Large battery tray casting thermal shaping system and thermal shaping method

Abstract

The invention relates to a large battery tray casting thermal shaping system and method, and the system comprises an edge cutting mechanism which is provided with a die cutting station used for cutting off a battery tray side die, and the die cutting station comprises at least one temperature control area; the heating mechanisms are arranged in the temperature control areas and used for abutting against a bottom plate of the battery tray, the number of the heating mechanisms corresponds to that of the temperature control areas, and the heating mechanisms are used for heating the corresponding temperature control areas; the shape correcting mechanism is provided with a shape correcting station used for correcting the battery tray bottom plate; and the cooling mechanism is used for reducing the temperature of the shape correcting station. The bottom plate of the battery tray is synchronously heated when the side die of the battery tray is cut off, so that subsequent thermal shaping of the battery tray is facilitated, and the problems that in the prior art, the correction and shaping success rate is low after the bottom plate of the product is cooled, and the product quality and the production efficiency are affected are solved.

Description

Technical Field

[0001] This application relates to the field of battery tray post-processing manufacturing, and in particular to a hot forming system and method for large battery tray castings. Background Technology

[0002] In the manufacturing process of large battery tray die castings, after the edge of the battery tray with the gating system is cut off, the material shrinks and cools quickly, resulting in large differences in temperature drop efficiency and structural strength in different areas, which leads to severe deformation of the base plate. Therefore, the base plate needs to be reshaped.

[0003] However, when shaping and straightening the product base plate, the plasticity of the product base plate decreases after cooling, making it difficult to flatten effectively, resulting in low shaping success rate and affecting product quality and production efficiency. Summary of the Invention

[0004] This application provides a hot forming system and method for large battery tray castings to solve the problem in related technologies where straightening is performed after the product base plate has cooled, resulting in low forming success rate and affecting product quality and production efficiency.

[0005] In a first aspect, a hot forming system for large battery tray castings is provided, comprising: The edge-cutting mechanism is provided with a cutting station for cutting off the edge mold of the battery tray, and the cutting station includes at least one temperature control area; A heating mechanism is disposed within the temperature control area and is used to abut against the bottom plate of the battery tray. The number of heating mechanisms corresponds to the temperature control area, and the heating mechanism is used to heat the corresponding temperature control area. The orthopedic mechanism is equipped with an orthopedic station for correcting the bottom plate of the battery tray; In addition, a cooling mechanism is provided to reduce the temperature of the orthopedic station.

[0006] In conjunction with the first aspect, in one embodiment, the edge-cutting mechanism includes: Upper die for trimming; In addition, a lower cutting die, which forms a cutting station for cutting off the edge of the battery tray between itself and the upper cutting die, the cutting station including at least a temperature control area.

[0007] In conjunction with the first aspect, in one embodiment, the heating mechanism includes: Multiple heating blocks are provided and located at either end of the upper or lower die of the cutting edge mold. The multiple heating blocks are spaced apart along the length or width direction of the cutting edge station.

[0008] In conjunction with the first aspect, in one embodiment, the heating mechanism further includes: A heating oil pipe passes through the heating blocks to connect all the heating blocks in series, and forms an inlet end and an outlet end at both ends in the length direction. The inlet end is used to connect to the outlet of the oil temperature controller, and the outlet end is used to connect to the inlet of the oil temperature controller.

[0009] In conjunction with the first aspect, in one embodiment, a hot forming system for a large battery tray casting further includes: Positioning pins are provided on either end of the upper or lower die of the cutting edge mold, and each positioning pin is fitted with a heating block.

[0010] In conjunction with the first aspect, in one embodiment, a hot forming system for a large battery tray casting further includes: A fastening bolt passes through the heating block and is threadedly connected to either the upper or lower end of the trimming die.

[0011] In conjunction with the first aspect, in one embodiment, a hot forming system for a large battery tray casting further includes: A monitoring device is located within the temperature control area and is used to contact the bottom plate of the battery tray within the temperature control area to detect the temperature of the bottom plate of the battery tray.

[0012] In conjunction with the first aspect, in one embodiment, the orthopedic mechanism includes: The orthopedic hydraulic press is equipped with an orthopedic station for straightening the bottom plate of the battery tray.

[0013] In conjunction with the first aspect, in one embodiment, the cooling mechanism includes: A cooling water device is provided, which is directed toward the straightening station and is used to reduce the temperature of the straightening station.

