Cable core wire shaping device and connector cable welding method

Abstract

The invention provides a cable core wire shaping device and a connector cable welding method. The cable core wire shaping device comprises a core wire table, the table top of the core wire table is provided with a positioning groove extending in the first direction, and the positioning groove is used for containing a part of a core wire of a cable in the second direction; the first sliding block is provided with a shaping block used for shaping the core wire, the first sliding block can slide in the third direction and drive the shaping block to move to the table top of the core wire table, and any two of the first direction, the second direction and the third direction are perpendicular to each other; the punching rod is provided with a shaping part and a cutting part, the shaping part and the cutting part are arranged in a spaced mode in the second direction, and the punching rod can move in the second direction so that the punching rod can have a shaping position and a cutting position; and the driving part can drive the first sliding block and the material punching rod to move. Therefore, according to the cable core wire shaping device provided by the invention, the core wire can be extruded and cut conveniently.

Description

Technical Field

[0001] This invention relates to the field of connector welding technology, specifically to a cable core shaping device and a connector cable welding method. Background Technology

[0002] The connector's signal pins (terminals) are flat rectangular structures, meaning their width is much greater than their thickness (at least twice as much), while the cable's core is cylindrical. Traditional processes require additional metal solder, increasing complexity and cost. Furthermore, soldering necessitates overlapping the rectangular and cylindrical structures, resulting in a large metal cross-section in the overlapping area, leading to significant impedance fluctuations and impacting high-frequency performance. To control the TDR (Time Domain Reflectometer) impedance, secondary processing of the core is required, necessitating multiple additional manufacturing processes. In related technologies, this secondary processing involves numerous steps and is time-consuming. Summary of the Invention

[0003] This invention aims to at least partially solve one of the technical problems in related technologies. To this end, embodiments of this invention provide a cable core forming device and a connector cable welding method.

[0004] The cable core shaping device of this invention includes:

[0005] A core wire platform, wherein a positioning groove extending in a first direction is provided on the platform surface, the positioning groove being used to accommodate a portion of the core wire of the cable in a second direction; A first slider having a shaping block for shaping the core wire, the first slider being slidable upward in a third direction and moving the shaping block to the surface of the core wire table, wherein any two of the first direction, the second direction and the third direction are perpendicular to each other; A punching rod is provided with a shaping part and a cutting part, which are spaced apart in a second direction. The punching rod can move in the second direction to have a shaping position and a cutting position. In the shaping position, the shaping part of the punching rod and the shaping block of the first slider press the core wire in a third direction to shape the core wire. During the process of the punching rod moving from the shaping position to the cutting position, the cutting part cuts the core wire on one side in the third direction. The driving unit can drive the first slider and the punch rod to move.

[0006] Therefore, the cable core shaping device according to the present invention can facilitate the extrusion and cutting of the core wire.

[0007] In some embodiments, there are multiple positioning slots, multiple first sliders, at least one punching rod, and the driving unit can simultaneously drive multiple first sliders to move.

[0008] In some embodiments, the surface of the core wire table has a discharge hole, into which the punching rod can extend.

[0009] In some embodiments, there are two positioning slots, which are spaced apart in the third direction, and the punching rod and the discharge hole are located between the two positioning slots in the third direction. There are two first sliders, which are located on both sides of the punch rod in the third direction; The punching rod is provided with the shaping part and the cutting part on both sides of the third direction.

[0010] In some embodiments, the second direction is the up-down direction, the opening of the positioning groove faces upward, and the punching rod can move downward from the shaping position to the cutting position.

