Automatic integrating, cutting and forming machine for energy storage wire harnesses

Abstract

The invention relates to the technical field of energy storage wire harness cutting, in particular to an energy storage wire harness automatic integration cutting forming machine which comprises a base, a feeding end rack and a discharging end rack are fixedly arranged at the top of the base, supporting frames are fixedly connected to the two side walls of the adjacent ends of the feeding end rack and the discharging end rack correspondingly, and an equipment frame is fixedly installed at the top ends of the corresponding supporting frames; a hydraulic cutting tool is fixedly installed on the top of the inner side of the equipment frame and used for cutting the energy storage wire harness, torsion assemblies are arranged on the two sides of the equipment frame respectively, and the torsion assemblies are used for conducting torsion machining on the two sides of a notch of the cut energy storage wire harness. According to the scheme, wires in the wire harnesses on the two sides of the cutting position are tightly gathered through synchronous reverse torsion, positioning is stable, a hydraulic cutting tool is assisted to achieve the effects that notches are smooth and free of burrs, sections are consistent and the wire harnesses are complete in structure, meanwhile, tool abrasion is reduced, and the consistency and stability of cutting quality in batch machining are guaranteed.

Description

Technical Field

[0001] This invention relates to the field of energy storage harness cutting technology, specifically an automated integrated cutting and forming machine for energy storage harnesses. Background Technology

[0002] Energy storage harnesses are key connection components of energy storage systems, mainly used for power transmission and signal transmission between core equipment such as battery packs, inverters, and energy storage converters. Cutting and slitting energy storage harnesses is a critical process in their manufacturing. After cutting, the regularity of the shielding layer and core wires must be processed simultaneously to lay the foundation for subsequent terminal crimping, welding and other processes, and to ensure the overall electrical performance and safety reliability of the harness.

[0003] In the field of energy storage harness cutting, existing equipment only uses a single process of clamping and directly cutting without pre-processing the harness at the cutting point. This inevitably results in the wires inside the harness being in a loose and disordered state. The loose wires are subjected to uneven force during cutting, which directly causes problems such as burrs on the cut, wire misalignment, and even some wires not being cut. This contradicts the requirement of energy storage harnesses to have a flat cross-section to ensure the reliability of subsequent assembly. At the same time, without the cohesive tension and precise positioning provided by the pre-processing stage, the harness is prone to compression deformation due to local force imbalance at the moment of cutting, which further damages the structural integrity. This is contrary to the requirements of energy storage scenarios for the structural stability of the harness.

[0004] From the perspective of batch processing, loose wires increase the dispersion resistance during tool cutting, accelerate tool wear, and due to the lack of a unified bundle pretreatment standard, the cutting quality of different wire bundles varies significantly, resulting in a high scrap rate. This conflicts with the efficiency and consistency requirements of mass production of energy storage wire bundles. Even though some automatic cutting equipment has achieved automated clamping, it has not been optimized for the core problem of "loose wires" and still cannot break through the cutting quality bottleneck.

[0005] Therefore, developing an energy storage harness cutting device that can solve the problem of loose wires through pre-processing before cutting, help improve cutting accuracy, and take into account both automation and batch processing stability has become an urgent need to break through the limitations of existing technology and ensure the connection safety of energy storage devices.

[0006] To address the aforementioned technical shortcomings, a solution is proposed. Summary of the Invention

[0007] The purpose of this invention is to provide an automated integrated cutting and forming machine for energy storage harnesses, which solves the problems mentioned in the background art above.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] An automated integrated cutting and forming machine for energy storage wire harnesses includes a base, on the top of which a feeding end frame and a discharging end frame are fixedly provided. Support frames are fixedly connected to the side walls of adjacent ends of the feeding end frame and the discharging end frame, and an equipment frame is fixedly installed at the top of the support frame.

[0010] A hydraulic cutting tool is fixedly installed on the inner top of the equipment frame. The hydraulic cutting tool is used to perform cutting operations on the energy storage wire harness. Torsion components are respectively arranged on both sides of the equipment frame. The torsion components are used to perform torsion processing on both sides of the cut of the energy storage wire harness.

