frequency fluctuation curve to obtain the change synchronization;

[0132] When the change synchronization degree is greater than the preset synchronization degree threshold, it is determined that the event type of the abnormal event is a deformation coupling disturbance.

[0133] By collecting continuous fluctuation data on trimming burr height and mold vibration frequency within a preset time period, their standard deviations are calculated to form burr height fluctuation values and vibration frequency fluctuation values, respectively, and these are plotted as time-varying curves. Subsequently, by calculating the absolute value of the cosine similarity between the two fluctuation curves (first vectorizing each and then calculating the cosine similarity, which is a prior art method and will not be repeated here), the synchronization of their changing trends is quantified. If the degree of synchronization exceeds the preset synchronization threshold, it is considered that there is a significant coupling relationship between the burr fluctuation and the vibration fluctuation, and the current abnormal event is determined to be a "deformation coupling disturbance."

[0134] Based on the interaction between mechanics and vibration systems, the system accurately identifies anomaly types by introducing the synchronization of fluctuations between burr height (reflecting the material's microscopic fracture characteristics) and mold vibration frequency (reflecting the system's dynamic state). Cosine similarity, a quantitative indicator of change trends, conforms to a common mathematical metric for correlations in high-dimensional data. When impact and deformation during machining trigger synchronous fluctuations, the system can promptly identify deformation coupling disturbances, providing a basis for subsequent adjustments. This close integration of material mechanical behavior, machining dynamic response, and signal analysis demonstrates data-driven intelligent machining judgment capabilities, effectively improving the stability and intelligence of the production process.

[0135] Please continue reading Figure 3 As shown, it is a decision logic diagram for judging the occurrence of processing risks in this embodiment;

[0136] The process of determining the occurrence of processing risks based on the hook angle and the curvature of the bending section includes:

[0137] When the hook angle is greater than a preset hook angle threshold, or the curvature of the bending section is greater than a preset curvature threshold, the standard deviation of the hook angle within the preset risk determination time is calculated to obtain an angle fluctuation value, and the standard deviation of the curvature of the bending section within the preset risk determination time is calculated to obtain a curvature fluctuation value;

[0138] When the angle fluctuation value is smaller than a preset angle fluctuation threshold, and the curvature fluctuation value is smaller than a preset curvature fluctuation threshold, it is determined that a processing risk occurs.

[0139] The preset hook angle threshold refers to the upper limit of the angle used to determine whether the hook molding of the contact spring is out of tolerance. It depends on the hook function requirements and assembly tolerances in the product design drawings. It is usually set between 5° and 15°. In this embodiment, it is set to 10°. It can promptly identify functional deviations or mold fatigue problems caused by excessive hook molding.

[0140] 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 bending structure design radius and the material elastic modulus, and is usually set at 0.1mm.-1 to 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.

[0141] The preset angle fluctuation threshold is the allowable fluctuation range for judging whether there is a dynamic abnormality in the hook angle. It depends on the stamping stability of the equipment and the consistency of the material. It is usually set between 0.2° and 1.0°. In this embodiment, it is set to 0.5°. It can be used to identify whether the processing process is stable or there is a slight fatigue accumulation effect.

[0142] The preset curvature fluctuation threshold is the upper limit of the standard deviation used to evaluate whether the bending curvature variation 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 at 0.01mm. -1 to 0.05mm -1 In this embodiment, it is set to 0.03mm -1 , it can determine whether there is molding deviation caused by uneven mold gap or insufficient lubrication.

[0143] By continuously monitoring the hook angle and curvature of the bent section of the finished contact spring, the system first determines whether these exceed preset angle or curvature thresholds. If so, the system then calculates the standard deviation of the hook angle and curvature of the bent section within a preset risk assessment period to determine the angle fluctuation value and curvature fluctuation value. If both fluctuations are small, that is, below their respective fluctuation thresholds, a processing risk is determined to have occurred in the current forming process.

[0144] By taking angle and curvature as the main indicators of forming accuracy and integrating the dual judgment logic of absolute value and volatility, if the angle or curvature of the finished product is large but the fluctuation is small, it means that the deviation has been finalized and no dynamic correction behavior has occurred, indicating 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, occasional fluctuation misjudgment can be eliminated, the accuracy and robustness of risk identification can be improved, and a theoretical basis can be provided for timely intervention and parameter correction to achieve stable and controllable stamping quality assurance.