[0011] The cable core shaping device of this embodiment also includes The lower mold body has the core wire platform fixed inside it. Two first sliders are slidably disposed in the lower mold body along the third direction. Each first slider is provided with a first elastic element. The first elastic element can undergo elastic deformation in the third direction. The two first elastic elements are respectively connected to the core wire platform on both sides in the third direction. The upper mold body is provided with two clamping blocks and a limiting block. The limiting block and the two clamping blocks are slidably disposed on the upper mold body in the vertical direction. Each clamping block has a guide slope that is inclined downwards and away from the corresponding first slider. The guide slopes of the two clamping blocks are slidably connected to the two first sliders respectively. When the clamping block moves downwards, it can drive the first slider to overcome the elastic force of the first elastic element and move towards the adjacent punch rod. The top of the clamping block is provided with an outwardly protruding clamping block. The limiting block... The top of the device is provided with an outwardly protruding limiting block. The limiting block and the clamping block cooperate with the slot of the upper mold body. The limiting block is located above the core wire platform. The limiting block includes a downwardly protruding limiting protrusion. The limiting protrusion has a punching hole that passes through it in the vertical direction. The punching rod is movably disposed in the punching hole in the vertical direction. The limiting block has a limiting groove with an opening facing upward. A second elastic element is provided in the limiting groove. The second elastic element can undergo elastic deformation in the vertical direction. The bottom of the second elastic element is connected to the limiting block. A drive plate is connected to a drive unit and is located above the upper mold body. The drive unit can drive the drive plate to move downward and abut against the clamping block and the second elastic element. During the downward movement of the drive plate, it overcomes the elastic force of the second elastic element and abuts against the top of the punch rod so that the punch rod moves to the cutting position. A fixing platform is used to fix cables, and the fixing platform is connected to the lower mold body.

[0012] In some embodiments, both the cutting part and the shaping part are bosses, the cutting part is a right-angled boss, and a transition surface is formed between the shaping part and the punching rod.

[0013] In some embodiments, the maximum distance between the two cutting portions in the third direction is between 0.01 mm and 0.05 mm greater than the maximum distance between the two shaping portions in the third direction.

[0014] The present invention also proposes a connector cable welding method using the above-mentioned cable core shaping device, comprising the following steps: The core wire is cut using the aforementioned cable core wire shaping device so that the welding end of the core wire is flat. The connector terminals and the core wire are fixed at a preset relative position so that the surfaces to be connected form a tight contact or a precise gap. A pair of shaping electrodes are used to apply pressure to the connection area between the fixed terminal and the core wire, and a pulse current is applied. The Joule heat generated by the contact resistance causes the contact interface between the terminal and the core wire to partially melt and form an initial metallurgical bond, thus completing the mechanical positioning and electrical connection.

[0015] In some embodiments, a laser beam is used to scan and irradiate the initial bonding area formed by resistance welding along the outer surface of the bonding area, causing localized secondary melting and solidification of the bonding area, thereby strengthening the initial bonding point and optimizing the interface; and / or Impedance testing and axial pull-out force testing were performed on the welded parts. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of a cable core shaping device according to an embodiment of the present invention.

[0017] Figure 2 This is a schematic diagram of a cable core shaping device according to an embodiment of the present invention.

[0018] Figure 3 This is a cross-sectional view of a cable core shaping device according to an embodiment of the present invention.

[0019] Figure 4This is a partially enlarged view of the core wire platform and punching rod according to an embodiment of the present invention.

[0020] Figure 5 This is a schematic diagram of the limiting block and the clamping block according to an embodiment of the present invention.

[0021] Figure 6 This is a schematic diagram showing the core wire before and after cutting according to an embodiment of the present invention.

[0022] Figure 7 This is a schematic diagram of cable and terminal welding according to an embodiment of the present invention.

[0023] Figure 8 This is a schematic diagram of the cable and terminal after welding according to an embodiment of the present invention.