[0011] Furthermore, a rail support frame is fixedly connected to the top of the base and to both sides of the equipment frame, and a ring track is fixedly connected to the top of each rail support frame, and the cross-section of the ring track is T-shaped.

[0012] Furthermore, the torsion assembly includes two circular clamps, and the outer peripheral wall of each circular clamp is provided with multiple sets of mounting holes in a ring array with its center as the center. A first electric push rod is fixedly installed in each set of mounting holes, and the output end of the first electric push rod is fixedly connected to an arc-shaped buckle plate for clamping the outer side of the energy storage harness.

[0013] Furthermore, a sector-shaped connecting plate is fixedly connected to one side of the circular clamp by spot welding, and an arc-shaped conical tooth plate and an arc-shaped slide bar adapted to slide on the annular track are fixedly connected to the two side walls of the sector-shaped connecting plate, respectively.

[0014] Furthermore, a cutting table is fixedly connected to the top of the base and directly below the equipment frame. A bevel gear drive wheel that meshes with the arc-shaped bevel gear plate is provided at the top of the base and directly below the cutting table. A rotating shaft is fixedly connected to the bottom end of the bevel gear drive wheel, and the bottom end of the rotating shaft is rotatably connected to the top of the base. A swing sleeve is fixedly connected to the outer side of the rotating shaft.

[0015] Furthermore, a second electric push rod is fixedly installed on the top of the base, and a fixed block is fixedly connected to the output end of the second electric push rod. A sliding groove for guiding the fixed block is opened through the outer wall of the swing sleeve.

[0016] Furthermore, the top of the feed end frame and the discharge end frame are respectively fixedly installed with a feed track and a discharge track. The top and bottom of the feed end frame are respectively fixedly installed with a first bearing frame and a second bearing frame. Both ends of the first bearing frame are movably connected to two guide rollers through bearings.

[0017] Furthermore, the feeding track and the top of the feeding end frame are both provided with cutting grooves, and the inner walls of the first and second bearing frames are both fixedly connected with lifting push rods, and the output end of the lifting push rods is fixedly connected with a splitting tool.

[0018] Furthermore, multiple mounting slots are provided on one side of the top of both the feeding track and the discharging track. A first arc-shaped clamping plate is slidably arranged in each of the two mounting slots of the feeding track, and a second arc-shaped clamping plate is slidably arranged in each of the two mounting slots of the discharging track.

[0019] A third electric push rod is fixedly connected to the outer side of both the feeding track and the discharging track, and the output end of the third electric push rod is fixedly connected to the corresponding first arc-shaped clamping plate and second arc-shaped clamping plate.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] 1. Before cutting, the equipment uses a bevel gear drive wheel and an arc-shaped bevel gear plate to drive the stripped wire harness on both sides of the cutting position to rotate synchronously in the opposite direction at a small angle, making the internal wires of the wire harness tightly attached and neatly arranged. This twisting state allows the wire harness to form a "tightly aggregated" structure at the cut point. When the hydraulic cutting blade descends to cut, it can effectively avoid problems such as burrs on the cut, wire misalignment, or individual wires not being cut due to loose wires, ensuring a smooth cut and consistent cross-section. At the same time, the slight tension generated by the twisting allows the wire harness to be evenly stressed at the moment of cutting, reducing local compression deformation during cutting, ensuring the structural integrity of both ends of the wire harness after cutting, and avoiding wire splitting and sheath curling that are prone to occur in traditional non-twist cutting. This lays a good foundation for subsequent terminal crimping, welding, and other processes during wire harness assembly, reducing assembly failures caused by cut quality problems.