[0145] Specifically, the process of determining whether the risk level of processing risk is severe includes:

[0146] Performing maximum-minimum normalization processing on all the hook angles within the preset risk determination time to obtain a normalized angle set, and performing maximum-minimum normalization processing on all the bending section curvatures within the preset risk determination time to obtain a normalized curvature set;

[0147] Calculating the Pearson correlation coefficient between the normalized angle set and the normalized curvature set to obtain a coupling degree;

[0148] When the coupling degree is greater than a preset coupling degree threshold, the risk level is determined to be a severe level.

[0149] The preset risk judgment time is the time window used to collect hook angle and bending section curvature data, which depends on the stability of the processing technology and the response time of the equipment. It 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 judgment.

[0150] The preset coupling threshold is the critical value for determining the degree of linear correlation between the hook angle and the curvature of the bending section. It depends on the process tolerance and abnormality 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 anomalies and avoid false alarms and missed judgments.

[0151] By performing maximum-minimum normalization on the hook angle and bend section curvature within a preset risk assessment timeframe (a technique not described here), a normalized angle set and a normalized curvature set are formed, eliminating dimensionality and numerical scale differences. Subsequently, the Pearson correlation coefficient between the two is calculated (a technique not described here) to determine the degree of linear coupling. If the coupling degree exceeds a preset threshold, it indicates a high correlation between the changing trends of the angle and curvature, and the processing risk is determined to have reached a critical level.

[0152] The hook angle and bend curvature, respectively, reflect macro-angular deviation and local plastic deformation during the forming process. Their coupling reflects the potential for 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 conditions caused by mold synchronization misalignment, material plastic overload, or process fatigue, avoiding misjudgment based on a single indicator and enabling more scientific and reasonable risk level identification and early warning.

[0153] Please continue reading Figure 4 As shown, it is a decision logic diagram for adjusting the preset blanking force and the preset forming force in this embodiment;

[0154] 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:

[0155] Calculating the standard deviation of the difference between the vibration frequency and the preset vibration frequency within the preset first adjustment time period to obtain a frequency deviation fluctuation value;

[0156] When the frequency deviation fluctuation value is greater than a preset frequency deviation fluctuation threshold, the preset punching force and the preset forming force are adjusted according to the trimming burr height and the hook angle.

[0157] The preset frequency deviation fluctuation threshold is the threshold used to determine abnormal vibration frequency fluctuations. It depends on the mechanical rigidity and process stability of the equipment and is usually set between 0.1Hz and 1Hz. In this embodiment, it is set to 0.3Hz, which can effectively identify vibration anomalies and trigger process parameter adjustments to ensure the stability of the stamping process.

[0158] The preset first adjustment time is the time window for vibration frequency fluctuation calculation, which depends on the device 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.

[0159] By calculating in real time the standard deviation of the difference between the vibration frequency within the preset adjustment time and the preset vibration frequency, the frequency deviation fluctuation value is obtained. When this value exceeds the preset threshold, the preset blanking force or forming force is dynamically adjusted in combination with the changes in the trimming burr height and the hook angle to optimize the stamping process parameters and ensure the quality of the finished product.

[0160] Fluctuations in vibration frequency reflect the dynamic state of the mechanical system. Frequency deviation fluctuations accurately capture equipment anomalies or fatigue changes. Trimming burr height and hook angle serve as intuitive indicators of processing quality, closely linked to dynamic changes in vibration frequency. By synergizing these three factors, the system can scientifically adjust the blanking and forming forces, achieving adaptive optimization of processing parameters, significantly improving the stability and reliability of the finished contact spring and reducing the defective rate.

[0161] 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:

[0162] Performing maximum-minimum normalization processing on all the trimming burr heights within the preset second adjustment time to obtain a normalized height set, and calculating an average value of all the trimming burr heights to obtain an average burr height;

[0163] Performing maximum-minimum normalization processing on all the hook angles within the preset second adjustment time to obtain a normalized angle set, and calculating an average value of all the hook angles to obtain an average angle;

[0164] Calculating a relative deviation between the average burr height and a preset height adjustment threshold to obtain a height deviation;

[0165] Calculating a relative deviation between the average angle and a preset angle adjustment threshold to obtain an angle deviation;

[0166] When the height deviation is greater than a preset height deviation threshold, and the angle deviation is greater than a preset angle deviation threshold, calculating the Pearson correlation coefficient of the normalized height set and the normalized angle set to obtain a correlation;