[0014] Secondly, a method for hot forming the large battery tray casting hot forming system is provided, characterized by comprising the following steps: Turn on the heating module to raise the temperature of the controlled area to the preset temperature; The battery tray is placed in the cutting station and the bottom plate of the battery tray is attached to the heating module. The upper and lower molds of the cutting edge mold are closed for a first preset time to complete the cutting edge and make the temperature difference between the bottom plate of the battery tray and the surrounding structure less than the preset temperature difference. After the edge trimming is completed, the battery tray is transferred from the die-cutting station to the straightening station and straightened to the theoretical position. After pressing the battery tray to the theoretical position, the cooling mechanism is activated to spray the straightening station for a second preset time to complete the hot forming of the battery tray casting.

[0015] The beneficial effects of the technical solution provided in this application include: after the die casting of the battery tray is completed, the battery tray is placed in the die cutting station of the die cutting mechanism. Since the die cutting station is equipped with at least one temperature control area and a heating mechanism is provided in the temperature control area, the die cutting mechanism and the heating mechanism can be turned on to heat the battery tray simultaneously during the edge cutting process, thereby preventing the battery tray from cooling down during the edge cutting process. After the edge cutting of the battery tray is completed, the battery tray is transferred to the straightening station of the straightening mechanism, so that the battery tray can be straightened at a high temperature, thereby improving its straightening success rate. In conjunction with the cooling mechanism, the straightening station is cooled down to fix the straightened state of the battery tray and improve its straightening quality.

[0016] This application provides a hot forming system and method for large battery tray castings. Because it simultaneously heats the bottom plate of the battery tray when cutting off the side mold of the battery tray, it facilitates the subsequent hot forming of the battery tray. Therefore, it solves the problem in related technologies where the product bottom plate is cooled before correction, resulting in low forming success rate and affecting product quality and production efficiency. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the structure of a large battery tray casting thermal forming system provided in one embodiment of this application; Figure 2 This is a top view of a large battery tray casting thermal forming system provided in another embodiment of this application.

[0019] In the diagram: 1. Trimming mechanism; 11. Upper trimming die; 12. Lower trimming die; 13. Temperature control area; 2. Heating module; 21. Heating block; 22. Heating oil pipe; 221. Inlet end; 222. Outlet end. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0021] This application provides a hot forming system and method for large battery tray castings, which can solve the problems in related technologies where straightening is performed after the product base plate has cooled, resulting in low forming success rate and affecting product quality and production efficiency.

[0022] Reference Figure 1 This application discloses a hot forming system for large battery tray castings, comprising a trimming mechanism 1, a heating mechanism, a straightening mechanism, and a cooling mechanism. The trimming mechanism 1 is equipped with a cutting station for cutting off the side molds of the battery tray. During the cutting of the battery tray side molds, the die-cast battery tray is placed into the cutting station, and the trimming mechanism 1 performs the side mold cutting process on the base of the battery tray. The cutting station includes at least one temperature control zone 13, and the heating mechanism is located within the temperature control zone 13 and is used to abut against the base plate of the battery tray, thereby facilitating the cutting of the battery tray side molds. The battery tray base plate is heated sequentially. After die cutting, the battery tray is transferred from the die cutting station to the straightening station. The battery tray is straightened while the base plate is still at a high temperature. Because the base plate is at a high temperature, it facilitates the straightening mechanism and improves the straightening success rate. Then, the cooling mechanism cools down the battery tray in the straightening station to achieve the desired straightening and shaping, thereby improving product quality and production efficiency. This solves the problem in related technologies where straightening is performed after the product base plate has cooled down, resulting in low straightening success rate and affecting product quality and production efficiency.

[0023] More specifically, in one embodiment of this application, the edge-cutting mechanism 1 includes an upper edge-cutting mold 11 and a lower edge-cutting mold 12. A cutting station for cutting off the edge mold of the battery tray is formed between the upper edge-cutting mold 11 and the lower edge-cutting mold 12. The cutting station includes at least one temperature control zone 13. During the edge-cutting process of the battery tray, after the battery tray is die-cast, the battery tray is placed in the cutting station, and the upper edge-cutting mold 11 and the lower edge-cutting mold 12 are closed to complete the edge mold cutting process of the battery tray. When setting up the cutting mechanism in the early stage, the heat characteristics of each area of ​​the battery tray base plate are analyzed according to the characteristics of the base plate, and the temperature control zone 13 is planned and designed.

