Manufacturing process of relay binding post

Abstract

The invention discloses a manufacturing process of a relay binding post, which comprises the following steps of: cold heading forming: carrying out plastic deformation on a metal wire or bar through a cold heading machine to manufacture a preformed part with a basic shape of the relay binding post; performing numerical control finish machining: transferring the preformed part to a numerical control machine tool, and cutting at least one part of the preformed part to form final size and precision requirements; cleaning is conducted, specifically, the workpiece obtained after finish machining is cleaned; detecting, namely detecting the quality of the cleaned workpiece; and packaging is conducted, specifically, the qualified workpieces are packaged. Multi-station continuous cold heading forming and numerical control finish machining are combined, the technical problems that in a traditional whole-process numerical control cutting technology, material waste is serious, production efficiency is low, manufacturing cost is high, and consistency of batch products is difficult to guarantee are effectively solved, and meanwhile the large-scale, low-cost and high-quality production requirements are met.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of relays, in particular to a manufacturing process of a relay terminal post. BACKGROUND

[0002] The relay terminal post is a key conductive component of a relay, and the manufacturing process thereof directly affects the electrical performance and reliability of the relay. In the traditional process, full-process numerical control cutting machining is adopted, which has high precision but has problems of great material waste, low production efficiency and high cost. Especially for precious metal materials such as copper, the low material utilization rate leads to a significant increase in production cost. In addition, the consistency of the traditional process is poor in batch production, and it is difficult to meet the demand of modern relays for high reliability and large batch production. SUMMARY

[0003] The application aims to provide a manufacturing process of a relay terminal post, and solve the technical problems of low material utilization rate and low production efficiency in the traditional cutting process.

[0004] To achieve the above-mentioned purpose, the application provides the following technical scheme: a manufacturing process of a relay terminal post, comprising the following steps: S1: cold upsetting forming, plastic deformation of a metal wire or rod by a cold upsetting machine to form a preformed part with a basic shape of the relay terminal post; S2: numerical control finishing, transferring the preformed part to a numerical control machine tool, and cutting machining at least one part of the preformed part to form the final size and precision requirements; S3: cleaning, cleaning the finished workpiece; S4: detection, quality detection of the cleaned workpiece; S5: packaging, packaging of the workpiece that passes the inspection; In step S1, the cold upsetting forming is a multi-station continuous cold upsetting forming, and the cold upsetting forming at least includes feeding, cutting and a plurality of continuous cold forging processes.

[0005] Preferably, the metal wire or rod is made of copper or copper alloy material, and is continuously fed by a roller assembly in the cold upsetting machine and cut into a cylindrical shape.

[0006] Preferably, the S1 includes a continuous cold forging process, which includes: Process one: the front end of the cut material is pressed into an inverted angle and a rounded corner connected to the inner end of the inverted angle, wherein the angle of the inverted angle is 135°, and the radius of the rounded corner is 2mm; Process two: the front end of the cut material is cold forged into a rounded corner with a radius of 2mm, and the cut material is inclined from front to rear to the middle, and the rear end of the cut material is punched into a counterbore with a depth of 1.2mm; Step three: cutting and forging into two sections, wherein the diameter of the rear section is larger than that of the front section, and the front section is forged into a cylindrical shape; Step four: both the front and rear sections are forged into a cylindrical shape, and a counterbore is continuously punched, with a depth of 3mm, and the outer end of the front section is chamfered with a radius of 3mm; Step five: the counterbore of the rear section is continuously punched, with a depth of 9.6mm, and at the same time, an annular groove is punched from the end close to the front section to the rear, with a diameter matching that of the front section, and a depth of 0.2mm, and the inner side of the annular groove is chamfered with a radius of 0.2mm; Step six: the annular groove of the front section is continuously punched, with a depth of 0.7mm, and the inner side of the annular groove is chamfered with a radius of 0.3mm, forming a preformed product.

[0007] Preferably, in step S2, the numerical control machine tool is a numerical control gang tool or a numerical control lathe, and the cutting machining includes at least one of machining threads, turning end faces, or cutting grooves.

[0008] Preferably, in step S1, the material utilization rate of the cold upsetting forming is not less than 90%.

[0009] Preferably, the material utilization rate is not less than 97%.

[0010] Preferably, the overall production efficiency of the process is improved by more than 10 times compared with the traditional process using full numerical control cutting machining.

[0011] Preferably, in step S4, the quality detection at least includes thread size detection and visual appearance detection.

[0012] Preferably, in step S3, the cleaning at least includes electroplating cleaning and negative pressure vacuum cleaning.

