Capacitor lead aluminum wire forming, cleaning and forming all-in-one machine

Abstract

The capacitor lead aluminum wire forming, cleaning and forming all-in-one machine comprises a working machine table, an automatic discharging mechanism and a punching machine are arranged at the top of the working machine table, an ultrasonic cleaning machine, a forming device, a drying device and a material collecting mechanism are sequentially arranged on one side of the working machine table, and a base table is arranged at the bottom of the drying device and the bottom of the material collecting mechanism; the punching machine comprises a punching machine shell, a punching air cylinder is installed in the punching machine shell, an upper die base is installed at the output end of the punching air cylinder, a lower die base is arranged on the outer side of the punching machine shell and located below the upper die base, a flattening male die is connected to the bottom of the upper die base, and a plurality of bearings used for fixing lead aluminum wires are rotationally connected to the top of the lower die base and located on the two sides of the upper die base. The problem that the final product yield is affected by process dispersion and low efficiency in the prior art is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of capacitor devices, and particularly to an integrated machine for forming, cleaning, and chemical conversion of capacitor lead aluminum wires. Background Art

[0002] As a core component in electronic circuits, the performance of aluminum electrolytic capacitors highly depends on the processing quality of lead aluminum wires. The lead aluminum wires need to go through key processes such as stamping and forming, surface cleaning, and electrochemical conversion to form a structure with excellent electrical conductivity and insulating oxide layers.

[0003] In the prior art, processes such as stamping, cleaning, and chemical conversion of aluminum wires are usually completed in segments by independent equipment, requiring multiple manual loading, unloading, and transfer operations. Frequent material handling not only increases the production cycle but also easily causes scratches or damage to the oxide layer on the surface of the aluminum wires, affecting the yield of the final product. Traditional stamping equipment lacks a dynamic positioning mechanism, and the aluminum wires are prone to deviation or distortion during stamping, resulting in dimensional deviation of the formed parts. Especially for thin-diameter aluminum wires, the rigid clamping of conventional jigs easily causes surface indentations, affecting the uniformity of the subsequent chemical conversion process. Summary of the Invention

[0004] The present invention aims to solve the above-mentioned defects in the prior art and provides an integrated machine for forming, cleaning, and chemical conversion of capacitor lead aluminum wires, which solves the problems of scattered processes and low efficiency in the prior art, affecting the yield of the final product.

[0005] The object of the present invention is achieved through the following technical solutions. An integrated machine for forming, cleaning, and chemical conversion of capacitor lead aluminum wires includes a working table (1). An automatic feeding mechanism (2) is arranged on the top of the working table (1). A stamping machine (3), an ultrasonic cleaning machine (4), a chemical conversion device (5), a drying device (6), and a material receiving mechanism (7) are sequentially arranged on one side of the working table (1). A base (11) is arranged at the bottoms of the drying device (6) and the material receiving mechanism (7).

[0006] Further, the automatic feeding mechanism (2) includes a first reel support frame (21) installed on the top of the working table (1). A first rotating shaft (22) is rotatably connected to the first reel support frame (21). An aluminum wire feeding reel (23) is connected to the surface of the first rotating shaft (22). One end of the first rotating shaft (22) extends outside the first reel support frame (21) and is connected to a ratchet wheel (24). A ratchet pawl (25) is rotatably connected to one side of the first reel support frame (21).

[0007] Further, the stamping machine (3) includes an assembly bed (301), on which a crankshaft (302) is rotatably connected. One end of the crankshaft (302) is connected to a flywheel (303). A connecting rod (313) is arranged on the crankshaft (302), and a ball head rod (304) is connected to the bottom of the connecting rod (313). Guide rails (305) are installed on both sides of the assembly bed (301), and an assembly slider (306) is slidably connected to the two guide rails (305). A ball groove for the rotation of the ball head rod (304) is arranged on the top of the assembly slider (306). A ball head cover (307) is installed on the top of the assembly slider (306), and an upper die holder (308) is installed on the bottom of the assembly slider (306). A lower die holder (309) is arranged below the upper die holder (308) on the assembly bed (301). A flattening punch (310) is connected to the bottom of the upper die holder (308). A number of groups of bearings (314) for fixing the lead aluminum wire are rotatably connected to the top of the lower die holder (309) on both sides of the upper die holder (308). A motor (311) is installed on the assembly bed (301), and a small pulley (312) is connected to one end of the motor (a11). The small pulley (312) is connected to the flywheel (303) through a belt drive.

