Automatic equipment applied to twist needle welding and operation method

Abstract

The invention discloses automatic equipment applied to twist needle welding and an operation method. The equipment comprises a rack, a wire drawing mechanism, a wire cutting mechanism and a displacement welding device. The wire drawing mechanism drags and straightens the wire; the wire cutting mechanism performs laser cutting on the wire; the displacement welding device comprises a linear displacement mechanism, a first turntable displacement mechanism, a second turntable displacement mechanism, a welding wire positioning mechanism and two laser welders. The linear displacement mechanism is responsible for transferring wires among the stations, the double-rotating-disc displacement mechanism synchronously transfers the wires, the welding wire positioning mechanism is used for centralizing and positioning the wires, and the laser welding device is used for welding the two ends of the wires respectively. The full-process automation of the twist needle from paying off, straightening, fixed-length cutting to double-end welding is achieved, a large amount of manual labor is saved, and the twist needle automatic welding machine has the advantages of being high in production efficiency, good in welding precision and high in automation degree.

Description

Technical Field

[0001] This invention relates to the field of connector manufacturing equipment, and in particular to an automated device and operating method for twisted pin soldering. Background Technology

[0002] In the connector manufacturing industry, twisted pins, as a critical conductive connecting element, directly determine the performance and reliability of the final product through their soldering quality. Traditional twisted pin manufacturing processes typically face a series of severe challenges. First, the production process is highly dependent on manual labor or semi-automated equipment, with processes operating in isolation—wire straightening, quantitative cutting, manual transfer, individual positioning, and the final soldering operation are often performed by different equipment or workstations. This model not only results in slow production cycles and low efficiency, making it difficult to meet the demands of large-scale orders, but also introduces numerous uncertainties due to frequent manual intervention, leading to poor product consistency and a persistently high defect rate.

[0003] Secondly, due to the inherent internal stress in the wire, traditional simple guide wheels cannot completely eliminate its bending deformation. This leads to positional misalignment during subsequent cutting and transfer, resulting in inaccurate alignment during welding and severely affecting the mechanical strength and electrical conductivity of the weld joint. Although some automation attempts have been made, most equipment is single-function, with poor coordination between modules and insufficient precision in the transfer and positioning mechanisms, making high-precision end welding impossible. Furthermore, existing technologies lack effective mechanisms for cleaning debris generated during production, which may contaminate the workpiece and affect weld quality.

[0004] Therefore, the industry has long needed a fully automated device that integrates wire processing, precise positioning, efficient double-end welding, and quality monitoring to overcome production capacity bottlenecks, improve quality standards, and reduce overall costs. This invention is an improved design specifically addressing the aforementioned long-standing technical challenges. Summary of the Invention

[0005] In view of this, the present invention addresses the shortcomings of existing technologies, and its main objective is to provide an automated equipment and operating method for twist needle welding, thereby solving problems such as reliance on manual operation, low efficiency, difficulty in guaranteeing welding accuracy, and unresolved wire stress affecting welding quality in traditional twist needle welding processes. By integrating wire pulling, wire cutting, dual-rotor synchronous shifting welding, and precise positioning into an automated system, continuous, efficient, and high-precision welding of twist needles from wire to finished product is achieved, significantly improving production efficiency and product quality.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: An automated device for twisted wire welding includes a frame, a wire pulling mechanism mounted on the frame for pulling the wire, a wire cutting mechanism for cutting the wire, and a shifting welding device for transferring the wire and welding both ends of the wire. The wire pulling mechanism, the wire cutting mechanism, and the shifting welding device are connected sequentially along the wire's movement direction. The shifting welding device includes a linear shifting mechanism with multiple moving wire clamping cylinders, a first turntable shifting mechanism for shifting the wire, a first laser welder for welding one end of the wire, and a device for welding the wire. The system includes a second turntable shifting mechanism, a wire positioning mechanism for clamping and positioning the wire, and a second laser welder for welding the other end of the wire. The linear shifting mechanism is arranged along the wire movement direction. The first turntable shifting mechanism and the second turntable shifting mechanism are sequentially arranged beside the linear shifting mechanism along the wire movement direction. The wire positioning mechanism is arranged between the first turntable shifting mechanism and the second turntable shifting mechanism. The first laser welder and the second laser welder are located above the wire positioning mechanism and correspond to the wire clamping position of the wire positioning mechanism.

[0007] As a preferred embodiment: the first turntable shifting mechanism and the second turntable shifting mechanism each include a shifting bracket, a rotary drive motor, a turntable, multiple wire clamping assemblies for clamping wires, and an opening clamping assembly that sequentially opens the clamps for each wire clamping assembly. The rotary drive motor is mounted on the shifting bracket, the turntable is mounted on the shaft end of the rotary drive motor, and the multiple wire clamping assemblies are spaced apart on the turntable. The shifting bracket has a welding station, a cleaning station, and multiple material transfer stations. An opening clamping assembly is respectively provided on the shifting bracket corresponding to the cleaning station and the multiple material transfer stations. As the turntable rotates, the multiple wire clamping assemblies sequentially correspond to the opening clamping assemblies at the corresponding stations, and the opening clamping assemblies cooperate with the wire clamping assemblies to perform opening and clamping operations.