[0024] The heating mechanism includes multiple heating blocks 21, located at either end of the upper die 11 or the lower die 12 of the trimming mold. The heating blocks 21 are spaced apart along the length or width of the trimming station. In one embodiment of this application, the heating blocks 21 are disposed on the upper die and arranged in multiple rows along the width of the trimming station, with each row of heating blocks 21 spaced apart along the length of the trimming station. Before the trimming process, the heating blocks 21 are preheated based on the actual heating requirements of the battery tray, heating them to the required temperature. Then, after mold closing, the bottom plate of the battery tray is heated while being trimmed. Simultaneously, because the heating blocks 21 are in contact with the bottom plate of the battery tray, the bottom plate is directly heated, creating a temperature difference with other structures of the battery tray. This allows the battery tray to be heated simultaneously with the trimming, ensuring it is in a high-temperature state during subsequent straightening, thereby improving the straightening success rate.

[0025] Furthermore, in one embodiment of this application, the heating block 21 is specifically made of a metal material with good thermal conductivity. To facilitate temperature control of the heating block 21, the heating mechanism also includes a heating oil pipe 22. The heating block 21 has a through hole for the heating oil pipe 22 to pass through, and the heating oil pipe 22 passes through all the heating blocks 21, connecting them in series. The two ends of the heating oil pipe 22 along its length form an inlet end 221 and an outlet end 222, respectively. The inlet end 221 is used to connect to the outlet of the oil temperature controller, and the outlet end 222 is used to connect to the oil temperature controller. In actual use, the heating oil pipe 22 is connected to the oil temperature controller, and the oil temperature controller is turned on, allowing the heat-conducting oil in the oil temperature controller to flow through the heating oil pipe 22 through all the heating blocks 21, thereby raising the temperature of the heating blocks 21 to the required temperature.

[0026] Specifically, in the early manufacturing stage, the heating block 21 can be made of metals such as copper or aluminum. Copper is a commonly used thermally conductive metal with outstanding thermal conductivity, enabling rapid and uniform heat transfer. Copper also has good corrosion resistance and ductility, making it easy to mold into complex shapes, although it is relatively heavy. Its moderate cost makes it suitable for heating scenarios requiring high thermal conductivity. Secondly, aluminum is easy to process, forming various structures through extrusion or casting. The naturally formed oxide layer on its surface enhances its corrosion resistance, and aluminum is relatively inexpensive, making it suitable for applications requiring reduced overall weight. Besides pure metals, some alloy materials can also be chosen for the heating block 21. For example, aluminum alloys, while maintaining aluminum's lightweight and good thermal conductivity, have their strength and hardness improved by adding other elements, making them suitable for heating environments requiring high mechanical properties. Copper alloys such as brass or bronze have slightly lower thermal conductivity than pure copper, but better wear resistance and strength, making them suitable for applications requiring both thermal conductivity and structural support. When selecting materials, factors such as thermal conductivity, weight, cost, processing difficulty, and usage environment must be comprehensively considered to ensure that the heating block 21 is stable and reliable in long-term operation.

[0027] To facilitate the positioning of the heating block 21, in one embodiment of this application, a plurality of positioning pins are provided on either end of the upper mold 11 or the lower mold of the trimming die, so as to facilitate the positioning and installation of the heating block 21. During the early manufacturing process, the position of the positioning pins on the cutting die station is designed based on the product specifications of the battery tray. The positioning pins can pass through the heating block 21 to complete the positioning of the heating block 21, or a positioning station can be formed between two positioning pins to assist in the positioning of the heating block 21.

[0028] Furthermore, in order to facilitate the installation of the heating block 21 and improve the connection stability between the heating block 21 and the upper die 11 of the trimming die, in one embodiment of this application, the heating block 21 is specifically connected to the upper die 11 of the trimming die by a fastening bolt. The heating block 21 has a threaded hole for the fastening bolt to pass through, and the upper die 11 of the trimming die has a positioning hole. By tightening the fastening bolt, the heating block 21 and the upper die 11 of the trimming die can be detachably connected.

[0029] Because the die-casting process of the battery tray can cause temperature differences in local areas of the base plate, in order to ensure that the temperature of the battery tray base plate is heated evenly and to improve the quality of subsequent straightening, the thermal forming system of this application also includes a monitoring mechanism located in the temperature control zone 13 and used to contact the battery tray base plate in the temperature control zone 13. The monitoring mechanism can detect the temperature of the battery tray base plate in the temperature control zone 13, so that the operator can adjust the temperature of its heating mechanism based on the temperature of the battery tray base plate in the temperature control zone 13, thereby ensuring that the temperature of the battery tray base plate is heated evenly and further improving the quality of subsequent straightening.