[0008] Further, the forming device (5) includes an electrolytic cell (51), which is filled with electrolyte. An anode conductive roller (52) is installed on the top of the electrolytic cell (51) through an insulating bracket. A cathode plate (53) is arranged in the electrolytic cell (51). The material of the cathode plate (53) is a titanium plate. A stable DC voltage is provided to the cathode plate (53) and the anode conductive roller (52) through a constant voltage power supply. First guide rollers (54) are installed on both sides of the top of the electrolytic cell (51), and a second guide roller (55) is installed inside the electrolytic cell (51). The second guide roller (55) is made of corrosion-resistant material.

[0009] Further, the drying device (6) includes a hot air circulation box (61) arranged on the top of the base (11). Infrared heating tubes (62) are installed on the inner top of the hot air circulation box (61). A number of high-temperature resistant conveying rollers (63) are rotatably connected between the inner walls of the hot air circulation box (61).

[0010] Further, the material receiving mechanism (7) includes a second reel support frame (71) installed on the top of the base (11). A second rotating shaft (72) is rotatably connected to the second reel support frame (71). An aluminum wire receiving reel (73) is connected to the surface of the second rotating shaft (72). One end of the second rotating shaft (72) extends outside the second reel support frame (71) and is connected to a grooved pulley (74). A driving dial (75) with a cylindrical pin is arranged in the concave part of the grooved pulley (74). The grooved pulley (74) and the driving dial (75) are installed on a mounting frame (76). A servo motor (77) is installed on the top of the base (11), and the output end of the servo motor (77) is connected to the driving dial (75).

[0011] Further, third guiding rollers (41) are installed on both sides of the top of the ultrasonic cleaning machine (4), and a fourth guiding roller (42) is rotatably connected inside the cleaning tank of the ultrasonic cleaning machine (4).

[0012] In summary, compared with the prior art, the present invention has the following advantages:

[0013] 1. The equipment of the present invention integrates six processes of feeding, stamping, ultrasonic cleaning, chemical conversion, drying, and material receiving, completely eliminating problems such as material transfer, manual intervention, and production rhythm mismatch caused by multi-device segmented operation in the traditional process. The processing process of the aluminum wire from raw material to finished product does not require manual handling, significantly improving production continuity and reducing operation complexity, especially suitable for large-scale industrial scenarios

[0014] 2. In the stamping machine (3) of the present invention, a crankshaft (302)-connecting rod (313)-ball head rod (304) transmission structure is adopted. Combined with the precise guidance of the guide rail (305) and the assembly slider (306), the upper die holder (308) and the flattening punch (310) are driven to achieve high-precision stamping actions; the rotating bearings (314) on both sides of the lower die holder (309) dynamically clamp the aluminum wire, avoiding the offset or scratching of the aluminum wire during the stamping process and ensuring the consistency of the forming size.

[0015] 3. In the ultrasonic cleaning machine of the present invention, the cavitation effect completely peels off the grease, oxide layer, and fine particles on the surface of the aluminum wire, avoiding the influence of residual pollutants on the quality of the oxide layer in the subsequent chemical conversion process. The immersion design of the guiding roller ensures that the aluminum wire fully contacts the cleaning liquid in the cleaning tank, improving the cleaning efficiency and providing a high-purity substrate for the chemical conversion process.

[0016] 4. In the present invention, the combined design of the anode conductive roller and the titanium cathode plate, combined with the precise regulation of the constant voltage power supply, ensures the uniform progress of the oxidation reaction on the surface of the aluminum wire. The multi-stage guiding rollers in the electrolytic cell guide the aluminum wire to immerse in the electrolyte in a constant path, avoiding uneven oxidation layer thickness caused by bending or floating, and significantly improving the denseness of the dielectric layer and the electrical performance stability.

[0017] 5. In the present invention, the hot air circulation box uses infrared heating tubes and high-temperature resistant conveyor rollers to work together. Through the dual effects of hot air circulation and radiation heating, the residual electrolyte on the surface of the aluminum wire is quickly evaporated. The closed box design reduces heat loss and at the same time avoids the influence of high-temperature air leakage on the operating environment, taking into account both drying efficiency and energy consumption optimization.