[0008] As a preferred embodiment: the wire clamping assembly includes an upper wire clamping plate, a lower wire clamping plate, an upper roller, a lower roller, a first tension spring, and a second tension spring. The upper and lower wire clamping plates are opposite to each other and are slidably mounted on the turntable. The upper roller is mounted on the upper wire clamping plate, and the lower roller is mounted on the lower wire clamping plate, with the upper and lower rollers facing each other. The first tension spring connects the upper wire clamping plate and the turntable, and the second tension spring connects the lower wire clamping plate and the turntable. The upper and lower wire clamping plates remain closed under the action of the first and second tension springs.

[0009] As a preferred embodiment: the clamping assembly includes a clamping cylinder and a wedge-shaped clamping head mounted on the shaft end of the clamping cylinder; a shuttle hole is provided on the turntable corresponding to the upper roller and the lower roller, and the wedge-shaped clamping head moves back and forth in the shuttle hole under the drive of the clamping cylinder to roll and contact the upper roller and the lower roller, so that the upper clamping plate and the lower clamping plate separate or close with each other.

[0010] As a preferred embodiment: the upper clamping plate has an upper clamping head installed at its front end, and the lower clamping plate has a lower clamping head installed at its front end. The upper clamping head is provided with a V-shaped groove for clamping the wire and a guide groove for precisely engaging the upper and lower clamping heads. The V-shaped groove is located in the middle of the upper clamping head, and the guide groove is located on both sides of the upper clamping head. The lower clamping head is provided with a V-shaped block and a guide block. The V-shaped block is located in the middle of the lower clamping head, and a notch for accommodating the wire is provided at the top of the V-shaped block. The guide blocks are located on both sides of the lower clamping head. The V-shaped block can be detachably engaged with the V-shaped groove, and the guide block can be detachably engaged with the guide groove.

[0011] As a preferred embodiment: the bottom of the displacement bracket is provided with a cleaning component for blowing away wire debris from the wire clamping assembly. The cleaning component includes an air pump and an air blowing pipe, the air blowing pipe being connected to the air pump and facing the wire clamping end of the wire clamping assembly.

[0012] As a preferred embodiment, the turntable is equipped with four wire clamping assemblies, which are distributed at 90-degree intervals from each other.

[0013] As a preferred embodiment: the wire bonding positioning mechanism includes a positioning bracket, a first positioning component for positioning the wire on the first turntable shifting mechanism, and a second positioning component for positioning the wire on the second turntable shifting mechanism. The positioning bracket is installed between the first turntable shifting mechanism and the second turntable shifting mechanism. The first positioning component and the second positioning component are disposed back-to-back on the positioning bracket. The first positioning component and the second positioning component each include a positioning drive cylinder and a wire clamping positioning unit connected to the shaft end of the positioning drive cylinder. The positioning drive cylinder is installed on the positioning bracket. On the bracket, the wire clamping positioning unit includes a drive plate that can be slidably mounted on the positioning bracket, a left wire clamping block and a right wire clamping block that can be slidably mounted on the positioning bracket, and a return spring that drives the left and right wire clamping blocks to close together; the drive plate is connected to the shaft end of the positioning drive cylinder, and its front end is provided with a trapezoidal groove. The left and right wire clamping blocks are respectively provided with drive rollers, which are opposite to each other and make rolling contact with the inner walls on both sides of the trapezoidal groove. As the drive plate slides forward, the left and right wire clamping blocks close together.

[0014] As a preferred embodiment: the linear shifting mechanism includes a shifting drive assembly, a transverse sliding plate, three moving wire clamping cylinders, and a feeding and collecting assembly. The transverse sliding plate is slidably mounted on the frame. The shifting drive assembly is mounted on the frame, and its output end is connected to the transverse sliding plate. The three moving wire clamping cylinders are spaced apart from left to right on the transverse sliding plate. The feeding and collecting assembly includes a feeding trough and a collecting bin. The feeding trough is located next to the right-side moving wire clamping cylinder and is inclinedly connected to the collecting bin.

[0015] An operating method for the automated equipment includes the following steps: S1. The wire is pulled into the wire cutting mechanism by the wire pulling mechanism, and the wire cutting mechanism cuts the wire. S2. The left-side moving clamping cylinder of the linear shifting mechanism clamps the cut wire and transfers it to the clamping assembly of the first turntable shifting mechanism. S3. The turntable of the first turntable shifting mechanism rotates, transferring the clamped wire to the wire welding positioning mechanism; the wire welding positioning mechanism straightens and positions the wire, and the first laser welder welds one end of the wire; the wire after welding one end is clamped by the middle moving clamping cylinder of the linear shifting mechanism and transferred to the clamping assembly of the second turntable shifting mechanism. S4. The turntable of the second turntable shifting mechanism rotates, transferring the wire to the wire welding positioning mechanism; the wire welding positioning mechanism once again straightens and positions the wire, and the second laser welder welds the other end of the wire. S5. After welding, the wire is clamped by the right-side moving clamping cylinder of the linear shifting mechanism, transferred to the unloading trough and slid into the storage bin; wherein, the first turntable shifting mechanism and the second turntable shifting mechanism operate synchronously to realize the continuous transfer and welding of the wire.

[0016] Compared with the prior art, the present invention has obvious advantages and beneficial effects. Specifically, as can be seen from the above technical solution: First, by integrating the functions of wire drawing, wire cutting, shifting, welding and blanking into one, the entire process of twisted needle production from wire to finished product is automated, completely eliminating the dependence on manual operation and greatly improving production efficiency and cycle continuity.