[0024] Figure label: 1. Lower mold body; 11. Core wire platform; 111. Positioning groove; 112. Blanking hole; 12. First slider; 121. Shaping block; 13. First elastic element; 2. Upper mold body, 21. Limiting block, 211. Limiting protrusion, 212. Limiting block, 22. Punching rod, 23. Shaping part, 24. Cutting part, 25. Second elastic element, 26. Pressing block, 261. Guide slope, 262. Pressing block; 3. Fixed platform; 4. Cable, 41. Core wire; 5. Terminal. Detailed Implementation

[0025] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0026] The cable core shaping device according to an embodiment of the present invention will now be described with reference to the accompanying drawings. Figures 1 to 8 As shown, the cable core forming device according to an embodiment of the present invention includes a core forming table 11, a first slider 12, a punching rod 22, and a driving unit.

[0027] The core wire platform 11 has a positioning groove 111 extending in a first direction on its surface. The positioning groove 111 is used to accommodate a portion of the core wire 41 of the cable 4 in a second direction. Specifically, the second direction is the vertical direction, the platform surface of the core wire platform 11 is the top surface facing upwards, the opening of the positioning groove 111 faces upwards, and the lower part of the core wire 41 can be placed in the positioning groove 111 to position the core wire 41. For example, the positioning groove 111 is an arc-shaped groove.

[0028] The first slider 12 has a shaping block 121 for shaping the core wire 41. The first slider 12 can slide in a third direction and move the shaping block 121 onto the surface of the core wire table 11. Any two of the first direction, the second direction, and the third direction are perpendicular to each other. Specifically, the shaping block 121 is a block-shaped structure for pressing the core wire 41 in a third direction. The first direction can be a front-back direction, and the third direction can be a left-right direction. For example, the positioning groove 111 extends in the front-back direction, and the first slider 12 can move the shaping block 121 in the left-right direction.

[0029] The punching rod 22 is provided with a shaping section 23 and a cutting section 24, which are spaced apart in a second direction. The punching rod 22 can move in the second direction to have a shaping position and a cutting position. Specifically, the shaping section 23 is located below the cutting section 24, and the punching rod 22 can move downward from the shaping position to the cutting position. The driving unit can drive the first slider 12 and the punching rod 22 to move. That is, the driving unit can drive the first slider 12 to slide upward in a third direction, and the punching rod 22 moves in the second direction.

[0030] In the shaping position, the shaping part 23 of the punching rod 22 and the shaping block 121 of the first slider 12 press the core wire 41 in the third-party upward direction to shape the core wire 41. Specifically, in the shaping position, the core wire 41 is adjacent to the shaping part 23 of the punching rod 22 on the third-party upward side, and the shaping block 121 of the first slider 12 moves in the third-party upward direction toward the core wire 41 to press the core wire 41 in the third-party upward direction, thereby allowing the cylindrical core wire 41 to be compressed into a plate-like structure.

[0031] During the process of the punching rod 22 moving from the forming position to the cutting position, the cutting part 24 cuts one side of the core wire 41 in a third direction. Specifically, during the process of the punching rod 22 moving from the forming position to the cutting position, the cutting part 24 moves downward to cut one side of the plate-shaped core wire 41, thereby further reducing the thickness of the plate-shaped core wire 41 so that the cut core wire 41 can be easily soldered to the terminal 5. The cable core wire forming device according to the embodiment of the present invention can extrude and cut the core wire, thereby improving the efficiency of core wire processing.

[0032] Therefore, the cable core shaping device according to the present invention can facilitate the extrusion and cutting of the core wire.

[0033] like Figure 3 As shown, in some embodiments, the core wire table 11 has a dropping hole 112 on its surface, and the punching rod 22 can extend into the dropping hole 112. Specifically, the dropping hole 112 and the punching rod 22 extend in the vertical direction. After the cutting part 24 cuts the core wire 41, the cutting part 24 can drive the dropping part into the dropping hole 112.

[0034] In some embodiments, there are multiple positioning slots 111, multiple first sliders 12, and at least one punching rod 22. The driving unit can simultaneously drive multiple first sliders 12 to move. Therefore, the cable core forming device of this embodiment can simultaneously extrude and cut multiple cores 41, thereby improving the efficiency of processing the cores 41.