[0022] 2. During the synchronous reverse twisting process, the arc-shaped slider guides and limits the movement within the circular track, ensuring not only stable twisting action without deviation but also maintaining precise cutting position of the wire harness before cutting, preventing cutting position deviation caused by twisting offset. Simultaneously, the tight wire harness structure after twisting reduces the dispersed resistance experienced by the cutting tool, lowering tool wear rate, extending tool life, and minimizing production interruptions caused by frequent tool changes. This collaborative design of "twist-assisted cutting" ensures highly consistent cutting quality for each wire harness, avoiding individual differences when manually adjusted or without assisted cutting, significantly reducing scrap rate, and improving the stability of continuous processing. It perfectly meets the dual requirements of high efficiency and high quality for mass production of energy storage wire harnesses. Attached Figure Description

[0023] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings;

[0024] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0025] Figure 2 This is a schematic diagram of the ring track structure in this invention;

[0026] Figure 3 This is a schematic diagram of the circular clamp structure in this invention;

[0027] Figure 4 This is a schematic diagram of the arc-shaped slider structure in this invention;

[0028] Figure 5 This is a schematic diagram of the cutting table structure in this invention;

[0029] Figure 6 This is a schematic diagram of the breaking tool structure in this invention;

[0030] Figure 7 This is a schematic diagram of the guide roller structure in this invention;

[0031] Figure 8 This is a schematic diagram of the feeding track structure in this invention;

[0032] Figure 9 This is a schematic diagram of the first arc surface clamping plate structure in this invention;

[0033] Reference numerals: 1. Base; 201. Feeding end frame; 202. Discharge end frame; 3. Equipment frame; 4. Circular track; 501. Circular clamp; 502. First electric push rod; 503. Arc-shaped buckle plate; 504. Fan-shaped connecting plate; 505. Arc-shaped conical tooth plate; 506. Arc-shaped slide bar; 507. Conical tooth drive wheel; 508. Swing sleeve; 509. Second electric push rod; 6. Cutting table; 601. Feeding track; 602. Discharge track; 701. First bearing frame; 702. Second bearing frame; 8. Lifting push rod; 9. Breaking cutter; 10. First arc-shaped face clamping plate; 11. Second arc-shaped face clamping plate; 12. Guide roller. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] Example 1: As Figure 1 , Figure 2 Figures 6-9As shown, an automated integrated cutting and forming machine for energy storage harnesses includes a base 1, on the top of which a feeding end frame 201 and a discharging end frame 202 are fixedly provided. Support frames are fixedly connected to the adjacent side walls of the feeding end frame 201 and the discharging end frame 202, and an equipment frame 3 is fixedly installed on the top of the corresponding support frame.

[0036] Feeding track 601 and discharging track 602 are fixedly installed on the top of the feeding end frame 201 and the discharging end frame 202, respectively. A first bearing frame 701 and a second bearing frame 702 are fixedly installed on the top and bottom of the feeding end frame 201, respectively. Two guide rollers 12 are movably connected to both ends of the first bearing frame 701 through bearings. Cutting grooves are opened through the feeding track 601 and the top of the feeding end frame 201. Lifting push rods 8 are fixedly connected to the inner walls of the first bearing frame 701 and the second bearing frame 702. A splitting tool 9 is fixedly connected to the output end of the lifting push rod 8.

[0037] Multiple mounting slots are provided on one side of the top of the feeding track 601 and the discharging track 602. A first arc-shaped clamping plate 10 is slidably arranged in the two mounting slots of the feeding track 601, and a second arc-shaped clamping plate 11 is slidably arranged in the two mounting slots of the discharging track 602.

[0038] A third electric push rod is fixedly connected to the outer side of both the feeding track 601 and the discharging track 602, and the output end of the third electric push rod is fixedly connected to the corresponding first arc-shaped clamping plate 10 and second arc-shaped clamping plate 11.

[0039] One end of the energy storage harness is placed into the feeding track 601, and the harness is pushed so that one end passes through the torsion assembly and finally extends into the discharge track 602, completing the initial laying of the energy storage harness within the equipment. This stage, through the cooperation of the feeding track 601 and the discharge track 602, achieves precise guidance of the energy storage harness, avoiding misalignment in subsequent processing due to positioning deviations during manual feeding. This lays the foundation for fully automated processing and effectively reduces the time cost and error risk of manual positioning.