[0017] Secondly, the dual-turntable synchronous shifting welding mechanism allows for parallel processing of welding operations at both ends of the wire. Combined with the coordinated transmission of the linear shifting mechanism, this forms a highly efficient serial workflow, significantly increasing equipment capacity. Regarding welding quality, the equipment effectively eliminates bending stress in the wire through a uniquely designed tensioning wire pulling mechanism. Furthermore, the precision mechanical structure of the welding wire positioning mechanism straightens and positions the wire, ensuring absolute accuracy of the focal point during laser welding. This significantly improves welding precision and product consistency.

[0018] Furthermore, the equipment boasts excellent adaptability and reliability. The detachable wire clamp design facilitates replacement to accommodate different wire diameters, the cleaning component automatically removes debris to prevent contamination, and the real-time quality monitoring by the CCD system collectively ensures stable production processes and a high product yield. Overall, this invention not only solves the pain points of low efficiency and poor precision in traditional production methods, but its compact, coordinated, and intelligent design also provides an efficient and reliable automated solution for the connector manufacturing industry.

[0019] To more clearly illustrate the structural features and effects of the present invention, a detailed description is provided below in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description

[0020] Figure 1 This is a three-dimensional schematic diagram of the device of the present invention; Figure 2 This is a three-dimensional schematic diagram of the wire-pulling mechanism of the present invention; Figure 3 This is a three-dimensional schematic diagram of the tangent mechanism of the present invention; Figure 4 This is a three-dimensional schematic diagram of the displacement welding device of the present invention; Figure 5 This is a three-dimensional schematic diagram of the main body of the shift welding device of the present invention; Figure 6 This is a three-dimensional schematic diagram of the turntable shifting mechanism of the present invention; Figure 7 This is a three-dimensional schematic diagram of the turntable shifting mechanism of the present invention from another perspective; Figure 8 This is a three-dimensional schematic diagram of the wire bonding positioning mechanism of the present invention; Figure 9 This is a three-dimensional schematic diagram of the linear displacement mechanism of the present invention; Figure 10 for Figure 6 Enlarged diagram of point M.

[0021] Explanation of reference numerals in the attached diagram: 10. Frame; 20. Wire pulling mechanism; 21. Wire reel; 22. Wire guide wheel; 23. Wire pulling bracket; 24. Tensioning assembly; 241. First tensioning wheel; 242. Second tensioning wheel; 25. Movable arm; 26. Arc plate; 261. Arc groove; 27. Wire feeding cylinder; 30. Wire cutting mechanism; 31. Wire pulling assembly; 311. Wire pulling support; 312. Lateral drive cylinder; 313. Lateral slide; 314. Vertical wire clamping cylinder; 32. Laser cutter; 40. Shift welding. Device; 41. Linear shifting mechanism; 411. Shifting drive assembly; 412. Lateral sliding plate; 413. Moving wire clamping cylinder; 414. Material unloading and storage assembly; 4141. Unloading chute; 4142. Storage bin; 42. First turntable shifting mechanism; 421. Shifting bracket; 4211. Welding station; 4212. Cleaning station; 4213. Material transfer station; 422. Rotary drive motor; 423. Turntable; 4231. Slide rail; 4232. Shuttle hole; 424. Wire clamping assembly Components; 4241, Upper clamping plate; 4242, Lower clamping plate; 4243, Upper roller; 4244, Lower roller; 4245, First tension spring; 4246, Second tension spring; 4247, Upper clamping wire end; 42471, V-groove; 42472, Guide groove; 4248, Lower clamping wire end; 42481, V-block; 42482, Guide block; 42483, Notch; 425, Clamping assembly; 4251, Clamping cylinder; 4252, Wedge-shaped clamping head; 426, Cleaning assembly Components; 4261, air blowing pipe; 43, first laser welder; 44, second turntable shifting mechanism; 45, wire welding positioning mechanism; 451, positioning bracket; 452, first positioning component; 453, second positioning component; 454, positioning drive cylinder; 455, wire clamping positioning unit; 4551, drive plate; 45511, trapezoidal groove; 4552, left wire clamping block; 4553, right wire clamping block; 4554, return spring; 4555, drive roller; 46, second laser welder. Detailed Implementation

[0022] The present invention is as follows Figures 1 to 10 As shown, an automated device and operating method for twisted needle welding includes a frame 10, a wire pulling mechanism 20 mounted on the frame 10 for pulling the wire, a wire cutting mechanism 30 for cutting the wire, and a shifting welding device 40 for transferring the wire and welding both ends of the wire, wherein: The wire pulling mechanism 20, the wire cutting mechanism 30, and the shifting welding device 40 are connected in sequence along the wire moving direction. The wire pulling mechanism 20 includes a wire reel 21 for winding the wire and multiple guide wheels 22. After the wire is drawn out from the wire reel 21, it passes around the multiple guide wheels 22 and enters the wire cutting mechanism 30.

[0023] The wire pulling mechanism 20 also includes a wire pulling bracket 23, a tensioning component 24, and a wire feeding cylinder 27. The wire reel 21 is installed on the top of the wire pulling bracket 23, and a portion of the guide wheels 22 face the right side of the wire pulling bracket 23, while another portion of the guide wheels 22 face the front side of the wire pulling bracket 23. Multiple guide wheels 22 are arranged alternately from top to bottom. After the wire is drawn out from the wire reel 21, it passes around multiple guide wheels 22 from top to bottom. The bending stress of the wire itself is relieved by the guide wheels arranged in different directions and alternately, so that the wire is straightened, which facilitates the subsequent cutting and welding operations of the wire.