[0035] like Figure 4 As shown, in some embodiments, there are two positioning slots 111, which are spaced apart in the third direction. The punching rod 22 and the dropping hole 112 are located between the two positioning slots 111 in the third direction. There are two first sliders 12, which are located on both sides of the punching rod 22 in the third direction. The punching rod 22 is provided with a shaping part 23 and a cutting part 24 on both sides in the third direction. This allows for the simultaneous shaping and cutting of two core wires 41. For example, the two first sliders 12 are symmetrically arranged, the top of the core wire platform 11 is a trapezoidal structure, and the first slider 12 has a groove structure that mates with the top of the core wire platform 11.

[0036] In the shaping position, the two core wires 41 are located on both sides of the two shaping parts 23 of the punching bar 22 in the third direction. The shaping blocks 121 of the two first sliders 12 move relative to each other in the third direction so as to move towards the adjacent core wires 41 respectively. This allows the two first sliders 12 and the two shaping parts 23 to squeeze the core wires 41 in the third direction, thereby allowing the two core wires 41 to be squeezed into a plate-like structure.

[0037] As the punching rod 22 moves from the forming position to the cutting position, the cutting part 24 moves downward, and the cutting parts 24 on both sides of the punching rod 22 cut the two core wires 41 on opposite sides in a third direction. This further reduces the thickness of the two core wires 41 in the plate-like structure, so that the two core wires 41 after cutting can be easily soldered to the terminal 5.

[0038] like Figure 4 As shown, in some embodiments, both the cutting portion 24 and the shaping portion 23 are bosses, with the cutting portion 24 being a right-angled boss, and a transition surface formed between the shaping portion 23 and the punching rod 22. Specifically, the bottom surface of the cutting portion 24 is perpendicular to the side away from the punching rod 22 to cut the core wire 41. The upper and lower sides of the shaping portion 23 form transition surfaces with the punching rod 22.

[0039] In some embodiments, the maximum distance between the two cutting portions 24 in the third direction is 0.01 mm to 0.05 mm greater than the maximum distance between the two shaping portions 23 in the third direction, in order to control the amount of cutting of the core wire 41. For example, the maximum distance between the two cutting portions 24 in the left-right direction is 0.02 mm, 0.03 mm, or 0.04 mm greater than the maximum distance between the two shaping portions 23 in the left-right direction.

[0040] like Figures 1 to 5 As shown, in some embodiments, the cable core forming device according to the present invention further includes a lower mold body 1, an upper mold body 2, a drive plate, and a fixing platform 3.

[0041] The lower mold body 1 is generally annular in structure. The core wire platform 11 is fixed inside the lower mold body 1, with its surface located above the lower mold body 1. Two first sliders 12 are slidably disposed within the lower mold body 1 along a third direction, and the lower mold body 1 can limit the movement of the first sliders 12. Each first slider 12 is provided with a first elastic element 13, which can elastically deform in a third direction. The two first elastic elements 13 are respectively connected to the core wire platform 11 on both sides in the third direction. Thus, the first elastic element 13 can use its elastic force to drive the first slider 12 to move away from the core wire platform 11. For example, the first elastic element 13 is a spring, and the first slider 12 has a receiving groove with an opening facing the core wire platform 11, within which the first elastic element 13 is located. The first elastic element 13 can elastically deform in the left-right direction, and the first slider 12 is slidably disposed within the lower mold body 1 along the left-right direction.

[0042] The upper mold body 2 is provided with two clamping blocks 26 and a limiting block 21. The limiting block 21 and the two clamping blocks 26 are slidably disposed on the upper mold body 2 in the vertical direction. Specifically, the top of the clamping block 26 is provided with an outwardly protruding clamping block 262, and the top of the limiting block 21 is provided with an outwardly protruding limiting block 212. The limiting block 212 and the clamping block 262 cooperate with the groove of the upper mold body 2. Thus, when the limiting block 21 and the two clamping blocks 26 move downward relative to the upper mold body 2 to a certain position, the limiting block 212 abuts against the groove of the upper mold body 2, thereby preventing the limiting block 21 from moving further downward, and the clamping block 26 abuts against the groove of the upper mold body 2, thereby preventing the clamping block 26 from moving further downward.