[0167] When the correlation is greater than a preset correlation threshold, the preset blanking force is increased according to the relative deviation between the correlation and the preset correlation threshold, the preset height deviation weight, and the preset force adjustment coefficient, and the preset forming force is increased according to the relative deviation between the correlation and the preset correlation threshold, the preset angle deviation weight, and the preset force adjustment coefficient, Fc'=Fc×[1+kf×a×(W-W0) / W0], where Fc' is the preset blanking force after increase, Fc is the preset blanking force before increase, kf is the preset force adjustment coefficient, W is the correlation, W0 is the preset correlation threshold, and a is the preset height deviation weight;

[0168] Fx'=Fx×[1+kf×b×(W-W0) / W0], where Fx' is the preset forming force after increase, Fc is the preset forming force before increase, and b is the preset angle deviation weight.

[0169] The preset second adjustment time is the time window for calculating the edge burr height and hook angle fluctuation, which depends on the punching and forming rhythm and is usually set between 2 seconds and 8 seconds. In this embodiment, it is set to 4 seconds, which can balance data representativeness and response timeliness.

[0170] The preset height adjustment threshold is the burr height reference value that triggers the blanking force adjustment. It depends on the material thickness and the blade gap and is usually set between 20µm and 80µm. In this embodiment, it is set to 50µm, which can effectively suppress burrs from exceeding the standard.

[0171] The preset angle adjustment threshold is the reference value of the hook angle deviation that triggers the forming force adjustment. It depends on the spring design requirements and tolerance range and is usually set between 1° and 3°. In this embodiment, it is set to 2° to ensure the geometric accuracy of the hook.

[0172] The preset height deviation threshold is the limit 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 slight and severe deviations.

[0173] The preset angle deviation threshold is the limit value for judging the average angle deviation, which depends on the molding 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 degree of deviation.

[0174] The preset correlation threshold is the limit value of the Pearson correlation coefficient for evaluating the relationship between the burr and the angle. It depends on the coupling sensitivity and the misjudgment tolerance and is usually set between 0.7 and 0.9. In this embodiment, it is set to 0.8, which can identify high-coupling disturbances.

[0175] The preset height deviation weight is the weight coefficient of the contribution to the burr height deviation when adjusting the blanking force. It depends on the proportion of the influence of the burr 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 various parameters.

[0176] The preset angle deviation weight is the weight coefficient of the contribution to the hook angle deviation when adjusting the forming force. It depends on the sensitivity of the angle to the spring performance and is usually set between 0.3 and 0.7. In this embodiment, it is set to 0.4, which can ensure accurate angle adjustment.

[0177] The preset force adjustment coefficient is a proportional coefficient that converts the deviation and weight into the actual force increment. It depends on the rigidity of the stamping frame and the response characteristics of the actuator. It is usually set between 50N / unit and 200N / unit deviation. In this embodiment, it is set to 100N / unit deviation, which can achieve smooth and effective parameter correction.

[0178] First, the trimming burr height and hook angle within the preset second adjustment time are normalized separately to obtain a unified dimension of height and angle sets, and their average values are calculated to reflect the overall processing status. Subsequently, the relative deviations between the average burr height and the preset height adjustment threshold, and the average hook angle and the preset angle adjustment threshold, are calculated to determine whether they exceed the corresponding thresholds. If both exceed the thresholds, the Pearson correlation coefficient of the normalized height set and the normalized angle set is further calculated to evaluate the correlation between the two. When the correlation is higher than the preset correlation threshold, the preset blanking force and the preset forming force are dynamically increased based on the relative deviation of the correlation and the preset weight to optimize the processing parameters and achieve improved process stability.

[0179] As direct physical indicators of processing quality, trimming burr height and hook angle reflect the mutual influence and coupling between the blanking and forming processes. Normalization makes the two parameters comparable, and correlation calculations reveal their synergistic fluctuation patterns. Dynamic adjustment based on these two key parameters enables precise control of the blanking and forming forces, 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.