[0024] The tensioning assembly 24 includes a first tensioning wheel 241 and a second tensioning wheel 242. The bottom of the wire pull bracket 23 is provided with a rotatable movable arm 25 and an arc-shaped plate 26 with an arc-shaped groove 261. The end of the movable arm 25 slidably engages with the arc-shaped groove 261. The first tensioning wheel 241 is mounted on the end of the movable arm 25; the second tensioning wheel 242 is mounted beside the first tensioning wheel 241. The wire feeding cylinder 27 is mounted below the multiple guide rollers 22 and is used to clamp the wire guided downwards by the guide rollers 22, pulling it downwards to feed the wire downwards. After passing through the multiple guide rollers 22, the wire passes through the wire feeding cylinder 27 and then sequentially passes around the first tensioning wheel 241 and the second tensioning wheel 242. As the movable arm 25 rotates along the arc-shaped slide groove 261, the distance between the first tensioning wheel 241 and the second tensioning wheel 242 can be adjusted, thereby adjusting the tension of the wire. After the tension of the wire is adjusted to the correct position, the movable arm 25 can be fixed to the arc-shaped plate 26 with screws to keep the wire tension constant.

[0025] The wire cutting mechanism 30 includes a wire pulling assembly 31 for pulling the wire pulled forward by the wire pulling mechanism 20 and a laser cutter 32 for laser cutting the wire. The wire pulling assembly 31 is connected to the wire pulling mechanism 20. The wire pulling assembly 31 includes a wire pulling support 311, a horizontal drive cylinder 312, a horizontal slide block 313, and a vertical wire clamping cylinder 314. The wire pulling support 311 is located beside the wire pulling mechanism 20. The horizontal drive cylinder 312 is mounted on the wire pulling support 311. The horizontal slide block 313 is slidably mounted on the wire pulling support 311 and connected to the shaft end of the horizontal drive cylinder 312. The vertical wire clamping cylinder 314 is mounted on the horizontal slide block 313. After the vertical wire clamping cylinder 314 clamps the wire, the horizontal drive cylinder 312 drives the horizontal slide block 313 to move forward, thereby driving the vertical wire clamping cylinder 314 to move forward and move the wire to the cutting position. The laser cutter 32 is positioned above the wire-carrying assembly 31, with its laser lens corresponding to the wire exit position of the wire-carrying assembly 31. After the shift welding device 40 clamps the end of the wire, the laser cutter 32 will simultaneously cut the wire, and the cut wire will be transferred by the shift welding device 40 to the welding station for welding.

[0026] The shifting welding device 40 includes a linear shifting mechanism with multiple moving wire clamping cylinders 413, a first turntable shifting mechanism 42 for shifting the wire, a first laser welder 43 for welding one end of the wire, a second turntable shifting mechanism 44 for shifting the wire, a wire positioning mechanism 45 for clamping and positioning the wire, and a second laser welder 46 for welding the other end of the wire.

[0027] The linear shifting mechanism 41 is arranged along the wire movement direction and includes a shifting drive assembly 411, a transverse sliding plate 412, three moving wire clamping cylinders 413, and a feeding and collecting assembly 414. The transverse sliding plate 412 is slidably mounted on the frame 10. The shifting drive assembly 411 is mounted on the frame 10, and its output end is connected to the transverse sliding plate 412. In this embodiment, the shifting drive assembly 411 includes a motor and a lead screw. The lead screw is connected to the motor shaft end. The transverse sliding plate 412 cooperates with the lead screw. As the lead screw rotates, the transverse sliding plate 412 moves laterally on the frame 10. The feeding and collecting assembly 414 includes a feeding trough 4141 and a collecting bin 4142. The feeding trough 4141 is located next to the right moving wire clamping cylinder 413 and is inclinedly connected to the collecting bin 4142.

[0028] Three movable wire clamping cylinders 413 are installed on the transverse sliding plate 412 from left to right at intervals. The left movable wire clamping cylinder 413 is used to receive wire (wire cut by laser cutter 32) for clamping and transfer by the wire clamping assembly 424 of the first turntable shifting mechanism 42. The middle movable wire clamping cylinder 413 is used to receive wire (one end of the wire has been welded) clamped on the first turntable shifting mechanism 42 for clamping and transfer by the wire clamping assembly 424 of the second turntable shifting mechanism 44. The right movable wire clamping cylinder 413 is used to receive wire (both ends of the wire are welded) clamped on the second turntable shifting mechanism 44. After receiving the wire, the right movable wire clamping cylinder 413 moves to the right under the drive of the shifting drive assembly 411 and drops the welded wire into the feeding trough 4141. The wire slides down the feeding trough 4141 into the receiving bin. It should be noted that while the right-side moving wire clamping cylinder 413 places the wire into the feeding trough 4141, the left-side moving wire clamping cylinder 413 simultaneously completes the action of receiving and cutting the wire, and the middle moving wire clamping cylinder 413 simultaneously completes the action of receiving the wire with one end welded. That is, the three moving wire clamping cylinders 413 reciprocate between the wire cutting mechanism 30, the first turntable shifting mechanism 42, the second turntable shifting mechanism 44, and the feeding and collecting assembly 414 to form a series process operation for continuous wire transfer.

[0029] The first turntable shifting mechanism 42 and the second turntable shifting mechanism 44 are sequentially arranged beside the linear shifting mechanism along the wire moving direction; the wire welding positioning mechanism 45 is arranged between the first turntable shifting mechanism 42 and the second turntable shifting mechanism 44; the first laser welder 43 and the second laser welder 46 are located above the wire welding positioning mechanism 45 and correspond to the wire clamping position of the wire welding positioning mechanism 45.