[0040] After the wire harness is initially positioned, the first support frame 701 and the second support frame 702 on the feed end frame 201 simultaneously start their respective lifting push rods 8, and the lifting push rods 8 drive the cutting tool 9 to move towards the energy storage wire harness. In this process, the splitting cutter 9 on the second support frame 702 passes through the cutting grooves opened between the feed end frame 201 and the feed track 601, and acts on the bottom of the energy storage harness. At the same time, the splitting cutter 9 on the first support frame 701 acts on the top of the energy storage harness. The two sets of splitting cutters 9 simultaneously split the upper and lower parts of the energy storage harness. The split outer surface layer of the energy storage harness will pass through the gap between the guide rollers 12 at both ends of the first support frame 701. It should be noted that an electric winding roller (not shown in the figure) is installed at the top of the feed end frame 201 near the guide roller 12. At this time, the electric winding roller at the top of the feed end frame 201 near the guide roller 12 is activated to synchronously wind and recycle the split outer surface layer, and finally make the stripped energy storage harness move towards the discharge track 602.

[0041] This stage employs a combined design of "synchronous breaking from top to bottom, material guiding assistance, and automatic winding and recycling." On the one hand, it avoids problems such as skin residue and scratches on the energy storage harness body that are prone to occur during manual peeling, ensuring the stability of peeling quality. On the other hand, the cooperation between the material guiding roller 12 and the electric winding roller enables timely cleaning of the outer surface layer, eliminating the need for subsequent manual processing of waste skin, reducing process connection time, and significantly improving the processing efficiency of the peeling process.

[0042] When the stripped energy storage harness moves to the preset processing length within the discharge track 602, the third electric push rod on the outer side of the feed track 601 drives the first arc face to move closer to the clamping plate 10, clamping the unstripped harness segment. Simultaneously, the third electric push rod on the outer side of the discharge track 602 drives the second arc face to move synchronously to the clamping plate 11, clamping the stripped energy storage harness segment. At the same time, the first electric push rod 502 in the torsion assembly pushes the arc-shaped buckle plate 503, clamping the stripped harness portion from multiple directions along the outer wall of the energy storage harness. This stage employs a "segmented clamping + targeted fixing" method, which firmly fixes the harness position, prevents the energy storage harness from shifting during subsequent torsion and cutting, ensures the structural integrity of the processed energy storage harness, and significantly reduces the scrap rate caused by improper clamping.

[0043] Example 2: Figures 1-5 As shown, a hydraulic cutting tool is fixedly installed on the top inner side of the equipment frame 3. The hydraulic cutting tool is used to perform cutting operations on the energy storage wire harness. Torsion components are respectively arranged on both sides of the equipment frame 3. The torsion components are used to perform torsion processing on both sides of the cut of the energy storage wire harness.

[0044] The base 1 is fixedly connected to the top of the equipment frame 3 on both sides, and the top of the support rail is fixedly connected to the ring rail 4, and the cross-section of the ring rail 4 is T-shaped.

[0045] The torsion assembly includes two circular clamps 501. The outer peripheral wall of each circular clamp 501 has multiple sets of mounting holes arranged in a ring with its center as the center. A first electric push rod 502 is fixedly installed in each set of mounting holes. An arc-shaped buckle plate 503 for clamping the outer side of the energy storage harness is fixedly connected to the output end of the first electric push rod 502.

[0046] A fan-shaped connecting plate 504 is fixedly connected to one side of the circular clamp 501 by spot welding. Arc-shaped conical tooth plates 505 and arc-shaped slide bars 506 adapted to slide on the annular track 4 are fixedly connected to the two side walls of the fan-shaped connecting plate 504, respectively. A cutting table 6 is fixedly connected to the top of the base 1 and directly below the equipment frame 3. A bevel tooth drive wheel 507 that meshes with the arc-shaped conical tooth plate 505 is set at the top of the base 1 and directly below the cutting table 6. A rotating shaft is fixedly connected to the bottom end of the bevel tooth drive wheel 507, and the bottom end of the rotating shaft is rotatably connected to the top of the base 1. A swing sleeve 508 is fixedly connected to the outside of the rotating shaft. A second electric push rod 509 is fixedly installed on the top of the base 1. A fixed block is fixedly connected to the output end of the second electric push rod 509. A groove for guiding the fixed block is opened through the outer side wall of the swing sleeve 508.