[0018] 6. In the present invention, the material receiving mechanism realizes the step-by-step winding of the aluminum wire through the intermittent transmission design of the grooved wheel and the driving dial, effectively matching the production rhythm of each process. The servo motor drive is combined with the tension feedback mechanism to dynamically adjust the winding speed, avoiding problems such as breakage and stacking of the aluminum wire caused by excessive stretching or relaxation, and ensuring the winding neatness and convenience of subsequent processing. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a schematic structural diagram of the present invention;

[0020] Figure 2 is a schematic structural diagram of the automatic feeding mechanism of the present invention;

[0021] Figure 3 is a schematic structural diagram of the punching machine of the present invention;

[0022] Figure 4 is a schematic structural diagram of the ultrasonic cleaning machine of the present invention;

[0023] Figure 5 is a schematic structural diagram of the forming device of the present invention;

[0024] Figure 6 is a schematic structural diagram of the drying device of the present invention;

[0025] Figure 7 is a schematic structural diagram of the material receiving mechanism of the present invention.

[0026] In the figure: 1 - working machine table, 2 - automatic feeding mechanism, 3 - punching machine, 4 - ultrasonic cleaning machine, 5 - forming device, 6 - drying device, 7 - material receiving mechanism, 11 - base, 301 - assembly bed, 302 - crankshaft, 303 - flywheel, 304 - ball head rod, 305 - guide rail, 306 - assembly slider, 307 - ball head cover, 308 - upper die holder, 309 - lower die holder, 310 - flattening punch, 311 - motor, 312 - small pulley, 313 - connecting rod, 314 - bearing, 21 - first reel support frame, 22 - first rotating shaft, 23 - aluminum wire feeding reel, 24 - ratchet wheel, 25 - ratchet pawl, 51 - electrolytic cell, 52 - anode conductive roller, 53 - cathode plate, 54 - first guiding roller, 55 - second guiding roller, 61 - hot air circulation box, 62 - infrared heating tube, 63 - high temperature resistant conveying roller, 71 - second reel support frame, 72 - second rotating shaft, 73 - aluminum wire receiving reel, 74 - Geneva wheel, 75 - driving dial, 76 - mounting bracket, 77 - servo motor, 41 - third guiding roller, 42 - fourth guiding roller. Detailed implementation manners

[0027] The technical solutions of the present invention will be further specifically described below through specific embodiments, but the present invention is not limited to these embodiments.

[0028] Combined with Figures 1 to 7 As shown in the figure, a capacitor lead aluminum wire forming, cleaning and forming integrated machine includes a working machine table 1. An automatic feeding mechanism 2 is arranged on the top of the working machine table 1. A punching machine 3, an ultrasonic cleaning machine 4, a forming device 5, a drying device 6 and a material receiving mechanism 7 are sequentially arranged on one side of the working machine table 1. A base 11 is arranged at the bottoms of the drying device 6 and the material receiving mechanism 7.

[0029] Combined with Figure 2 As shown in the figure, the automatic feeding mechanism 2 includes a first reel support frame 21 installed on the top of the working machine table 1. A first rotating shaft 22 is rotatably connected to the first reel support frame 21. An aluminum wire feeding reel 23 is connected to the surface of the first rotating shaft 22. One end of the first rotating shaft 22 extends outside the first reel support frame 21 and is connected with a ratchet wheel 24. A ratchet pawl 25 is rotatably connected to one side of the first reel support frame 21. The aluminum wire reel 23 controls the unidirectional feeding through the engagement of the ratchet wheel 24 and the ratchet pawl 25 to avoid rewinding. The aluminum wire is smoothly released from the aluminum wire feeding reel 23 on the first reel support frame 21 and enters the subsequent working stations. The engagement of the ratchet wheel 24 and the ratchet pawl 25 prevents the aluminum wire reel 23 from accidentally rewinding, ensuring the stability of the aluminum wire release process and avoiding wire breakage or loosening caused by tension fluctuations.