[0030] The first turntable shifting mechanism 42 and the second turntable shifting mechanism 44 respectively include a shifting bracket 421, a rotary drive motor 422, a turntable 423, multiple wire clamping assemblies 424 for clamping wires, and an opening clamping assembly 425 that sequentially opens for each wire clamping assembly 424. The rotary drive motor 422 is mounted on the shifting bracket 421, the turntable 423 is mounted on the shaft end of the rotary drive motor 422, and the multiple wire clamping assemblies 424 are spaced apart on the turntable 423. The shifting bracket 421 has a welding station 4211, a cleaning station 4212, and multiple material transfer stations 4213. Opening clamping components 425 are respectively provided on the shifting bracket 421 corresponding to the cleaning station 4212 and the multiple material transfer stations 4213. Multiple wire clamping components 424 are sequentially aligned with the opening clamping components 425 on the corresponding station as the turntable 423 rotates. The opening clamping components 425 and the wire clamping components 424 cooperate to perform opening and clamping operations.

[0031] In this embodiment, four wire clamping assemblies 424 are installed on the turntable 423, and the four wire clamping assemblies 424 are distributed at 90-degree intervals. A welding station 4211, a cleaning station 4212, and two material transfer stations 4213 are provided on the shifting bracket 421. The welding station 4211 is located at the top of the shifting bracket 421, the cleaning station 4212 is located at the bottom of the shifting bracket 421, and the two material transfer stations 4213 are located on both sides of the shifting bracket 421. The specific station settings can be set according to actual conditions. The clamping opening assemblies 425 located on both sides are used to open the wire clamping assemblies 424 that have rotated to the material transfer stations 4213 on both sides. The clamping opening assembly 425 located at the bottom is used to clean the wire clamping assemblies 424 that have rotated to the cleaning station 4212.

[0032] A rotary drive motor 422 drives a turntable 423 to rotate in accordance with the rhythm of the linear shifting mechanism to transfer the wire. The wire clamping assembly 424 includes an upper clamping plate 4241, a lower clamping plate 4242, an upper roller 4243, a lower roller 4244, a first tension spring 4245, and a second tension spring 4246. The upper clamping plate 4241 and the lower clamping plate 4242 are opposite to each other and are slidably mounted on the turntable 423. The upper roller 4243 is mounted on the upper clamping plate 4241, and the lower roller 4244 is mounted on the lower clamping plate 4242. 3 and the lower roller 4244 are opposite to each other; the first tension spring 4245 is connected between the upper wire clamping plate 4241 and the turntable 423, and the second tension spring 4246 is connected between the lower wire clamping plate 4242 and the turntable 423 (the attached figure only shows the setting positions of the first tension spring 4245 and the second tension spring 4246 on one of the wire clamping components 424; the first tension spring 4245 and the second tension spring 4246 are set in the same way on other wire clamping components 424). The upper wire clamping plate 4241 and the lower wire clamping plate 4242 are kept in a normally closed state under the action of the first tension spring 4245 and the second tension spring 4246. Slide rails 4231 are respectively provided on the turntable 423 corresponding to the upper wire clamping plate 4241 and the lower wire clamping plate 4242, and the upper wire clamping plate 4241 and the lower wire clamping plate 4242 are slidably mounted on the slide rails 4231. There are two first tension springs 4245 corresponding to the upper clamping plate 4241, and two second tension springs 4246 corresponding to the lower clamping plate 4242. The two first tension springs 4245 are arranged parallel to each other, and the two second tension springs 4246 are arranged parallel to each other. Two tension springs are arranged for the upper clamping plate 4241 and the lower clamping plate 4242 respectively. On the one hand, it increases the closing clamping force of the upper clamping plate 4241 and the lower clamping plate 4242 under normal conditions and avoids the wire clamping loosening. On the other hand, it makes the force on the upper clamping plate 4241 and the lower clamping plate 4242 balanced. In addition, the two tension springs are equivalent to double insurance. Even if one of them loses effective tension, the other can still ensure the stability of the wire clamping state.

[0033] The clamping assembly 425 includes a clamping cylinder 4251 and a wedge-shaped clamping head 4252 mounted on the shaft end of the clamping cylinder 4251. A shuttle hole 4232 is provided on the turntable 423 at a position corresponding to the position between the upper roller 4243 and the lower roller 4244. The wedge-shaped clamping head 4252 moves back and forth in the shuttle hole 4232 under the drive of the clamping cylinder 4251 to roll and contact the upper roller 4243 and the lower roller 4244, so that the upper clamping plate 4241 and the lower clamping plate 4242 separate or close with each other. Specifically, the upper roller 4243 and lower roller 4244 are pushed forward by the convex arc of the upper and lower side walls of the wedge-shaped clamp 4252, overcoming the tension of the first tension spring 4245 and the second tension spring 4246, so that the wire clamping assembly 424 is opened to allow the wire to enter the clamping area (between the upper clamping plate 4241 and the lower clamping plate 4242); after the wire clamping assembly 424 clamps the wire, the wedge-shaped clamp 4252 is driven by the clamping cylinder 4251 to retract backward, and the upper clamping plate 4241 and the lower clamping plate 4242 close again to clamp the wire under the pull of the first tension spring 4245 and the second tension spring 4246.