[0043] Each clamping block 26 has a guide slope 261, which is inclined downwards and away from the corresponding first slider 12. The guide slopes 261 of the two clamping blocks 26 are slidably connected to the two first sliders 12 respectively. When the clamping block 26 moves downwards, it can drive the first slider 12 to overcome the elastic force of the first elastic element 13 and move towards the adjacent punching rod 22. Thus, when the two clamping blocks 26 move downwards, the two first sliders 12 can be driven to move relative to each other under the pressure of the guide slopes 261 of the two clamping blocks 26, so as to squeeze the two core wires 41.

[0044] The limiting block 21 is located above the core wire platform 11. The limiting block 21 includes a downwardly protruding limiting protrusion 211, which has a punching hole extending through it in the vertical direction. The punching rod 22 is movably disposed within the punching hole in the vertical direction. The limiting block 21 has a limiting groove with its opening facing upward. A second elastic member 25 is disposed within the limiting groove. The second elastic member 25 can elastically deform in the vertical direction, and its bottom is connected to the limiting block 21. For example, the second elastic member 25 is a spring.

[0045] The drive plate is connected to the drive unit and is located above the upper mold body 2. The drive unit can drive the drive plate to move downward and abut against the clamping block 26 and the second elastic member 25. After the drive plate moves downward and abuts against the clamping block 26, it can drive the clamping block 26 to move downward and overcome the elastic force of the first elastic member 13, so as to drive the first slider 12 to move in the direction adjacent to the punching rod 22.

[0046] After the drive plate moves downward and comes into contact with the second elastic member 25, the second elastic member 25 is compressed and drives the limiting block 21 to move downward until the limiting block 21 comes into contact with the first slider 12. Then the drive plate continues to move downward, and the second elastic member 25 is further compressed. During the downward movement of the drive plate, it overcomes the elastic force of the second elastic member 25 and comes into contact with the top of the punching rod 22, so as to drive the punching rod 22 to move downward relative to the limiting block 21 (limiting protrusion 211) so that the punching rod 22 moves to the cutting position.

[0047] The fixing platform 3 is used to fix the cable 4, and the fixing platform 3 is connected to the lower mold body 1. Specifically, the fixing platform 3 is equipped with a fixing component to fix the cable 4.

[0048] The present invention also proposes a connector cable welding method using a cable core forming device according to an embodiment of the present invention. The connector cable welding method according to an embodiment of the present invention includes the following steps: like Figure 6 As shown, the core wire 41 is cut using the cable core wire shaping device according to an embodiment of the present invention so that the welding end of the core wire 41 is flat. Specifically, the welding end of the cylindrical core wire 41 is squeezed and cut by the cable core wire shaping device to form a flat structure.

[0049] The connector terminal 5 and the core wire 41 are fixed in a preset relative position, so that the surfaces to be connected form a tight contact or a precise gap. The flat solder end of the core wire 41 facilitates the contact of the connector terminal 5 with the board. Precise gap or contact control is directly related to the uniformity and consistency of heat generation during resistance welding.

[0050] A pair of shaping electrodes are used to apply pressure to the connection area between the fixed terminal 5 and the core wire 41, and a pulse current is applied. The Joule heat generated by the contact resistance causes the contact interface between the welding end of the terminal 5 and the core wire to partially melt and form an initial metallurgical bond, thus completing the mechanical positioning and electrical connection.