[0180] Specifically, the process of adjusting the preset tension threshold or the preset synchronization threshold according to the curvature of the bending section includes:

[0181] Calculating the average curvature of all the bending sections within the preset threshold adjustment time to obtain an average curvature;

[0182] Calculating the absolute value of the relative deviation between the average curvature and a preset average curvature threshold to obtain a curvature deviation;

[0183] When the curvature deviation is greater than a preset curvature deviation threshold, calculating the absolute value of the first-order derivative of the curvature of each bending section within the preset threshold adjustment time to obtain the absolute curvature change rate;

[0184] When the absolute curvature change rate is less than a preset rate threshold, the synchronization threshold is increased according to the relative deviation between the preset rate threshold and the absolute curvature change rate and the preset threshold adjustment coefficient, R'=R×[1+r×(V0-V) / V], where R' is the synchronization threshold after increase, 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;

[0185] When the absolute curvature change rate is greater than or equal to a preset rate threshold, calculating the absolute value of the second-order derivative of the curvature of each bending section within the preset threshold adjustment time to obtain the absolute curvature change acceleration;

[0186] When the absolute curvature change acceleration is greater than the preset acceleration threshold, the preset tension threshold is reduced 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 preset tension threshold after reduction, Y is the preset tension threshold before reduction, Va is the absolute curvature change acceleration, and Va0 is the preset acceleration threshold.

[0187] The preset threshold adjustment time refers to the time window used to calculate 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.

[0188] The preset average curvature threshold is the benchmark value for judging whether the curvature of the bending section is abnormal. It depends on the material and process requirements and is usually set at 0.1mm. -1 to 0.5mm -1 In this embodiment, it is set to 0.3mm -1 , which can accurately reflect the reasonable deformation range.

[0189] The preset curvature deviation threshold is the limit used to determine whether the average curvature deviation is significant. It 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.

[0190] The preset rate threshold is used to determine whether the curvature change rate is in a rapid change state. It depends on the processing speed and material response and is usually set at 0.01mm. -1 / s to 0.05mm -1 / s, in this embodiment it is set to 0.02mm -1 / s, which can sensitively capture the curvature change trend.

[0191] The preset threshold adjustment coefficient is a 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. In this embodiment, it is set to 0.3, which can ensure that the adjustment range is moderate and avoid excessive fluctuations.

[0192] The preset acceleration threshold is used to determine whether the acceleration of the curvature change reaches the threshold for the risk of rapid deformation. It depends on the mechanical properties of the material and is usually set at 0.001mm. -1 / s 2 to 0.01mm -1 / s 2 In this embodiment, it is set to 0.005mm -1 / s 2 , can accurately identify sudden deformations and provide early warning of risks.

[0193] First, the average value of the curvature of the bending section within the preset threshold adjustment time is calculated, and the curvature deviation is obtained based on this; when the curvature deviation exceeds the preset threshold, the absolute value of the first-order derivative of the curvature is further calculated to obtain the curvature change rate, and the synchronization threshold is adjusted based on the comparison between the rate and the preset rate threshold; if the curvature change rate is higher than the threshold, the absolute value of the second-order derivative of the curvature is calculated to reflect the acceleration of the curvature change, and the preset tension threshold is appropriately lowered according to the relationship between the acceleration and the acceleration threshold, so as to achieve dynamic optimization adjustment of the tension and synchronization thresholds.

[0194] Through multi-level analysis of the average level, rate of change, and acceleration of the bending section curvature, the dynamic characteristics of material deformation are accurately reflected, enabling scientific adjustment of processing parameters. Curvature deviation reflects static deviation, rate of change reflects deformation trend, and acceleration captures the risk of rapid changes. The combination of these three ensures that the adjustment of tension and synchronization thresholds is both sensitive and stable, avoiding over-response or hysteresis, and improving the safety and accuracy of the processing process.

[0195] 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:

[0196] Calculate the standard deviation of the number of times risk determination results are formed within the preset speed adjustment time to obtain the risk frequency fluctuation value;

[0197] When the risk number fluctuation value is greater than the preset risk number fluctuation threshold, the preset feeding speed is reduced according to the relative deviation between the risk number fluctuation value and the preset risk number fluctuation threshold and the preset feeding adjustment coefficient, Vs'=Vs×[1-g×(P-P0) / P0], wherein Vs' is the preset feeding speed after reduction, Vs is the preset feeding speed before reduction, g is the preset feeding adjustment coefficient, P is the risk number fluctuation value, and P0 is the preset risk number fluctuation threshold.

[0198] The preset speed adjustment time is the time interval used to statistically calculate the number of risk judgment results. It depends on the feeding cycle and processing rhythm and is usually set between 5 seconds and 30 seconds. In this embodiment, it is set to 20 seconds, which can ensure that representative fluctuation characteristic data is obtained.