[0034] The upper clamping plate 4241 has an upper clamping head 4247 installed at its front end, and the lower clamping plate 4242 has a lower clamping head 4248 installed at its front end. The upper clamping head 4247 has a V-shaped groove 42471 for clamping the wire and guide grooves 42472 for precisely fitting the upper clamping head 4247 and the lower clamping head 4248 together. The V-shaped groove 42471 is located in the middle of the upper clamping head 4247, and the guide grooves 42472 are located on both sides of the upper clamping head 4247. The lower clamping head 4248 has a V-shaped block 42481 and a guide block 42482. The V-shaped block 42481 is located on the lower clamping head. In the middle of 4248, a notch 42483 for accommodating wire is provided at the top of the V-shaped block 42481. The guide block 42482 is provided on both sides of the lower clamping wire end 4248. The V-shaped block 42481 can be detachably engaged with the V-shaped groove 42471, and the guide block 42482 can be detachably engaged with the guide groove 42472. By utilizing the engagement of the V-shaped block 42481 and the V-shaped groove 42471, as well as the engagement of the guide block 42482 and the guide groove 42472, when the upper clamping wire end 4247 and the lower clamping wire end 4248 are closed together to clamp the wire, the clamping angle is more precise, avoiding positional displacement and damage to the wire, and improving the wire welding quality. The upper clamping head 4247 is detachably installed at the front end of the upper clamping plate 4241, and the lower clamping head 4248 is detachably installed at the front end of the lower clamping plate 4242. The detachable design makes it easy to replace different types of clamping heads to accommodate different types of wires and improve the versatility of applications.

[0035] The bottom of the shifting bracket 421 is provided with a cleaning component 426 for blowing away wire debris from the wire clamping assembly 424. The cleaning component 426 includes an air pump and an air blowing pipe 4261. The air blowing pipe 4261 is connected to the air pump and faces the wire clamping end of the wire clamping assembly 424. Each wire clamping assembly 424 passes through the air blowing pipe 4261 under the drive of the rotary drive motor 422. The high-pressure gas blown out by the air blowing pipe 4261 can clean the wire debris remaining on the wire clamping assembly 424, preventing the debris from adhering to the next wire to be welded and affecting product quality.

[0036] The wire bonding positioning mechanism 45 includes a positioning bracket 451, a first positioning component 452 for positioning the wire on the first turntable shifting mechanism 42, and a second positioning component 453 for positioning the wire on the second turntable shifting mechanism 44. The positioning bracket 451 is installed between the first turntable shifting mechanism 42 and the second turntable shifting mechanism 44. The first positioning component 452 and the second positioning component 453 are disposed back-to-back on the positioning bracket 451. The first positioning component 452 corresponds to the wire clamping component 424 on the first turntable shifting mechanism 42, and the second positioning component 453 corresponds to the wire clamping component 424 on the second turntable shifting mechanism 44.

[0037] The first positioning component 452 and the second positioning component 453 respectively include a positioning drive cylinder 454 and a wire clamping positioning unit 455 connected to the shaft end of the positioning drive cylinder 454. The positioning drive cylinder 454 is mounted on the positioning bracket 451. The wire clamping positioning unit 455 includes a drive plate 4551 that can be slidably mounted on the positioning bracket 451 laterally, a left wire clamping block 4552 and a right wire clamping block 4553 that can be slidably mounted on the positioning bracket 451 longitudinally, and a return spring 4554 that drives the left wire clamping block 4552 and the right wire clamping block 4553 to close together (the return spring 4554 abuts against the left wire clamping block 4552 and the right wire clamping block 4553, not shown in the figure). The drive plate 4551 and the shaft of the positioning drive cylinder 454 The two ends are connected, and the front end is provided with a trapezoidal groove 45511 that is wider on the outside and narrower on the inside. The left clamping block 4552 and the right clamping block 4553 are respectively provided with driving rollers 4555. The driving rollers 4555 on the left clamping block 4552 and the right clamping block 4553 are opposite to each other and make rolling contact with the inner walls on both sides of the trapezoidal groove 45511. As the driving plate 4551 slides forward, the driving rollers 4555 on the left clamping block 4552 and the right clamping block 4553 gradually move closer under the guidance of the inner walls on both sides of the trapezoidal groove 45511. The left clamping block 4552 and the right clamping block 4553 then close together and clamp the wire to be welded in the middle position, straightening the wire so that the end of the wire is located at the focal point of the laser welder lens, improving welding accuracy and product quality.

[0038] The frame 10 is equipped with CCD monitoring cameras corresponding to the laser cutter 32, the first laser welder 43, and the second laser welder 46 to monitor the wire cutting and welding effects. For defective cut or welded products, a signal will be sent for them to be picked out.