[0051] The shaping electrode ensures uniform pressure application to the target area, while its shape design facilitates controllable deformation of the core wire 41 under pressure, optimizing the contact interface. Applying pressure serves two key purposes: first, it ensures tight contact and stabilizes initial resistance; second, it provides forging force during solidification of the molten metal, contributing to the formation of a dense weld nugget. Applying a pulsed current utilizes the Joule heating effect (Q=I²Rt) to generate concentrated heat at the contact surface between terminal 5 and core wire 41, instantly reaching the melting temperature and achieving atomic diffusion and fusion of the two materials under pressure. This process does not add any foreign metal material, avoiding impedance mismatch caused by dissimilar materials from the outset. Resistance welding forms a preliminary, pure metal-metallurgical bond, providing basic mechanical strength and electrical conductivity. The crimping action of the shaping electrode actively guides the core wire 41 material to fill the gaps, significantly reducing or eliminating the inherent cross-sectional discontinuities of traditional stacked structures, laying the structural foundation for a smooth electrical signal transition.

[0052] For example, such as Figure 7 As shown, the shaping electrode includes a resistance welding head (upper electrode) and a resistance welding base (lower electrode). The resistance welding base is provided with a T-shaped support platform. The terminal 5 pad is placed on the surface of the support platform near the resistance welding head. The core wire 41 is placed in the center on the surface of the terminal 5 pad. The resistance welding head presses the core wire 41 to perform resistance welding on the terminal 5 and the core wire 41.

[0053] In some embodiments, a laser beam is used to scan and irradiate the initial bonding area formed by resistance welding along the outer surface of the bonding area, causing localized deep remelting of the bonding area, thereby strengthening the initial bonding point and optimizing the interface. The bonding area formed by resistance welding has microscopically incomplete fusion or uneven microstructure. The laser beam has extremely high energy density, concentrated and precisely controllable heat input, and scanning it can achieve: secondary remelting, making the bonding interface more uniform and dense; localized deep melting, increasing the effective bonding area and penetration depth; and surface trimming, optimizing the surface morphology of the bonding area. The non-contact nature of laser welding avoids mechanical interference, and the heat-affected zone is extremely small, preventing damage to surrounding structures and insulation materials, significantly improving the mechanical reliability (peel force) of the weld, and enabling the connection to withstand more severe physical stresses. By optimizing the microstructure and geometry of the bonding interface, the electrical signal transmission path is further optimized, ensuring that the excellent impedance continuity established by resistance welding is consolidated and enhanced.

[0054] In some embodiments, impedance and axial pull-out force tests are performed on the weld to assess the welding performance. For example, the characteristic impedance of the weld is tested using a time-domain reflectometer (TDR) with a bandwidth of at least 40 GHz, and the criterion is that the absolute value of the TDR impedance fluctuation caused by the weld is less than or equal to 1 ohm. Alternatively, the axial pull-out force of the weld is tested using a tensile testing machine, and the criterion is that the maximum breaking force of the weld is not less than 6 N.

[0055] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0056] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0057] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0058] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0059] In this invention, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0060] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A cable core shaping device, characterized in that, include: A core wire platform, wherein a positioning groove extending in a first direction is provided on the platform surface, the positioning groove being used to accommodate a portion of the core wire of the cable in a second direction; A first slider having a shaping block for shaping the core wire, the first slider being slidable upward in a third direction and moving the shaping block to the surface of the core wire table, wherein any two of the first direction, the second direction and the third direction are perpendicular to each other; A punching rod is provided with a shaping part and a cutting part, which are spaced apart in a second direction. The punching rod can move in the second direction to have a shaping position and a cutting position. In the shaping position, the shaping part of the punching rod and the shaping block of the first slider press the core wire in a third direction to shape the core wire. During the process of the punching rod moving from the shaping position to the cutting position, the cutting part cuts the core wire on one side in the third direction. The driving unit can drive the first slider and the punch rod to move.

2. The cable core shaping device according to claim 1, characterized in that, There are multiple positioning slots, multiple first sliders, at least one punching rod, and the driving unit can simultaneously drive multiple first sliders to move.