[0030] Combined with Figure 3As shown in the figure, the stamping machine 3 includes an assembled bed 301. A crankshaft 302 is rotatably connected to the assembled bed 301. One end of the crankshaft 302 is connected to a flywheel 303. A connecting rod 313 is arranged on the crankshaft 302. The bottom of the connecting rod 313 is connected to a ball head rod 304. Guide rails 305 are installed on both sides of the assembled bed 301. An assembled slider 306 is slidably connected to the two guide rails 305. A ball groove for the rotation of the ball head rod 304 is arranged at the top of the assembled slider 306. A ball head cover 307 is installed at the top of the assembled slider 306. An upper die holder 308 is installed at the bottom of the assembled slider 306. A lower die holder 309 is arranged below the upper die holder 308 on the assembled bed 301. A flattening punch 310 is connected to the bottom of the upper die holder 308. A number of groups of bearings 314 for fixing the lead aluminum wire are rotatably connected to the top of the lower die holder 309 on both sides of the upper die holder 308. A motor 311 is installed on the assembled bed 301. One end of the motor 311 is connected to a small pulley 312. The small pulley 312 and the flywheel 303 are connected by belt drive. The stamping machine 3 adopts a crankshaft 302 - connecting rod 313 - ball head rod 304 transmission structure. Combined with the precise guidance of the guide rail 305 and the assembled slider 306, it drives the upper die holder 308 and the flattening punch 310 to achieve high-precision stamping actions; the rotary bearings 314 on both sides of the lower die holder 309 dynamically clamp the aluminum wire, avoiding the offset or scratching of the aluminum wire during the stamping process, and ensuring the consistency of the forming size.

[0031] Combined with Figure 5 As shown in the figure, the forming device 5 includes an electrolytic cell 51. The electrolytic cell 51 is filled with electrolyte. An anode conductive roller 52 is installed at the top of the electrolytic cell 51 through an insulating support. A cathode plate 53 is arranged in the electrolytic cell 51. The material of the cathode plate 53 is a titanium plate. The cathode plate 53 and the anode conductive roller 52 are provided with a stable DC voltage by a constant voltage power supply. First guide rollers 54 are installed on both sides of the top of the electrolytic cell 51. A second guide roller 55 is installed inside the electrolytic cell 51. The second guide roller 55 is made of corrosion-resistant material. The cleaned aluminum wire is guided to the top of the electrolytic cell 51 by the first guide roller 54 and the anode conductive roller 52 at one end, and is guided by the second guide roller 55 to immerse in the electrolyte of the electrolytic cell 51. The anode conductive roller 52 contacts the aluminum wire and applies a positive voltage. The cathode plate 53 serves as the negative electrode. Under the action of the constant voltage power supply, an electrochemical oxidation reaction occurs on the surface of the aluminum wire to form a dense aluminum oxide Al2O3 dielectric layer. The anode conductive roller 52 is in direct contact with the aluminum wire to ensure uniform current distribution; the titanium cathode plate 53 has strong corrosion resistance and high stability during long-term use.

[0032] Combined with Figure 6As shown in the figure, the drying device 6 includes a hot air circulation box 61 arranged on the top of the base 11. An infrared heating tube 62 is installed on the inner top of the hot air circulation box 61. A number of high-temperature resistant conveying rollers 63 are rotatably connected between the inner walls of the hot air circulation box 61. The formed aluminum wire enters the hot air circulation box 61. High-temperature hot air is generated by the infrared heating tube 62. The high-temperature resistant conveying rollers 63 drive the aluminum wire to pass through evenly, quickly evaporating the residual electrolyte, ensuring the dryness and stability of the oxide layer. The infrared heating tube 62 combines radiation heating with hot air circulation to quickly evaporate the residual electrolyte on the surface of the aluminum wire, shortening the process time.