[0199] The preset risk number fluctuation threshold is a benchmark value for judging whether the risk formation fluctuation is abnormal. It depends on the product fault tolerance and control accuracy requirements. It is usually set between 0.5 and 2 times. In this embodiment, it is set to 1 time, which can effectively identify the unstable state of the risk judgment results during the processing process.

[0200] The preset feeding adjustment coefficient is a proportional parameter used to adjust the feeding speed according to the degree of risk fluctuation. It depends on the equipment response capability and speed regulation sensitivity requirements. It is usually set between 0.05 and 0.2. In this embodiment, it is set to 0.1, which can achieve smooth and effective dynamic control of the feeding speed.

[0201] The system monitors the number of risk determinations generated within a preset speed adjustment period and calculates its standard deviation to obtain a risk frequency fluctuation value. If this fluctuation value exceeds a preset risk frequency fluctuation threshold, the system is deemed to be in an unstable risk state. Based on the relative deviation between the risk frequency fluctuation value and the threshold, and in combination with a preset feed adjustment coefficient, the current preset feed speed is adjusted. Specifically, the preset feed speed is reduced to lower the system operating rate, thereby mitigating the risk fluctuations caused by an excessively high abnormal formation rate.

[0202] By comparing the deviation between the fluctuation value and the threshold value and combining the feeding speed adjustment coefficient for dynamic adjustment, it is found that 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 lead to reduced processing stability and frequent errors. Reducing the feeding speed can effectively extend the response time to anomalies, improve deformation control accuracy and finished product quality, reflecting a feedback adjustment mechanism based on the law of risk fluctuations.

[0203] Specifically, the process of determining the occurrence of an abnormal event based on the transport tension and the preset tension threshold and forming the abnormality determination result includes:

[0204] When the transport tension is greater than the preset tension threshold, start recording the current timestamp, and when the transport tension is less than or equal to the preset tension threshold, stop recording to obtain a duration;

[0205] When the duration is greater than a preset duration threshold, it is determined that the abnormal event occurs, and the abnormality determination result is formed.

[0206] The preset duration threshold is the time benchmark for determining whether the tension anomaly persists. It depends on the stress tolerance of the material and the process rhythm. It is usually set between 0.5 seconds and 3 seconds. In this embodiment, it is set to 1.5 seconds. It can effectively distinguish short-term fluctuations from actual abnormal events and improve the accuracy of abnormality judgment.

[0207] By monitoring the relationship between transport tension and a preset tension threshold in real time, the system begins recording a timestamp when the transport tension exceeds the threshold and stops recording when the tension returns to below the threshold to determine the duration of the abnormal tension. When this duration exceeds the preset duration threshold, the system determines that an abnormal event has occurred and generates a corresponding abnormality determination result.

[0208] By continuously monitoring the relationship between conveying tension and a set tension threshold and incorporating duration into the judgment, true tension anomalies can be effectively identified. This combined force and time dimension of the judgment mechanism adheres to the physical law that material damage occurs only when forces exceeding a critical value and persist. This avoids false alarms due to transient fluctuations, improves the scientific nature and reliability of the judgment, and helps ensure the stability of subsequent processes and product quality.

[0209] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that the present invention is susceptible to various modifications and variations. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. An integrated stamping process for new energy vehicle battery contact springs, characterized in that: include: Real-time data collection includes the conveying tension of the conductive tape on the material strip fed at a preset feeding speed, the vibration frequency of the mold, the height of the cutting burr of the conductive tape at the punching station punched at a preset punching force, and the hook angle and bending section curvature of the contact spring semi-finished product at the forming station formed at a preset forming force; determining the occurrence of an abnormal event based on the transport tension and a preset tension threshold, and forming an abnormality determination result; Based on the abnormality determination result, determining that the event type of the abnormal event is deformation coupling disturbance according to the trimming burr height, the vibration frequency, and a preset synchronization threshold, and obtaining the abnormality type; Based on the abnormality type, judging the occurrence of processing risk according to the hook angle and the curvature of the bending section, and judging the risk level of the processing risk to be a severe level, thereby forming a risk judgment result; Based on the risk determination result, adjusting the preset blanking force and the preset forming force according to the vibration frequency, the trimming burr height, and the hook angle; Based on the re-determined abnormality type of the adjusted preset blanking force and the adjusted preset forming force, adjusting the preset tension threshold or the preset synchronization threshold according to the curvature of the bending section; The preset feeding speed is adjusted based on the adjusted threshold or the risk determination result re-determined based on the preset synchronization threshold.