[0030] Specifically, refer to Figure 2 In one embodiment of this application, the monitoring mechanism uses a temperature sensor, and four temperature control zones 13 are set within the die-cutting station. Each temperature control zone 13 is equipped with a heating mechanism, thereby fine-tuning the temperature of different areas within the die-cutting station through the heating mechanisms in each temperature control zone 13. Combining the temperature of the battery tray base plate displayed by the monitoring mechanism with the performance characteristics of the battery tray base plate itself, a mapping relationship is established between each area of ​​the battery tray base plate and its required ideal temperature. By fine-tuning the temperature of different areas of the battery tray base plate using the heating mechanisms, the consistency and stability of the battery tray's heating state are achieved.

[0031] More specifically, in one embodiment of this application, the orthopedic mechanism is specifically an orthopedic hydraulic press. The orthopedic hydraulic press has an orthopedic station. After the battery tray completes the die-cutting process, the battery tray is transferred from the die-cutting station to the orthopedic station. This allows for thermal orthopedic treatment of the battery tray while it is at a high temperature, thereby improving the orthopedic success rate of the battery tray base plate and increasing the orthopedic efficiency.

[0032] The cooling mechanism includes a cooling water device, which is positioned towards the straightening station and used to reduce the temperature of the straightening station. During the straightening process, the product is pressed to the required state according to the actual straightening requirements of the battery tray, and then the cooling water device is turned on to spray water towards the straightening station to reduce the temperature of the straightening station, thereby achieving product shaping.

[0033] Based on the large battery tray casting hot forming system proposed in this application, this application also proposes a hot forming method, which specifically includes the following steps: S1: Turn on heating module 2 to raise the temperature control area 13 to the preset temperature; Before performing heat shaping, the product performance of the battery tray is obtained based on the actual working conditions, and the heating temperature that the battery tray can withstand is obtained based on the product performance of the battery tray, and set as the preset temperature.

[0034] Typically, in common embodiments of this application, the preset temperature is set to 250-300℃. In a specific embodiment of this application, the heating module 2 includes heating blocks 21 and heating oil pipes 22. Before placing the battery tray into the die-cutting station, the heating oil pipes 22 are connected to the oil temperature controller, and the oil temperature controller is turned on, so that the heat transfer oil enters the heating oil pipes 22 to preheat all the heating blocks 21 until the temperature in the temperature control area 13 reaches the preset temperature.

[0035] S2: Place the battery tray in the cutting station and make the bottom plate of the battery tray fit with the heating module 2. The upper mold 11 and the lower mold 12 of the cutting edge mold are closed for a first preset time to complete the cutting edge and make the temperature difference between the bottom plate of the battery tray and the surrounding structure less than the preset temperature difference. Specifically, in this application, the die-cutting mechanism includes an upper die-cutting mold 11 and a lower die-cutting mold 12. The die-cast battery tray is placed in the die-cutting station. In this embodiment, the heating block 21 and the heating oil pipe 22 are specifically arranged on the upper die-cutting mold 11. The battery tray is placed in the lower die-cutting mold 12, and then the upper die-cutting mold 11 and the lower die-cutting mold 12 are closed. The heating block 21 is then attached to the bottom plate of the battery tray, so that the battery tray can be heated simultaneously when the bottom plate of the battery tray is being die-cut.

[0036] Since this application achieves heat transfer by attaching the heating block 21 to the bottom plate of the battery tray, thereby raising the temperature of the bottom plate of the battery tray, due to the time delay of heat transfer, there will inevitably be a temperature difference between the bottom plate of the battery tray and the surrounding structure. Therefore, in the early design stage, it is necessary to obtain the first preset heating time based on the actual product performance of the battery tray, and ensure that after the first preset time, the temperature difference between the bottom plate of the battery tray and the surrounding structure is less than the preset temperature difference, so as to facilitate the subsequent heat straightening process and reduce the possibility of heat straightening failure due to the low temperature of the surrounding structure of the battery tray.

[0037] For example, in one embodiment of this application, the first preset time is specifically set to 25-30s, the preset temperature difference is 30℃, the initial temperature of the battery tray bottom plate is 110℃, and after the first preset time of mold closing, the temperature of the battery tray bottom plate is heated to 150-200℃, and at this time the preset temperature difference between the battery tray bottom plate and the surrounding structure is less than 30℃, then the edge cutting mold process is considered to be completed.

[0038] S3: After the edge trimming is completed, the battery tray is transferred from the die-cutting station to the straightening station and straightened to the theoretical position; Before thermal straightening, the theoretical position of the battery tray is obtained according to the actual working conditions. After the edge cutting is completed, the battery tray is transferred from the die cutting station to the straightening hydraulic press using a robot or transfer device. The straightening station closes the mold and presses the battery tray to its required theoretical position while it is in a high temperature state.