[0033] Combined with Figure 7 As shown in the figure, the wire receiving mechanism 7 includes a second reel support frame 71 installed on the top of the base 11. A second rotating shaft 72 is rotatably connected to the second reel support frame 71. An aluminum wire receiving reel 73 is connected to the surface of the second rotating shaft 72. One end of the second rotating shaft 72 extends outside the second reel support frame 71 and is connected with a grooved wheel 74. A driving dial 75 with a cylindrical pin is arranged in the concave part of the grooved wheel 74. The grooved wheel 74 and the driving dial 75 are installed on the mounting frame 76. A servo motor 77 is installed on the top of the base 11. The output end of the servo motor 77 is connected with the driving dial 75. The servo motor 77 drives the driving dial 75 to drive the grooved wheel 74 to rotate intermittently, realizing the step-by-step winding of the aluminum wire receiving reel 73. Cooperating with the tension adjustment to avoid the aluminum wire from being broken or slack, ensuring that the aluminum wire will remain stationary during stamping and guaranteeing the stamping quality. The intermittent movement of the grooved wheel 74 is synchronized with the front-end process, avoiding the aluminum wire from being broken due to too fast winding speed or being piled up due to too slow winding speed.

[0034] Combined with Figure 4 As shown in the figure, third guide rollers 41 are installed on both sides of the top of the ultrasonic cleaning machine 4. A fourth guide roller 42 is rotatably connected inside the cleaning tank of the ultrasonic cleaning machine 4. The formed aluminum wire is guided by the third guide roller 41 into the ultrasonic cleaning machine 4 and then enters the inside of the cleaning tank through the fourth guide roller 42. The surface oil and impurities are peeled off through the ultrasonic cavitation effect, improving the quality of the oxide layer in the subsequent chemical conversion process.

[0035] Working principle: The aluminum wire reel 23 controls the unidirectional feeding through the engagement of the ratchet 24 and the pawl 25 to avoid rewinding. The aluminum wire is smoothly released from the aluminum wire feeding reel 23 on the first reel support frame 21 and enters the subsequent workstations. The motor 311 drives the small pulley 312 to drive the flywheel 303 and the crankshaft 302 to rotate through belt transmission. The rotational motion of the crankshaft 302 is converted into the reciprocating linear motion of the ball head rod 304 through the connecting rod 313. The ball head at the bottom of the ball head rod 304 cooperates with the ball groove of the assembly slider 306 to drive the assembly slider to slide up and down along the guide rail 305, driving the upper die holder 308 and the flattening punch 310 to complete the stamping action. The rotary bearings 314 on both sides of the lower die holder 309 rotate synchronously with the movement of the aluminum wire during stamping, dynamically clamping the aluminum wire and reducing friction, ensuring that the aluminum wire has no deviation and no scratches. The formed aluminum wire is guided into the ultrasonic cleaning machine 4 by the third guide roller 41, and then enters the inside of the cleaning tank through the fourth guide roller 42. The surface oil and impurities are peeled off through the ultrasonic cavitation effect, improving the quality of the oxide layer in the subsequent forming process. The cleaned aluminum wire is guided to the top of the electrolytic cell 51 by the first guide roller 54 and the anode conductive roller 52 at one end, and is guided into the electrolyte of the electrolytic cell 51 through the second guide roller 55. The anode conductive roller 52 contacts the aluminum wire and applies a positive voltage. The cathode plate 53 serves as the negative electrode. Under the action of the constant voltage power supply, an electrochemical oxidation reaction occurs on the surface of the aluminum wire, forming a dense aluminum oxide (Al2O3) dielectric layer. The formed aluminum wire enters the hot air circulation box 61. High-temperature hot air is generated by the infrared heating tube 62. The high-temperature resistant conveyor roller 63 drives the aluminum wire to pass through at a constant speed, quickly evaporating the residual electrolyte, ensuring the dryness and stability of the oxide layer. The servo motor 77 drives the driving dial 75 to drive the sprocket 74 to rotate intermittently, realizing the step-by-step winding of the aluminum wire take-up reel 73, and cooperating with the tension adjustment to avoid breaking or loosening of the aluminum wire, ensuring that the aluminum wire will remain stationary during stamping and guaranteeing the stamping quality.

[0036] The embodiments of the present invention are not limited to those described in the above embodiments. Without departing from the spirit and scope of the present invention, those of ordinary skill in the art can make various changes and improvements in form and details, and all of these are considered to fall within the protection scope of the present invention.

Claims

1. A capacitor lead aluminum wire forming, cleaning and forming integrated machine, comprising a working machine (1), characterized in that: At the top of the working machine table (1), an automatic feeding mechanism (2) is provided. On one side of the working machine table (1), a punching machine (3), an ultrasonic cleaning machine (4), a forming device (5), a drying device (6), and a material receiving mechanism (7) are arranged in sequence. A base table (11) is provided at the bottoms of the drying device (6) and the material receiving mechanism (7).