[0047] After the energy storage harness is clamped and fixed, the second electric push rod 509 on the base 1 is activated, and the fixed block at its output end slides in the groove of the swing sleeve 508, driving the swing sleeve 508 and the rotating shaft fixed thereto to rotate; the bevel gear drive wheel 507 at the top of the rotating shaft rotates synchronously with the rotating shaft. Because the bevel gear drive wheel 507 meshes with the two arc-shaped bevel gear plates 505 of the torsion component, it drives the two arc-shaped bevel gear plates 505 to rotate synchronously in opposite directions.

[0048] The arc-shaped bevel plate 505 drives the sector-shaped connecting plate 504 to rotate. At this time, the arc-shaped slide bars 506 on both sides of the sector-shaped connecting plate 504 slide within the annular track 4, providing guidance and limiting for the rotation of the sector-shaped connecting plate 504, ensuring stability and preventing disengagement during the rotation process. The sector-shaped connecting plate 504 drives the corresponding circular clamp 501 to rotate. The circular clamp 501 drives the stripped energy storage harness on both sides of the cutting position to perform a small-angle synchronous reverse twist through the arc-shaped buckle plate 503. This twisting design achieves "synchronous reverse" action through bevel gear meshing transmission, making the wires on both sides of the energy storage harness tightly attached, improving the structural stability of the energy storage harness. At the same time, the cooperation between the annular track 4 and the arc-shaped slide bars 506 prevents the components from disengaging during twisting, ensuring the consistency of the twisting action, preventing harness deformation caused by unilateral twisting, and further improving the processing quality.

[0049] After the twisting operation is completed, the hydraulic cutting tool on the top inner side of the equipment frame 3 moves downward to precisely cut the twisted wire harness at the cutting position. After cutting, the equipment releases all clamps in sequence: the first electric push rod 502 drives the arc-shaped buckle plate 503 to reset and loosen, and the third electric push rod drives the first arc-shaped clamp plate 10 and the second arc-shaped clamp plate 11 to return to their initial positions, completing a single wire harness processing flow. The high-pressure cutting of the hydraulic cutting tool in this stage ensures that the wire harness cut is flat and burr-free, avoiding problems such as skewed cuts and rough edges that occur during manual cutting. The "cut first, then release clamp" sequence design prevents wire harness displacement during cutting from causing cut deviations. At the same time, the orderly reset of the release action prepares for the next processing, achieving seamless connection of processes without manual intervention, further improving the automation efficiency of the entire process and adapting to the needs of batch continuous production.

[0050] Combining Embodiments 1 and 2: This automated integrated cutting and forming machine for energy storage harnesses integrates feeding, peeling, clamping, twisting, cutting, and loosening into a fully automated process. This not only significantly shortens the processing cycle for a single harness and adapts to mass production to improve efficiency, but also ensures processing quality at multiple stages. In the peeling stage, the synchronous splitting cutter 9 and electric winding roller achieve residue-free peeling. In the clamping stage, segmented arc-shaped clamping prevents damage to the energy storage harness. In the twisting stage, bevel gear transmission and track guidance ensure stable synchronous reverse twisting. In the cutting stage, hydraulic cutters achieve clean cuts, effectively reducing the scrap rate. Simultaneously, synchronous reverse twisting optimizes the harness structure's tightness to meet the needs of energy storage scenarios. Stable transmission of each component reduces equipment failure and maintenance costs, and no secondary processing is required after processing, further reducing labor and material costs, achieving multiple optimizations in efficiency, quality, and cost.