[0039] S4: After pressing the battery tray to the theoretical position, start the cooling mechanism to spray the straightening station for the second preset time to complete the hot forming of the battery tray casting.

[0040] In this application, a cooling water device is selected as the cooling mechanism. After the battery tray is pressed to the theoretical position, the cooling water device is activated to spray the straightening station, thereby reducing the temperature of the straightening station and the battery tray inside it. A second preset time is set according to the actual working conditions so that after the straightening station is opened, the battery tray is shaped under the action of cooling water, thus establishing product strength.

[0041] For example, in one embodiment of this application, the second preset time is set to 30-40 seconds. At this time, the temperature of the straightening station drops below 50°C, the product strength is established, and the outline dimensions of the battery tray are stabilized within the preset range, achieving a better straightening effect.

[0042] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0043] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0044] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A large battery tray casting hot-shaping system, characterized by, It includes: The edge cutting mechanism (1) is provided with a cutting station for cutting off the edge mold of the battery tray, and the cutting station includes at least one temperature control area (13). A heating mechanism is provided in the temperature control area (13) and is used to abut against the bottom plate of the battery tray. The number of heating mechanisms is set according to the temperature control area (13). The heating mechanism is used to heat the corresponding temperature control area (13). The orthopedic mechanism is equipped with an orthopedic station for correcting the bottom plate of the battery tray; In addition, a cooling mechanism is provided to reduce the temperature of the orthopedic station.

2. A large battery tray casting hot shaping system as claimed in claim 1, characterized in that, The trimming mechanism (1) includes: Upper die for trimming (11); In addition, a lower cutting die (12) is formed between the lower cutting die (11) and the upper cutting die (11) to form a cutting station for cutting off the edge of the battery tray, the cutting station including at least a temperature control area (13).

3. The large battery tray casting hot forming system as described in claim 2, characterized in that, The heating mechanism includes: Multiple heating blocks (21) are provided and located at either end of the upper die (11) or the lower die (12) of the cutting die. The multiple heating blocks (21) are spaced apart along the length or width direction of the cutting die station.

4. The large battery tray casting hot forming system as described in claim 3, characterized in that, The heating mechanism also includes: The heating oil pipe (22) passes through the heating block (21) to connect all the heating blocks (21) in series, and forms an inlet end (221) and an outlet end (222) at both ends in the length direction. The inlet end (221) is used to connect to the outlet of the oil temperature machine, and the outlet end (222) is used to connect to the inlet of the oil temperature machine.

5. The large battery tray casting hot forming system as described in claim 3, characterized in that, It also includes: Positioning pins are provided on either end of the upper die (11) or the lower die (12) of the cutting edge mold, and each positioning pin is provided with a heating block (21).

6. The large battery tray casting hot forming system as described in claim 3, characterized in that, It also includes: A fastening bolt passes through the heating block (21) and is threaded to either end of the upper cutting die (11) or the lower cutting die (12).

7. The large battery tray casting hot forming system as described in claim 1, characterized in that, It also includes: A monitoring device is located within the temperature control zone (13) and is used to contact the bottom plate of the battery tray within the temperature control zone (13) to detect the temperature of the bottom plate of the battery tray.

8. The large battery tray casting hot forming system as described in claim 1, characterized in that, The orthopedic mechanism includes: The orthopedic hydraulic press is equipped with an orthopedic station for straightening the bottom plate of the battery tray.

9. A hot forming system for a large battery tray casting as described in claim 1, characterized in that, The cooling mechanism includes: A cooling water device is provided, which is directed toward the straightening station and is used to reduce the temperature of the straightening station.

10. A hot forming method based on the hot forming system for large battery tray castings according to any one of claims 1-9, characterized in that, It includes the following steps: Turn on the heating module (2) to raise the temperature control area (13) to the preset temperature; The battery tray is placed in the cutting station and the bottom plate of the battery tray is attached to the heating module (2). The upper mold (11) and the lower mold (12) of the cutting edge mold are closed for a first preset time to complete the cutting edge and make the temperature difference between the bottom plate of the battery tray and the surrounding structure less than the preset temperature difference. After the edge trimming is completed, the battery tray is transferred from the die-cutting station to the straightening station and straightened to the theoretical position. After pressing the battery tray to the theoretical position, the cooling mechanism is activated to spray the straightening station for a second preset time to complete the hot forming of the battery tray casting.

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