3. The cable core shaping device according to claim 2, characterized in that, The core wire platform has a discharge hole on its surface, and the punch rod can extend into the discharge hole.

4. The cable core shaping device according to claim 3, characterized in that, There are two positioning slots, which are spaced apart in the third direction. The punching rod and the discharge hole are located between the two positioning slots in the third direction. There are two first sliders, which are located on both sides of the punch rod in the third direction; The punching rod is provided with the shaping part and the cutting part on both sides of the third direction.

5. The cable core shaping device according to claim 4, characterized in that, The second direction is the up-down direction, the opening of the positioning groove faces upward, and the punching rod can move downward from the shaping position to the cutting position.

6. The cable core shaping device according to claim 5, characterized in that, Also includes The lower mold body has the core wire platform fixed inside it. Two first sliders are slidably disposed in the lower mold body along the third direction. Each first slider is provided with a first elastic element. The first elastic element can undergo elastic deformation in the third direction. The two first elastic elements are respectively connected to the core wire platform on both sides in the third direction. The upper mold body is provided with two clamping blocks and a limiting block. The limiting block and the two clamping blocks are slidably disposed on the upper mold body in the vertical direction. Each clamping block has a guide slope that is inclined downwards and away from the corresponding first slider. The guide slopes of the two clamping blocks are slidably connected to the two first sliders respectively. When the clamping block moves downwards, it can drive the first slider to overcome the elastic force of the first elastic element and move towards the adjacent punch rod. The top of the clamping block is provided with an outwardly protruding clamping block. The limiting block... The top of the device is provided with an outwardly protruding limiting block. The limiting block and the clamping block cooperate with the slot of the upper mold body. The limiting block is located above the core wire platform. The limiting block includes a downwardly protruding limiting protrusion. The limiting protrusion has a punching hole that passes through it in the vertical direction. The punching rod is movably disposed in the punching hole in the vertical direction. The limiting block has a limiting groove with an opening facing upward. A second elastic element is provided in the limiting groove. The second elastic element can undergo elastic deformation in the vertical direction. The bottom of the second elastic element is connected to the limiting block. A drive plate is connected to a drive unit and is located above the upper mold body. The drive unit can drive the drive plate to move downward and abut against the clamping block and the second elastic element. During the downward movement of the drive plate, it overcomes the elastic force of the second elastic element and abuts against the top of the punch rod so that the punch rod moves to the cutting position. A fixing platform is used to fix cables, and the fixing platform is connected to the lower mold body.

7. The cable core shaping device according to any one of claims 4-6, characterized in that, Both the cutting part and the shaping part are bosses, the cutting part is a right-angled boss, and a transition surface is formed between the shaping part and the punching rod.

8. The cable core shaping device according to claim 7, characterized in that, The maximum distance between the two cutting portions in the third direction is 0.01 mm to 0.05 mm greater than the maximum distance between the two shaping portions in the third direction.

9. A connector cable welding method using the cable core forming device according to any one of claims 1-8, characterized in that, Includes the following steps: The core wire is cut using the aforementioned cable core wire shaping device so that the welding end of the core wire is flat. The connector terminals and the core wire are fixed at a preset relative position so that the surfaces to be connected form a tight contact or a precise gap. A pair of shaping electrodes are used to apply pressure to the connection area between the fixed terminal and the core wire, and a pulse current is applied. The Joule heat generated by the contact resistance causes the contact interface between the terminal and the core wire to partially melt and form an initial metallurgical bond, thus completing the mechanical positioning and electrical connection.

10. The connector cable soldering method according to claim 9, characterized in that, In the initial bonding area formed by resistance welding, a laser beam is used to scan and irradiate along the outer surface of the bonding area, causing localized secondary melting and solidification of the bonding area, thereby strengthening the initial bonding point and optimizing the interface; and / or Impedance testing and axial pull-out force testing were performed on the welded parts.

Images