[0039] The working principle of the equipment is as follows: After the wire pulling mechanism 20 removes the bending stress of the wire, it reaches the wire cutting mechanism 30, where the laser cutter 32 cuts the wire. The left-side moving wire clamping cylinder 413 of the linear shifting mechanism clamps the cut wire and transfers it to the first turntable shifting mechanism 42. One of the wire clamping components 424 clamps the wire and, after the turntable rotates 90 degrees clockwise, it reaches the first positioning component 452 of the welding wire positioning mechanism 45. The welding wire positioning mechanism 45 further clamps and straightens the wire clamped by the wire clamping component 424, and the first laser welder 43 performs laser welding on one end of the straightened wire. Then, the turntable continues to rotate 90 degrees, and the middle moving wire clamp... Cylinder 413 clamps the wire with one end already welded and transfers it to the second turntable shifting mechanism 44. One of the wire clamping components 424 of the second turntable shifting mechanism 44 holds the wire with one end already welded, which is sent by the intermediate moving wire clamping cylinder 413. As the turntable of the second turntable shifting mechanism 44 rotates 90 degrees clockwise, it reaches the second positioning component 453 of the wire welding positioning mechanism 45 to perform wire alignment and laser welding of the other end of the wire. After welding is completed, the turntable continues to rotate 90 degrees to send the welded wire to the right moving wire clamping cylinder 413, which has already approached. The right moving wire clamping cylinder 413 moves to the right to place the wire into the unloading and collecting component 414, completing the unloading. It should be noted that the above is the operation sequence of a wire from cutting, welding to unloading. At the same time, the other wire clamping components 424 on the first turntable shifting mechanism 42 and the second turntable shifting mechanism 44 also cooperate with the linear shifting mechanism to repeat the above operation in sequence, so as to realize the synchronous material transfer (dual-axis drive) and welding of the two turntable shifting mechanisms, with a compact cycle and high continuity of wire processing.

[0040] An operating method for the aforementioned automated equipment includes the following steps: S1. The wire is drawn out from the wire reel 21 and guided into the wire cutting mechanism 30 by multiple guide wheels 22; S2, The cable pulling assembly 31 clamps the cable and pulls it forward to the predetermined cutting position; S3, the laser cutter 32 cuts the wire at the wire outlet of the wire-drawing assembly 31; S4. The left-side moving wire clamping cylinder 413 of the linear shifting mechanism clamps the cut wire and transfers it to the wire clamping assembly 424 of the first turntable shifting mechanism 42. S5. The turntable 423 of the first turntable shifting mechanism 42 rotates, transferring the clamped wire to the wire welding positioning mechanism 45; the wire welding positioning mechanism 45 straightens and positions the wire, and the first laser welder 43 welds one end of the wire; the wire after welding one end is clamped by the middle moving wire clamping cylinder 413 of the linear shifting mechanism and transferred to the wire clamping assembly 424 of the second turntable shifting mechanism 44. S6. The turntable 423 of the second turntable shifting mechanism 44 rotates to move the wire to the wire welding positioning mechanism 45; the wire welding positioning mechanism 45 once again straightens and positions the wire, and the second laser welder 46 welds the other end of the wire. S7. After welding, the wire is clamped by the right-side moving clamping cylinder 413 of the linear shifting mechanism, transferred to the unloading trough 4141 and slid into the storage bin 4142; wherein, the first turntable shifting mechanism 42 and the second turntable shifting mechanism 44 operate synchronously to realize the continuous transfer and welding of the wire.

[0041] The key design feature of this invention is the integration of a wire pulling mechanism, a wire cutting mechanism, a linear shifting mechanism, a double-turntable shifting mechanism, a wire welding positioning mechanism, and a laser welding system into a single, fully automated twist needle welding equipment. Specifically, the double-turntable shifting mechanism enables parallel wire transport and welding operations; the wire welding positioning mechanism, through the mechanical cooperation of a trapezoidal groove and drive rollers, achieves precise wire alignment; and the linear shifting mechanism, in conjunction with three moving wire clamping cylinders, ensures the orderly transfer of wire between the cutting, welding, and unloading stations. Through synchronous control and cycle time coordination, the system achieves efficient, continuous, and high-precision twist needle welding production.

[0042] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. An automated device for welding twisted needles, characterized in that: The device includes a frame, a wire pulling mechanism mounted on the frame for pulling the wire, a wire cutting mechanism for cutting the wire, and a shifting and welding device for transferring the wire and welding both ends of the wire. The wire pulling mechanism, the wire cutting mechanism, and the shifting and welding device are connected sequentially along the wire's movement direction. The shifting and welding device includes a linear shifting mechanism with multiple moving wire clamping cylinders, a first turntable shifting mechanism for shifting the wire, a first laser welder for welding one end of the wire, a second turntable shifting mechanism for shifting the wire, a wire positioning mechanism for clamping and positioning the wire, and a second laser welder for welding the other end of the wire. The linear shifting mechanism is arranged along the wire's movement direction. The first turntable shifting mechanism and the second turntable shifting mechanism are sequentially arranged beside the linear shifting mechanism along the wire's movement direction. The wire positioning mechanism is located between the first turntable shifting mechanism and the second turntable shifting mechanism. The first laser welder and the second laser welder are located above the wire positioning mechanism and correspond to the wire clamping position of the wire positioning mechanism.

2. The automated equipment for twist needle welding according to claim 1, characterized in that: The first and second turntable shifting mechanisms each include a shifting bracket, a rotary drive motor, a turntable, multiple wire clamping assemblies for clamping wires, and an opening clamping assembly that sequentially opens the clamps for each wire clamping assembly. The rotary drive motor is mounted on the shifting bracket, and the turntable is mounted on the shaft end of the rotary drive motor. The multiple wire clamping assemblies are spaced apart on the turntable. The shifting bracket has a welding station, a cleaning station, and multiple material transfer stations. An opening clamping assembly is provided on the shifting bracket corresponding to the cleaning station and the multiple material transfer stations. As the turntable rotates, the multiple wire clamping assemblies sequentially correspond to the opening clamping assemblies at the corresponding stations, and the opening clamping assemblies cooperate with the wire clamping assemblies to perform opening and clamping operations.