2. The capacitor lead aluminum wire forming, cleaning and forming all-in-one machine according to claim 1, characterized in that: The automatic feeding mechanism (2) includes a first reel support frame (21) installed on the top of the working machine table (1). A first rotating shaft (22) is rotatably connected to the first reel support frame (21). The surface of the first rotating shaft (22) is connected with an aluminum wire feeding reel (23). One end of the first rotating shaft (22) extends outside the first reel support frame (21) and is connected with a ratchet wheel (24). A ratchet pawl (25) is rotatably connected to one side of the first reel support frame (21).

3. The capacitor lead aluminum wire forming, cleaning and forming all-in-one machine according to claim 2, characterized in that: The punching machine (3) includes an assembled bed body (301). A crankshaft (302) is rotatably connected to the assembled bed body (301). One end of the crankshaft (302) is connected with a flywheel (303). A connecting rod (313) is arranged on the crankshaft (302). The bottom of the connecting rod (313) is connected with a ball head rod (304). Guide rails (305) are installed on both sides of the assembled bed body (301). An assembled slider (306) is slidably connected to the two guide rails (305). A ball groove for the rotation of the ball head rod (304) is arranged at the top of the assembled slider (306). A ball head cover (307) is installed at the top of the assembled slider (306). An upper die base (308) is installed at the bottom of the assembled slider (306). A lower die base (309) is arranged below the upper die base (308) on the assembled bed body (301). A flattening punch (310) is connected to the bottom of the upper die base (308). A number of groups of bearings (314) for fixing the lead aluminum wire are rotatably connected to both sides of the upper die base (308) at the top of the lower die base (309). A motor (311) is installed on the assembled bed body (301). One end of the motor (311) is connected with a small pulley (312). The small pulley (312) is connected with the flywheel (303) through a belt drive.

4. A capacitor lead aluminum wire forming, cleaning and forming-integrated machine according to claim 3, characterized in that: The forming device (5) includes an electrolytic cell (51). The electrolytic cell (51) is filled with electrolyte. An anode conductive roller (52) is installed at the top of the electrolytic cell (51) through an insulating support. A cathode plate (53) is arranged in the electrolytic cell (51). The material of the cathode plate (53) is a titanium plate. The cathode plate (53) and the anode conductive roller (52) are provided with a stable DC voltage through a constant voltage power supply. First guide rollers (54) are installed on both sides at the top of the electrolytic cell (51). A second guide roller (55) is installed inside the electrolytic cell (51). The second guide roller (55) is made of corrosion-resistant material.

5. A capacitor lead aluminum wire forming, cleaning and forming-in-one machine according to claim 4, characterized in that: The drying device (6) includes a hot air circulation box (61) arranged on the top of the base (11). An infrared heating tube (62) is installed on the inner top of the hot air circulation box (61). A plurality of high-temperature resistant conveyor rollers (63) are rotatably connected between the inner walls of the hot air circulation box (61).

6. The capacitor lead aluminum wire forming, cleaning and forming all-in-one machine according to claim 5, characterized in that: The material receiving mechanism (7) includes a second reel support frame (71) installed on the top of the base (11). A second rotating shaft (72) is rotatably connected to the second reel support frame (71). An aluminum wire receiving reel (73) is connected to the surface of the second rotating shaft (72). One end of the second rotating shaft (72) extends to the outside of the second reel support frame (71) and is connected to a grooved wheel (74). A driving dial (75) with a cylindrical pin is arranged in the concave part of the grooved wheel (74). The grooved wheel (74) and the driving dial (75) are installed on a mounting frame (76). A servo motor (77) is installed on the top of the base (11). The output end of the servo motor (77) is connected to the driving dial (75).

7. The capacitor lead aluminum wire forming, cleaning and forming all-in-one machine according to claim 6, characterized in that: Both sides of the top of the ultrasonic cleaning machine (4) are installed with third guide rollers (41). A fourth guide roller (42) is rotatably connected inside the cleaning tank of the ultrasonic cleaning machine (4).

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