[0051] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to any specific implementation. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. An automated integrated cutting and forming machine for energy storage wire harnesses, comprising a base (1), the top of which is fixedly provided with an infeed end frame (201) and an outlet end frame (202), characterized in that, The adjacent side walls of the feed end frame (201) and the discharge end frame (202) are both fixedly connected to support frames, and the top of the support frame is fixedly installed with an equipment frame (3). A hydraulic cutting tool is fixedly installed on the top inner side of the equipment frame (3). The hydraulic cutting tool is used to perform cutting operations on the energy storage wire harness. Torsion components are respectively arranged on both sides of the equipment frame (3). The torsion components are used to perform torsion processing on both sides of the cut of the energy storage wire harness after cutting.

2. The automated integrated cutting and forming machine for energy storage harnesses according to claim 1, characterized in that, The base (1) is fixedly connected to the top and to both sides of the equipment frame (3) respectively. The top of each rail bracket is fixedly connected to a ring track (4), and the cross-section of the ring track (4) is T-shaped.

3. The automated integrated cutting and forming machine for energy storage harnesses according to claim 1, characterized in that, The torsion assembly includes two circular clamps (501). The outer peripheral wall of each circular clamp (501) has multiple sets of mounting holes arranged in a ring with its center as the center. A first electric push rod (502) is fixedly installed in each set of mounting holes. The output end of the first electric push rod (502) is fixedly connected to an arc-shaped buckle plate (503) for clamping the outer side of the energy storage harness.

4. The automated integrated cutting and forming machine for energy storage wire harnesses according to claim 3, characterized in that, One side of the circular clamp (501) is fixedly connected to a fan-shaped connecting plate (504) by spot welding. The two side walls of the fan-shaped connecting plate (504) are respectively fixedly connected to an arc-shaped conical tooth plate (505) and an arc-shaped slide bar (506) adapted to slide on the annular track (4).

5. The automated integrated cutting and forming machine for energy storage harnesses according to claim 1, characterized in that, A cutting table (6) is fixedly connected to the top of the base (1) and directly below the equipment frame (3). A bevel gear drive wheel (507) that meshes with the arc-shaped bevel gear plate (505) is provided at the top of the base (1) and directly below the cutting table (6). A rotating shaft is fixedly connected to the bottom end of the bevel gear drive wheel (507), and the bottom end of the rotating shaft is rotatably connected to the top of the base (1). A swing sleeve (508) is fixedly connected to the outside of the rotating shaft.

6. The automated integrated cutting and forming machine for energy storage harnesses according to claim 5, characterized in that, The base (1) is fixedly mounted with a second electric push rod (509) on its top. The output end of the second electric push rod (509) is fixedly connected to a fixed block. The outer side wall of the swing sleeve (508) is provided with a sliding groove for guiding the fixed block to slide.

7. The automated integrated cutting and forming machine for energy storage harnesses according to claim 1, characterized in that, The top of the feed end frame (201) and the discharge end frame (202) are respectively fixedly installed with a feed track (601) and a discharge track (602). The top and bottom of the feed end frame (201) are respectively fixedly installed with a first bearing frame (701) and a second bearing frame (702). Both ends of the first bearing frame (701) are movably connected to two guide rollers (12) through bearings.

8. The automated integrated cutting and forming machine for energy storage wire harnesses according to claim 7, characterized in that, Cutting grooves are provided through the top of the feeding track (601) and the feeding end frame (201). Lifting push rods (8) are fixedly connected to the inner walls of the first bearing frame (701) and the second bearing frame (702). A splitting tool (9) is fixedly connected to the output end of the lifting push rod (8).

9. The automated integrated cutting and forming machine for energy storage wire harnesses according to claim 7, characterized in that, Multiple mounting slots are provided on one side of the top of the feeding track (601) and the discharging track (602). A first arc-shaped clamping plate (10) is slidably arranged in the two mounting slots of the feeding track (601), and a second arc-shaped clamping plate (11) is slidably arranged in the two mounting slots of the discharging track (602). The outer sides of the feeding track (601) and the discharging track (602) are both fixedly connected with a third electric push rod, and the output end of the third electric push rod is fixedly connected to the corresponding first arc-shaped clamping plate (10) and second arc-shaped clamping plate (11).

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