3. The automated equipment for twist needle welding according to claim 2, characterized in that: The wire clamping assembly includes an upper wire clamping plate, a lower wire clamping plate, an upper roller, a lower roller, a first tension spring, and a second tension spring. The upper and lower wire clamping plates are opposite to each other and are slidably mounted on the turntable. The upper roller is mounted on the upper wire clamping plate, and the lower roller is mounted on the lower wire clamping plate, with the upper and lower rollers facing each other. The first tension spring connects the upper wire clamping plate and the turntable, and the second tension spring connects the lower wire clamping plate and the turntable. The upper and lower wire clamping plates remain closed under the action of the first and second tension springs.

4. The automated equipment for twist needle welding according to claim 3, characterized in that: The clamping assembly includes a clamping cylinder and a wedge-shaped clamping head mounted on the shaft end of the clamping cylinder; a shuttle hole is provided on the turntable corresponding to the upper roller and the lower roller, and the wedge-shaped clamping head moves back and forth in the shuttle hole under the drive of the clamping cylinder to roll and contact the upper roller and the lower roller, so that the upper clamping plate and the lower clamping plate separate or close with each other.

5. The automated equipment for twist needle welding according to claim 3, characterized in that: The upper clamping plate has an upper clamping head installed at its front end, and the lower clamping plate has a lower clamping head installed at its front end. The upper clamping head has a V-shaped groove for clamping the wire and guide grooves for precisely fitting the upper and lower clamping heads together. The V-shaped groove is located in the middle of the upper clamping head, and the guide grooves are located on both sides of the upper clamping head. The lower clamping head has a V-shaped block and guide blocks. The V-shaped block is located in the middle of the lower clamping head, and has a notch at its top for accommodating the wire. The guide blocks are located on both sides of the lower clamping head. The V-shaped block can be detachably fitted with the V-shaped groove, and the guide blocks can be detachably fitted with the guide grooves.

6. The automated equipment for twist needle welding according to claim 2, characterized in that: The bottom of the displacement bracket is provided with a cleaning component for blowing away wire debris from the wire clamping assembly. The cleaning component includes an air pump and an air blowing pipe. The air blowing pipe is connected to the air pump and faces the wire clamping end of the wire clamping assembly.

7. The automated equipment for twist needle welding according to claim 2, characterized in that: The turntable is equipped with four wire clamping assemblies, which are distributed at 90-degree intervals from each other.

8. The automated equipment for twist needle welding according to claim 1, characterized in that: The wire bonding positioning mechanism includes a positioning bracket, a first positioning component for positioning the wire on the first turntable shifting mechanism, and a second positioning component for positioning the wire on the second turntable shifting mechanism. The positioning bracket is installed between the first and second turntable shifting mechanisms. The first and second positioning components are disposed back-to-back on the positioning bracket. Each of the first and second positioning components includes a positioning drive cylinder and a wire clamping and positioning unit connected to the shaft end of the positioning drive cylinder. The positioning drive cylinder is mounted on the positioning bracket. The wire clamping positioning unit includes a drive plate that can be slidably mounted on a positioning bracket, a left wire clamping block and a right wire clamping block that can be slidably mounted on the positioning bracket, and a return spring that drives the left and right wire clamping blocks to close together. The drive plate is connected to the shaft end of the positioning drive cylinder, and its front end is provided with a trapezoidal groove. The left and right wire clamping blocks are respectively provided with drive rollers. The drive rollers on the left and right wire clamping blocks are opposite to each other and make rolling contact with the inner walls on both sides of the trapezoidal groove. As the drive plate slides forward, the left and right wire clamping blocks close together.

9. The automated equipment for twist needle welding according to claim 1, characterized in that: The linear shifting mechanism includes a shifting drive assembly, a transverse sliding plate, three moving wire clamping cylinders, and a feeding and collecting assembly. The transverse sliding plate is horizontally slidably mounted on the frame. The shifting drive assembly is mounted on the frame, and its output end is connected to the transverse sliding plate. The three moving wire clamping cylinders are spaced apart from left to right on the transverse sliding plate. The feeding and collecting assembly includes a feeding trough and a collecting bin. The feeding trough is located next to the right-side moving wire clamping cylinder and is inclinedly connected to the collecting bin.

10. An operation method for an automated device as described in any one of claims 1-9, characterized in that, Includes the following steps: S1. The wire is pulled into the wire cutting mechanism by the wire pulling mechanism, and the wire cutting mechanism cuts the wire. S2. The left-side moving clamping cylinder of the linear shifting mechanism clamps the cut wire and transfers it to the clamping assembly of the first turntable shifting mechanism. S3. The turntable of the first turntable shifting mechanism rotates, transferring the clamped wire to the wire welding positioning mechanism; the wire welding positioning mechanism straightens and positions the wire, and the first laser welder welds one end of the wire; the wire after welding one end is clamped by the middle moving clamping cylinder of the linear shifting mechanism and transferred to the clamping assembly of the second turntable shifting mechanism. S4. The turntable of the second turntable shifting mechanism rotates, transferring the wire to the wire welding positioning mechanism; the wire welding positioning mechanism once again straightens and positions the wire, and the second laser welder welds the other end of the wire. S5. After welding, the wire is clamped by the right-side moving clamping cylinder of the linear shifting mechanism, transferred to the unloading trough and slid into the storage bin; wherein, the first turntable shifting mechanism and the second turntable shifting mechanism operate synchronously to realize the continuous transfer and welding of the wire.

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