[0013] Compared with the prior art, the beneficial effects of the present application are as follows: The present application effectively solves the technical problems of serious material waste, low production efficiency, high manufacturing cost, and difficult to guarantee the consistency of batch products in the traditional full numerical control cutting process by combining multi-station continuous cold upsetting forming with numerical control finishing, while ensuring excellent mechanical strength, electrical conductivity, dimensional accuracy, and batch stability of the relay terminal post, especially suitable for large-scale, low-cost, and high-quality production of terminal posts made of precious metals such as copper or copper alloy. BRIEF DESCRIPTION OF DRAWINGS

[0014] Fig. 1 is the process flowchart of the present application; Fig. 2 is a side view of the relay terminal post of the present application. DETAILED DESCRIPTION

[0015] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0016] In the description of the present application, it should be understood that the terms "center", "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "horizontal", "vertical", "top", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation of the present application. In addition, the terms "first", "second" are only for the purpose of description, and cannot be understood as indicating or implying relative importance.

[0017] Please refer to Figs. 1-2 The present application provides an embodiment: a manufacturing process of a relay terminal, comprising the following steps: S1: First, the cold heading forming process is performed, and copper or copper alloy wire or rod material meeting the dielectric performance requirement is selected as the raw material, the diameter of which is selected according to the maximum diameter of the finished product terminal, and the material is automatically and continuously fed through the precision roller assembly built in the cold heading machine. In the cold heading machine, the continuous wire is first cut to a fixed length by the cutting mechanism to obtain a cylindrical initial cutting blank, and then the cutting blank is sequentially fed into multiple forming stations to continuously perform cold forging plastic deformation at room temperature, gradually forming the basic geometric characteristics of the terminal. This continuous forming process specifically includes six closely connected steps.

[0018] Further, the copper can be T2 red copper; and the copper alloy can be C5191 phosphor bronze.

[0019] In the first step, the mold exerts pressure on the front end of the blank, forming a 135° angle at the end of the blank, and a 2mm radius transition fillet on the inside of the angle, which helps with subsequent assembly and improves stress concentration. In the second step, the front end is further forged, strengthening and shaping the fillet (R2mm) at the end of the blank, while the blank as a whole is slightly compressed axially and adjusted in shape. More importantly, in this step, the rear end of the blank is counter-stamped, forming an initial counterbore 11 about 1.2mm deep, laying the foundation for subsequent deepening of the hole. In the third step, the forming force causes the middle of the blank to change significantly in diameter, and the blank is forged into a two-segment structure, with the rear segment larger in diameter than the front segment, and the front segment 12 material is stretched and initially formed into a cylindrical shape. In the fourth step, the outer shape of the front and rear segments is finished to make them regular cylindrical shapes, and the counterbore 11 is further stamped to a depth of 3mm. In addition, the outermost end of the front segment 12 is shaped into a 3mm radius arc end face in this step.

[0020] The fifth step focuses on the rear segment; on the one hand, the counterbore 11 of the rear segment 13 is deep-drawn to a final depth of 9.6mm to meet the electrical connection depth requirement; on the other hand, a ring-shaped shallow groove is stamped in the area adjacent to the rear segment 13 and the front segment 12 by the mold; the diameter of the ring-shaped groove 14 is designed to match the diameter of the front segment, with a depth of 0.2mm, and the inner side edges of the groove are pressed into a small radius of 0.2mm, which may be used for assembly positioning or sealing ring accommodation; the last sixth step also stamps a ring-shaped groove 14 in the corresponding position of the front segment 12, with a depth of 0.7mm and an inner fillet radius of 0.3mm, which is usually used as a clamping slot or identification slot when wiring; after these six consecutive cold heading steps, a preform with most of the features of the terminal post, close to the finished product in size, and dense material organization is completed, as shown in Fig. 2 The material loss during the entire cold heading process is very small, and the actual material utilization rate can be as high as 97%.

[0021] S2: After the cold heading preforming is completed, the workpiece is transferred to a numerical control machining unit. Since the preformed part has a main body shape, numerical control machining only needs to finish the key functional parts. Usually, a numerical control gang tool machine or a numerical control lathe is selected. After the workpiece is clamped by a precision clamp, the machine tool performs cutting machining on the parts that need precise fitting on the preformed part according to a preset program. The most common machining contents include: turning precise threads on the outer cylindrical surface of the front section or the rear section for fastening connection of the relay; finish turning the end face to ensure the length size and the flatness of the end face; or finishing the preformed annular groove to achieve the precise width and depth tolerance. This step greatly plays the advantages of high precision and high flexibility of numerical control machining, but the machining allowance is small, and the time consumption is extremely short, thereby ensuring the high efficiency of the overall process.

[0022] Further, the thread machined by cutting can be a metric thread such as M3, M4, etc.

[0023] S3: After numerical control finishing, the workpiece surface is attached with cutting fluid and fine metal chips, and needs to be cleaned. The cleaning process usually adopts a combined mode to ensure cleanliness. First, electroplating cleaning is performed. The cavitation effect of ultrasonic waves penetrates into the fine structure of the workpiece, and oil stains and impurities are stripped. Then, negative pressure vacuum cleaning is performed. Surface residues are further removed by vacuum adsorption, and a clean surface is provided for possible subsequent electroplating or surface treatment.