2. The one-piece stamping process for the contact spring of a new energy vehicle battery according to claim 1, characterized in that: The event type of the abnormal event is determined to be a deformation coupling disturbance according to the trimming burr height, the vibration frequency, and a preset synchronization threshold. 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 time length 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 time length to obtain a plurality of vibration frequency fluctuation values; According to all the burr height fluctuation values, all the vibration frequency fluctuation values and the preset synchronization threshold, it is determined that the event type of the abnormal event is deformation coupling disturbance, and the abnormal type is obtained.

3. The one-piece stamping process for the contact spring of a new energy vehicle battery according to claim 2, characterized in that: The process of determining the event type of the abnormal event as deformation coupling disturbance according to all the burr height fluctuation values, all the vibration frequency fluctuation values, and the preset synchronization threshold includes: Drawing a curve of the burr height fluctuation value changing over time within the preset type-determined time length to obtain a height fluctuation curve; Plotting a curve of the vibration frequency fluctuation value changing over time within the predetermined time period to obtain a frequency fluctuation curve; Calculating the absolute value of the cosine similarity between the height fluctuation curve and the frequency fluctuation curve to obtain the change synchronization; When the change synchronization degree is greater than the preset synchronization degree threshold, it is determined that the event type of the abnormal event is a deformation coupling disturbance.

4. The one-piece stamping process for the contact spring of a new energy vehicle battery according to claim 3, characterized in that: The process of determining the occurrence of processing risks based on 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 bending section is greater than a preset curvature threshold, the standard deviation of the hook angle within the preset risk determination time is calculated to obtain an angle fluctuation value, and the standard deviation of the curvature of the bending section within the preset risk determination time is calculated to obtain a curvature fluctuation value; When the angle fluctuation value is smaller than a preset angle fluctuation threshold, and the curvature fluctuation value is smaller than a preset curvature fluctuation threshold, it is determined that a processing risk occurs.

5. The one-piece stamping process for the contact spring of a battery of a new energy vehicle according to claim 4, characterized in that: The process of determining the risk level of processing risks as severe includes: Performing maximum-minimum normalization processing on all the hook angles within the preset risk determination time to obtain a normalized angle set, and performing maximum-minimum normalization processing on all the bending section curvatures within the preset risk determination time to obtain a normalized curvature set; Calculating the Pearson correlation coefficient between 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, the risk level is determined to be a severe level.

6. The one-piece stamping process for the contact spring of a battery 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: Calculating the standard deviation of the difference between the vibration frequency and the preset vibration frequency within the preset first adjustment time period to obtain a frequency deviation fluctuation value; When the frequency deviation fluctuation value is greater than a preset frequency deviation fluctuation threshold, the preset punching force and the preset forming force are adjusted according to the trimming burr height and the hook angle.

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

8. The one-piece stamping process for the contact spring of a battery 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 bending section includes: Calculating the average curvature of all the bending sections within the preset threshold adjustment time to obtain an average curvature; Calculating 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, calculating the absolute value of the first-order derivative of the curvature of each bending section within the preset threshold adjustment time to obtain the absolute curvature change rate; When the absolute curvature change rate is less than a preset rate threshold, increasing the synchronization threshold according to a 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 a preset rate threshold, calculating the absolute value of the second-order derivative of the curvature of each bending section within the preset threshold adjustment time to obtain the absolute curvature change acceleration; When the absolute curvature change acceleration is greater than a preset acceleration threshold, the preset tension threshold is reduced according to a 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 contact spring of a new energy vehicle battery according to claim 8, characterized in that: 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 comprises: Calculate the standard deviation of the number of times risk determination results are formed within the preset speed adjustment time to obtain the risk frequency fluctuation value; When the risk number fluctuation value is greater than a preset risk number fluctuation threshold, the preset feeding speed is reduced according to a 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 contact spring of a new energy vehicle battery according to claim 9, characterized in that: The process of determining the occurrence of an abnormal event based on the transport tension and the preset tension threshold and forming an abnormality determination result includes: When the transport tension is greater than the preset tension threshold, start recording the current timestamp, and when the transport tension is less than or equal to the preset tension threshold, stop recording to obtain a duration; When the duration is greater than a preset duration threshold, it is determined that the abnormal event occurs, and the abnormality determination result is formed.

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