[0024] S4: The cleaned workpiece enters the detection link. The detection includes at least two aspects: one is thread size detection. The machined thread is quickly inspected using a thread go-no-go gauge to ensure that the go end can be smoothly screwed in and the stop end cannot be screwed in, so as to control the pitch diameter tolerance of the thread. The other is visual appearance detection. Artificial visual inspection or automatic visual equipment is used to check whether the workpiece surface has defects such as cracks, bruises, rust, burrs, etc., and whether each shaped feature is complete. Only if all the detection items are passed can the product be judged as a qualified product.

[0025] S5: Finally, the qualified relay terminal workpiece is packaged according to customer requirements or internal standards. The packaging usually adopts anti-static bags, plastic trays or reels, etc., and is attached with product identification, so as to facilitate storage, transportation and subsequent use, and complete the entire manufacturing process.

[0026] It is apparent for those skilled in the art that the present application is not limited to the details of the above exemplary embodiments, but can be implemented in other concrete forms without departing from the spirit or essential characteristics of the present application. Therefore, the embodiments should be considered as exemplary and non-limiting, and the scope of the present application is defined by the appended claims rather than the above description, and all changes falling within the meaning and range of equivalent elements of the claims are intended to be embraced in the present application. Any reference signs in the claims should not be considered as limiting the claims involved.

Claims

1. A manufacturing process for a relay terminal block, characterized in that, Includes the following steps: S1: Cold heading, which involves plastically deforming metal wires or bars using a cold heading machine to produce preforms with the basic shape of relay terminals; S2: CNC finishing, transferring the preform to a CNC machine tool, and machining at least one part of the preform to achieve the final dimensions and accuracy requirements; S3: Cleaning, cleaning the workpiece after finishing; S4: Inspection, performing quality inspection on the cleaned workpiece; S5: Packaging, packaging the inspected and qualified workpieces; In step S1, the cold heading is a multi-station continuous cold heading process, which includes at least feeding, cutting and multiple continuous cold forging processes.

2. The manufacturing process of the relay terminal according to claim 1, characterized in that, The metal wire or rod is made of copper or copper alloy and is continuously fed through a roller assembly in a cold heading machine and cut into cylindrical pieces.

3. The manufacturing process of the relay terminal according to any one of claims 1 or 2, characterized in that, S1 includes a continuous cold forging process, including: Step 1: Press the front end of the cut material into a chamfer and a rounded corner connecting the inner end of the chamfer. The chamfer angle is 135° and the radius of the rounded corner is 2mm. Step 2: The front end of the cutting material is cold-forged into a rounded corner with a radius of 2mm, and the cutting is inclined from front to back towards the middle. The rear end of the cutting material is punched into a countersunk hole with a depth of 1.2mm. Step 3: Cut and forge the material into two sections, with the diameter of the latter section being larger than that of the former section, and the former section being forged and stretched into a cylindrical shape; Step 4: Both the front and rear sections are forged into cylindrical shapes and continuously punched with countersunk holes. The countersunk hole depth is 3mm, and the outer end of the front section has a rounded corner with a radius of 3mm. Step 5: Continuously stamp the countersunk hole of the rear section, with a countersunk hole depth of 9.6mm. At the same time, the rear section is stamped with an annular groove from the end closest to the front section to the rear. The diameter of the annular groove is matched with the diameter of the front section, and the depth of the annular groove is 0.2mm. The inner side of the annular groove is rounded and forged with a radius of 0.2mm. Step 6: Continuously press the annular groove at the front end to a depth of 0.7mm, and forge the inner side of the annular groove with a rounded corner radius of 0.3mm to form a pre-formed product.

4. The manufacturing process of the relay terminal according to claim 1, characterized in that, In step S2, the CNC machine tool is a CNC gantry milling machine or a CNC lathe, and the cutting process includes at least one of machining threads, turning end faces, or cutting grooves.

5. The manufacturing process of the relay terminal according to claim 1, characterized in that, In step S1, the material utilization rate of the cold heading process is not less than 90%.

6. The manufacturing process of the relay terminal according to claim 5, characterized in that, The material utilization rate is no less than 97%.

7. The manufacturing process of the relay terminal according to claim 1, characterized in that, The overall production efficiency of this process is more than 10 times higher than that of the traditional process using full CNC cutting.

8. The manufacturing process of the relay terminal according to claim 1, characterized in that, In step S4, the quality inspection includes at least thread size inspection and visual inspection of appearance.

9. The manufacturing process of the relay terminal according to claim 1, characterized in that, In step S3, the cleaning process includes at least electroplating cleaning and negative pressure vacuum cleaning.

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